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Service and Repair Manual

September 2016

Introduction

ii

Z-34/22 IC

Part No. 1274592

Intr oducti on

Intr oducti on

Important

Read, understand and obey the safety rules and
operating instructions in the appropriate Operator's
Manual on your machine before attempting any
procedure.

This manual provides troubleshooting and repair
procedures for qualified service professionals.

Basic mechanical, hydraulic and electrical skills are
required to perform most procedures. However,
several procedures require specialized skills, tools,
lifting equipment and a suitable workshop. In these
instances, we strongly recommend that
maintenance and repair be performed at an
authorized Genie dealer service center.

Compliance

Machine Classification

Group B/Type 3 as defined by ISO 16368

Machine Design Life

Unrestricted with proper operation, inspection and
scheduled maintenance.

Technical Publications

Genie has endeavored to deliver the highest
degree of accuracy possible. However, continuous
improvement of our products is a Genie policy.
Therefore, product specifications are subject to
change without notice.

Readers are encouraged to notify Genie of errors
and send in suggestions for improvement. All
communications will be carefully considered for
future printings of this and all other manuals.

Contact Us:

Internet: www.genielift.com
E-mail: [email protected]

Find a Manual for this Model

Go to

http://www.genielift.com

Use the links to locate Service Manuals,
Maintenance Manuals, Service and Repair
Manuals, Parts Manuals and Operator's Manuals.

Copyright © 2015 by Terex Corporation

1274592 Rev A, September 2016

First Edition, First Printing

Genie is a registered trademark of Terex South Dakota, Inc. in
the U.S.A. and many other countries.

“Z” is a trademark of Terex South Dakota, Inc.

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Summary of Contents for Genie Z-34/22 IC

Page 1: ...415 10688 This manual includes Repair procedures Fault Codes Electrical and Hydraulic Schematics from Z3416F 10689 to Z3416F 11999 from Z34F 12000 For detailed maintenance procedures refer to the appropriate Maintenance Manual for your machine Part No 1274592 Rev A September 2016 ...

Page 2: ...n Life Unrestricted with proper operation inspection and scheduled maintenance Technical Publications Genie has endeavored to deliver the highest degree of accuracy possible However continuous improvement of our products is a Genie policy Therefore product specifications are subject to change without notice Readers are encouraged to notify Genie of errors and send in suggestions for improvement Al...

Page 3: ...n History Revision Date Section Procedure Page Description A 9 2016 Release Reference Examples Electronic Version Click on any content or procedure in the Table of Contents to view the update Section Repair Procedure 4 2 Section Fault Codes All charts Section Schematics Legends and schematics ...

Page 4: ... Number Legend To August 31 2016 1 Model 2 Model year 3 Facility code 4 Sequence number 5 Serial number stamped on chassis 6 Serial label located under cover From September 1 2016 1 Model 2 Facility code 3 Sequence number 4 Serial number stamped on chassis 5 Serial label located under cover ...

Page 5: ...ry Many of the hazards identified in the operator s manual are also safety hazards when maintenance and repair procedures are performed Do Not Perform Maintenance Unless You are trained and qualified to perform maintenance on this machine You read understand and obey manufacturer s instructions and safety rules employer s safety rules and worksite regulations applicable governmental regulations Yo...

Page 6: ...crushing hazards such as moving parts free swinging or unsecured components when lifting or placing loads Always wear approved steel toed shoes Workplace Safety Any person working on or around a machine must be aware of all known safety hazards Personal safety and the continued safe operation of the machine should be your top priority Be sure to keep sparks flames and lighted tobacco away from fla...

Page 7: ...ine Specifications 1 Machine Component Weights 2 Performance Specifications 2 Hydraulic Specification 3 Hydraulic Component Specifications 5 Machine Torque Specifications 6 Kubota WG 972 Engine Specifications 7 GM 998L Engine Specifications 8 Kubota D1105 Engine Specifications 9 Perkins 403D 11 Engine Specifications 10 Perkins 403F 11 Engine Specifications 11 Hydraulic Hose and Fitting Torque Spec...

Page 8: ...eveling Slave Cylinder 22 How to Remove the Platform Leveling Slave Cylinder 22 How to Bleed the Leveling Slave Cylinder 22 2 2 Platform Rotator 23 How to Remove the Platform Rotator 23 How to Bleed the Platform Rotator 24 2 3 Platform Overload System 25 How to Calibrate the Platform Overload System if equipped 25 Jib Boom Components 26 3 1 Jib Boom 26 How to Remove the Jib Boom 26 3 2 Jib Boom Be...

Page 9: ...oom Extension Cylinder 34 How to Remove the Primary Boom Extension Cylinder 34 4 5 Platform Leveling Master Cylinder 36 How to Remove the Platform Leveling Master Cylinder 36 Secondary Boom Components 38 5 1 Secondary Boom 39 How to Disassemble the Secondary Boom 39 5 2 Secondary Boom Lift Cylinders 42 How to Remove the Secondary Boom Lift Cylinders 42 Engines 44 6 1 Kubota Diesel Models 44 Timing...

Page 10: ...justment 48 RPM Adjustment 48 How to Remove the Flex Plate 49 How to Install the Flex Plate 49 Coolant Temperature and Oil Pressure Switches 49 6 4 GM 998L Models 50 Timing Adjustment 50 How to Remove the Flex Plate 51 How to Install the Flex Plate 51 Hydraulic Pumps 52 7 1 Auxiliary Pump 52 How to Test the Auxiliary Pump 52 How to Remove the Auxiliary Pump 52 7 2 Function Pump 53 How to Test the ...

Page 11: ...onents 2WD 62 8 6 Traction Manifold Components 4WD 63 8 7 Valve Adjustments 4WD Traction Manifold 65 8 8 Valve Coils 66 How to Test a Coil 66 Valve Coil Resistance Specification 66 How to Test a Coil Diode 67 Fuel and Hydraulic Tanks 68 9 1 Fuel Tank 68 How to Remove the Fuel Tank 68 9 2 Hydraulic Tank 69 How to Remove the Hydraulic Tank 69 Turntable Rotation Components 70 10 1 Turntable Rotation ...

Page 12: ...or Legends 84 Electrical Schematics Gasoline LPG Models 87 Electrical Schematic Gasoline LPG Kubota WG972 Models from serial number Z3413 9461 88 Ground Control Box Switch Panel Wiring Diagram Gasoline LPG Models 92 Ground Control Box Terminal Strip Wiring Diagram Gasoline LPG Models 93 Platform Control Box Wiring Diagram Gasoline LPG Models 96 Electrical Schematic Gasoline LPG Kubota WG972 Models...

Page 13: ... 114 Electrical Schematic Diesel Models from Z3413 9461 CE AS 116 Ground Control Box Switch Panel Wiring Diagram Diesel Models 120 Ground Control Box Terminal Strip Wiring Diagram Diesel Models from serial number Z3413 9461 CE AS 121 Platform Control Box Wiring Diagram Diesel Models from serial number Z3413 9461 ANSI CSA 124 Electrical Schematics Options 125 GM 998L Engine Schematic 126 GM Engine ...

Page 14: ...t torque dry 125 ft lbs 170 Nm 125 ft lbs 170 Nm Lug nut torque lubricated 95 ft lbs 129 Nm 95 ft lbs 129 Nm Tire pressure rough terrain 45 psi 3 1 bar 100 psi 6 9 bar Tires and wheels Hi flotation option Tire size 31 15 5 15 Tire ply rating 8 Overall tire diameter 31 in 78 7 cm Wheel diameter 15 in 38 1 cm Wheel width 13 in 33 cm Wheel lugs 9 5 8 18 Lug nut torque dry 125 ft lbs 170 Nm Lug nut to...

Page 15: ...h 5 1 km h 40 ft 6 1 sec 12 2 m 6 1 sec Raised or extended 0 6 mph 0 98 km h 40 ft 45 sec 12 2 m 45 sec Gradeability See Operator s Manual Braking distance maximum High range on paved surface 3 to 4 ft 0 9 to 1 2 m Joystick function speeds maximum from platform controls Primary boom up 15 to 21 seconds Primary boom down 13 to 19 seconds Primary boom extend 14 to 20 seconds Primary boom retract 14 ...

Page 16: ...lube HP 5046 Note Genie specifications require additional equipment and special installation instructions for the approved optional fluids Consult Genie Product Support before use Optional fluids may not have the same hydraulic lifespan and may result in component damage Note Extended machine operation can cause the hydraulic fluid temperature to increase beyond it s maximum allowable range If the...

Page 17: ...hevron 5606A hydraulic fluid or equivalent is required when ambient temperatures are consistently below 0 F 17 C unless an oil heating system is used Continued use of Chevron 5606A hydraulic fluid or equivalent when ambient temperatures are consistently above 32 F 0 C may result in component damage Petro Canada Environ MV 46 Fluid Properties ISO Grade 46 Viscosity index 154 Kinematic Viscosity cSt...

Page 18: ... gear pump Displacement per revolution 0 5 gpm 1 9 L min Auxiliary pump relief pressure 3400 psi 234 5 bar Function manifold System relief valve pressure maximum 3200 psi 220 6 bar Primary boom down relief valve pressure 1600 psi 110 bar Secondary boom down relief valve pressure 1600 psi 110 bar Steer flow regulator 1 0 gpm 3 8 L min platform rotate flow regulator 0 3 gpm 1 1 L min Traction Manifo...

Page 19: ...bs 379 Nm 3 8 16 outer bolts GR 8 dry 3 8 16 outer bolts GR 8 lubricated 44 ft lbs 60 Nm 33 ft lbs 45 Nm Turntable rotate assembly Rotate bearing mounting bolts lubricated 180 ft lbs 244 Nm Rotate bearing motor mounting bolts lubricated 93 ft lbs 126 Nm Drive motors and hubs Drive hub mounting bolts lubricated 180 ft lbs 244 Nm Drive motor mounting bolts lubricated 3 8 16 GR5 7 16 14 GR5 23 ft lbs...

Page 20: ...he use of alternative engine oils For oil requirements refer to the Engine Operator Manual for your engine Fuel Pump Fuel pressure static 4 26 psi 0 29 bar Fuel flow rate 0 11 gpm 0 40 L min Fuel requirement For fuel requirements refer to the engine Operator Manual for your engine Alternator output 40A 12V DC Fan belt deflection 1 4 to 3 8 in 7 to 9 mm Starter motor Brush length new 0 551 in 14 mm...

Page 21: ...3 0 liters Oil viscosity requirements Below 86 F 30 C 5W 20 4 F to 104 F 20 C to 40 C 10W 30 Above 14 F 10 C 15W 40 Unit ships with 15W 40 Extreme operating temperatures may require the use of alternative engine oils For oil requirements refer to the Engine Operator Manual for your engine Fuel requirement For fuel requirements refer to the engine Operator Manual for your engine Alternator output 7...

Page 22: ...l viscosity requirements 22 F to 86 F 30 C to 30 C 5W 30 synthetic 4 F to 90 F 20 C to 32 C 10W 40 Above 23 F 5 C 20W 50 Unit ships with 15W 40 Extreme operating temperatures may require the use of alternative engine oils For oil requirements refer to the Engine Operator Manual for your engine Engine coolant Capacity 3 3 quarts 3 1 liters Fuel injection system Injection pump make Bosch MD Injectio...

Page 23: ... 60 psi 2 76 to 4 1 bar Oil capacity including filter 4 6 quarts 4 4 liters Oil viscosity requirements Below 86 F 30 C 5W 20 4 F to 104 F 20 C to 40 C 10W 30 Above 14 F 10 C 15W 40 Unit ships with 15W 40 Extreme operating temperatures may require the use of alternative engine oils For oil requirements refer to the Engine Operator Manual for your engine Fuel injection system Injection pump make Bos...

Page 24: ... including filter 4 6 quarts 4 4 liters Oil viscosity requirements Below 86 F 30 C 5W 20 4 F to 104 F 20 C to 40 C 10W 30 Above 14 F 10 C 15W 40 Unit ships with 15W 40 Extreme operating temperatures may require the use of alternative engine oils For oil requirements refer to the Engine Operator Manual for your engine Fuel injection system Injection pump make Bosch Injection timing 23 BTDC 2800 rpm...

Page 25: ...18 1 8 3 4 16 1 10 7 8 14 1 12 1 1 16 12 1 16 1 5 16 12 1 20 1 5 8 12 1 24 1 7 8 12 1 SAE O ring Boss Port tube fitting installed into Aluminum all types SAE Dash Size Torque 4 14 ft lbs 19 Nm 6 23 ft lbs 31 2 Nm 8 36 ft lbs 54 2 Nm 10 62 ft lbs 84 Nm 12 84 ft lbs 114 Nm 16 125 ft lbs 169 5 Nm 20 151 ft lbs 204 7 Nm 24 184 ft lbs 249 5 Nm Adjustable Fitting Non adjustable fitting 1 jam nut SAE O r...

Page 26: ...d and retained properly 4 Position the tube and nut squarely on the face seal end of the fitting and tighten the nut finger tight 5 Tighten the nut or fitting to the appropriate torque Refer to the appropriate torque chart in this section 6 Operate all machine functions and inspect the hose fittings and related components to confirm there are no leaks JIC 37 fittings 1 Align the tube flare hex nut...

Page 27: ...t number of flats for the proper tightening position Note The marks indicate the correct tightening positions have been determined Use the second mark on the body hex fitting to properly tighten the joint after it has been loosened Illustration 2 1 body hex fitting 2 reference mark 3 second mark 4 Tighten the hex nut until the mark on the hex nut is aligned with the second mark on the body hex fit...

Page 28: ...September 2016 Service and Repair Manual Specifications Part No 1274592 Z 34 22 IC 15 ...

Page 29: ...on your machine Be sure that all necessary tools and parts are available and ready for use Use only Genie approved replacement parts Read each procedure completely and adhere to the instructions Attempting shortcuts may produce hazardous conditions Machine Configuration Unless otherwise specified perform each repair procedure with the machine in the following configuration Machine parked on a firm...

Page 30: ...ert personnel to potential personal injury hazards Obey all safety messages that follow this symbol to avoid possible injury or death Indicates a imminently hazardous situation which if not avoided will result in death or serious injury Indicates a potentially hazardous situation which if not avoided could result in death or serious injury Indicates a potentially hazardous situation which if not a...

Page 31: ...ick Electrocution burn hazard Contact with electrically charged circuits could result in death or serious injury Remove all rings watches and other jewelry 1 boom function speed controller 2 drive joystick 3 Locate and disconnect the wire connected to terminal A on the drive joystick circuit board 4 Set a multimeter to read DC current Note The multimeter when set to read DC current should be capab...

Page 32: ...0 mA 14 Push in the red Emergency Stop button to the off position at the platform controls 15 Disconnect the multimeter 16 Connect the wire that was disconnected in step 3 to terminal A of the drive joystick Set the stowed drive speed Note Select a test area that is firm level and free of obstructions 17 Pull out the red Emergency Stop button out to the on position at both the ground and platform ...

Page 33: ...rease the speed or counterclockwise to decrease the raised drive speed Continue to perform steps 24 through 26 until the raised drive speed meets specification 27 Lower the primary boom to the stowed position Turn the engine off 28 Close the platform control box lid and install the fasteners 1 2 Boom Function Speed Controller Boom Function Speed Contr oller Adj ustm ents Boom Function Speed Contro...

Page 34: ... the primary boom toggle switch in the up direction until the voltage reading appears Adjust the voltage to 5 5 to 6V DC Turn the threshold trimpot adjustment screw clockwise to increase the voltage or counterclockwise to decrease the voltage 7 Turn the boom function speed controller to the 9 position 8 Set the max out Press down the foot switch Move the primary boom toggle switch in the up direct...

Page 35: ... Hose and Fitting Torque Specifications 1 Extend the boom until the slave cylinder barrel end pivot pin is accessible 2 Raise the boom slightly and place blocks under the platform for support Lower the boom until the platform is resting on the blocks 3 Remove the pin retainer fastener from the rod end pivot pin 4 Remove the external snap ring from the barrel end pivot pin 5 Use a soft metal drift ...

Page 36: ...fting device Do not apply any lifting pressure 4 Remove the six mounting bolts from the platform mounting weldment Remove the center bolt and slide the platform mounting weldment off of the platform rotator 5 Support the platform rotator with a suitable lifting device Do not apply any lifting pressure 6 Remove the pin retaining fasteners from the jib boom and leveling links to platform rotator piv...

Page 37: ...switch to either side and hold the platform rotate toggle switch to the left position until the platform is fully rotated to the left Continue holding the toggle switch until air stops coming out of the bleed screw Close the bleed screw Crushing hazard Keep clear of the platform during rotation 5 Open the bottom bleed screw on the rotator but do not remove it Bodily injury hazard Spraying hydrauli...

Page 38: ...and the alarm sounds Result The overload indicator light and alarm is off Slowly loosen the load spring adjustment nut by turning it counterclockwise just until the overload indicator light and alarm turn on Note There may be an approximate 2 second delay before the overload indicator light turns on and the alarm sounds Note The platform will need to be moved up and down and allowed to settle betw...

Page 39: ...he jib boom manifold Cap the fittings on the manifold Bodily injury hazard Spraying hydraulic oil can penetrate and burn skin Loosen hydraulic connections very slowly to allow the oil pressure to dissipate gradually Do not allow oil to squirt or spray 6 Tag and disconnect the electrical wiring from the jib boom manifold 7 Attach a lifting strap from an overhead crane to the jib boom 8 Remove the p...

Page 40: ... 7 Remove the jib boom bell crank from the extension boom Crushing hazard The jib boom bellcrank may become unbalanced and fall if it is not properly supported when it is removed from the machine 3 3 Jib Boom Lift Cylinder How to R emove the Jib Boom Lift Cylinder How to Remove the Jib Boom Lift Cylinder Note Perform this procedure with the boom in the stowed position Note When removing a hose ass...

Page 41: ...g strap from an overhead crane to the rod end of the jib boom lift cylinder 6 Remove the pin retaining fasteners from the jib boom lift cylinder barrel end pivot pin Use a soft metal drift to remove the barrel end pivot pin 7 Use a soft metal drift to remove the jib boom lift cylinder rod end pivot pin Remove the jib boom lift cylinder from the machine Crushing hazard The jib boom lift cylinder ma...

Page 42: ...nk repair section of cable track is available through the Genie Service Parts Department 1 link separation point 2 lower clip 1 Use a slotted screwdriver to pry down on the lower clip 2 To remove a single link open the lower clip and then use a screw driver to pry the link to the side 3 Repeat steps 1 and 2 for each link 4 2 Primary Boom How to Shim the Primary Boom How to Shim the Primary Boom 1 ...

Page 43: ... How to Remove the Jib Boom Bell Crank 5 Support the slave cylinder 6 Tag and disconnect the hydraulic hoses to the slave cylinder and connect them together using a connector Plug the slave cylinder hoses from the cable track Bodily injury hazard Spraying hydraulic oil can penetrate and burn skin Loosen hydraulic connections very slowly to allow the oil pressure to dissipate gradually Do not allow...

Page 44: ...nder rod end pin Use a soft metal drift to remove the pin Crushing hazard The boom lift cylinder will fall unless it is properly supported 21 Lower the rod end of the primary boom lift cylinder onto support blocks Protect the cylinder rod from damage 22 Remove the hose clamp brackets from the underside of the primary boom 23 Remove the hose clamp from the side of the primary boom 24 Remove the lim...

Page 45: ...used with each wear pad 5 Carefully rotate the barrel end of the extension cylinder until the pin mounting bore is in a vertical position 6 Attach a lifting strap from an overhead crane to the extension tube at the platform end 7 Support and slide the extension tube out of the outer primary boom tube Place the extension boom tube on blocks for support Crushing hazard The boom tubes could become un...

Page 46: ...erhead crane to the primary boom for support Do not apply any lifting pressure 4 Place a block of wood across the upper secondary boom to support the cylinder when the rod end pivot pin is removed 5 Attach a lifting strap from a second overhead crane or other similar lifting device to the primary boom lift cylinder 6 Remove the rear turntable cover 7 Place a 4x4 inch 10 x 10 cm block between the l...

Page 47: ...ift cylinder to slowly swing down 19 Carefully remove the cylinder from the machine 4 4 Primary Boom Extension Cylinder The primary boom extension cylinder extends and retracts the primary boom extension tube The primary boom extension cylinder is equipped with counterbalance valves to prevent movement in the event of a hydraulic line failure How to R emove the Primary Boom Extensi on Cylinder How...

Page 48: ...to dissipate gradually Do not allow oil to squirt or spray 9 Remove the pin retaining fasteners from the extension cylinder pivot pin Use a soft metal drift to remove the pin 10 Carefully pull out and properly support the extension cylinder from the primary boom using a lifting strap from an overhead crane Crushing hazard The extension cylinder could fall when removed from the extension boom if no...

Page 49: ... Torque Specifications Note Before cylinder removal is considered bleed the cylinder to be sure that there is no air in the closed loop Refer to Repair Procedure How to Bleed the Slave Cylinder 1 Remove the rear turntable cover 2 Raise the secondary boom until the master cylinder barrel end pivot pin is above the turntable counterweights 3 Raise the primary boom until the master cylinder rod end p...

Page 50: ...nder barrel end pivot pin 10 Use a soft metal drift to remove the pin from the cylinder Do not remove the pin from the upper mid pivot Push the pin to one side only far enough to remove the cylinder Crushing hazard The upper secondary boom and the upper pivot may fall if the pivot pin is completely removed Note The pin should remain in one side of the upper secondary boom and upper mid pivot 11 Us...

Page 51: ...6 Secondary Boom Components 38 Z 34 22 IC Part No 1274592 Secondary Boom components 1 upper pivot 2 upper compression arm 3 mid pivot 4 compression link 5 lower secondary boom 6 turntable pivot 7 lower compression arm 8 upper secondary boom ...

Page 52: ...ck to the platform control box Number each cable and its entry location at the platform control box 7 Open the platform control box 8 Tag and disconnect each wire from the cables in the platform control box Electrocution burn hazard Contact with electrically charged circuits could result in death or serious injury Remove all rings watches and other jewelry 9 Pull the cables out of the platform con...

Page 53: ...nd out of the way Secure them from moving 24 Remove the pin retaining fasteners from the upper pivot to the upper secondary boom pivot pin Use a soft metal drift to remove the pin 25 Carefully remove the entire primary boom assembly from the machine primary boom assembly jib boom assembly platform master cylinder primary lift cylinder and upper pivot Crushing hazard The primary boom assembly could...

Page 54: ...models Remove the LPG hose from the tank and then remove the LPG tank 40 Remove the battery hold down and battery 41 Remove the pin retaining fasteners from the secondary boom lift cylinder barrel end pivot pins 42 Attach a lifting strap from an overhead crane to the lug on the rod end of the secondary boom lift cylinder 43 Tag disconnect and plug the hydraulic hoses from the secondary boom lift c...

Page 55: ...ne if not properly supported by the overhead crane 5 2 Secondary Boom Lift Cylinder The secondary boom lift cylinder raises and lowers the secondary boom The secondary boom lift cylinder is equipped with counterbalance valves to prevent movement in the event of a hydraulic line failure How to R emove the Secondary Boom Li ft Cyli nders How to Remove the Secondary Boom Lift Cylinder Bodily injury h...

Page 56: ...e secondary boom just enough to access the hydraulic hoses Component damage hazard Hoses can be damaged if they are kinked or pinched 9 Tag disconnect and plug the hydraulic hoses from the secondary boom lift cylinder Cap the fittings on the cylinder Bodily injury hazard Spraying hydraulic oil can penetrate and burn skin Loosen hydraulic connections very slowly to allow the oil pressure to dissipa...

Page 57: ...ctor plate from the three individual glow plugs Then one glow plug at a time measure the resistance between the glow plug and ground Result The resistance should be approximately 1 8Ω for each individual glow plug 3 Install the connector plate and wires to all three glow plugs 4 Turn the key switch to ground control and pull out the red Emergency Stop button to the on position 5 Connect the red po...

Page 58: ...to Install the Fl ex Plate How to Install the Flex Plate 1 Install the flex plate onto the flywheel with the raised spline away from the flywheel 1 pump 2 pump shaft 3 pump coupler 4 flex plate 5 flywheel 6 1 32 inch 0 8 mm gap 2 Apply removable Loctite thread sealant to the flex plate mounting fasteners Torque the flex plate mounting fasteners to 36 ft lbs 49 Nm 3 Install the coupler onto the pum...

Page 59: ...trols should turn on when the switch opens Component damage hazard Do not crank the engine with the low oil pressure light on 6 2 Kubota Gasoline LPG Models Choke Adjustment Choke Adjustment The choke is solenoid operated and functions only in the gasoline mode This choke will not operate in LPG mode Note Choke adjustments are affected by climate Richer adjustment will be necessary in colder clima...

Page 60: ...to Install the Fl ex Plate How to Install the Flex Plate 1 Install the flex plate onto the flywheel with the raised spline away from the flywheel 1 pump 2 pump shaft 3 pump coupler 4 flex plate 5 flywheel 6 1 32 inch 0 8 mm gap 2 Apply removable Loctite thread sealant to the flex plate mounting fasteners Torque the flex plate mounting fasteners to 36 ft lbs 49 Nm 3 Install the coupler onto the pum...

Page 61: ...engine oil switch is a normally closed switch The switch contacts open at approximately 7 psi 0 48 bar If the oil pressure drops below the switch point the contacts open and the engine will shut off to prevent damage A low oil pressure indicator light at the ground controls should turn on when the switch opens Component damage hazard Do not crank the engine with the low oil pressure light on 6 3 P...

Page 62: ...to Install the Fl ex Plate How to Install the Flex Plate 1 Install the flex plate onto the flywheel with the raised spline away from the flywheel 1 pump 2 pump shaft 3 pump coupler 4 flex plate 5 flywheel 6 1 32 inch 0 8 mm gap 2 Apply removable Loctite thread sealant to the flex plate mounting fasteners Torque the flex plate mounting fasteners to 36 ft lbs 49 Nm 3 Install the coupler onto the pum...

Page 63: ...when the switch closes Component damage hazard Do not crank the engine with the over temperature light on The engine oil switch is a normally closed switch The switch contacts open at approximately 7 psi 0 48 bar If the oil pressure drops below the switch point the contacts open and the engine will shut off to prevent damage A low oil pressure indicator light at the ground controls should turn on ...

Page 64: ...late from the engine How to Install the Fl ex Plate How to Install the Flex Plate 1 Install the flex plate onto the flywheel with the raised spline away from the flywheel 1 pump 2 pump shaft 3 pump coupler 4 flex plate 5 flywheel 6 1 32 inch 0 8 mm gap 2 Apply removable Loctite thread sealant to the flex plate mounting fasteners Torque the flex plate mounting fasteners to 36 ft lbs 49 Nm 3 Install...

Page 65: ...pull out the red Emergency Stop button to the on position at both the ground and platform controls 4 Activate any function using auxiliary power Result The pressure gauge reads 2800 psi 193 bar immediately stop The pump is good Result The pressure fails to reach 2800 psi 193 bar the pump is faulty and will need to be serviced or replaced 5 Remove the pressure gauge and install the hydraulic hose H...

Page 66: ...ontrols 5 Observe the pressure gauge while cranking the engine Immediately stop if the pressure reaches or exceeds 3000 psi 206 bar Result The pressure gauge reads 3000 psi 206 bar immediately stop cranking the engine The pump is good Result The pressure fails to reach 3000 psi 206 bar the pump is faulty and will need to be serviced or replaced Component damage hazard Hydraulic pressure in excess ...

Page 67: ...acity Refer to Specifications Hydraulic Specifications Bodily injury hazard Beware of hot oil Contact with hot oil may cause severe burns 2 Disconnect the electrical connectors from the coils of the NFPE controller NFPE located on the drive pump 3 Tag disconnect and plug the hydraulic hoses from the pump Bodily injury hazard Spraying hydraulic oil can penetrate and burn skin Loosen hydraulic conne...

Page 68: ...lve 1600 psi 110 bar J Secondary boom down 25 30 ft lbs 34 41 Nm 6 Relief valve 1600 psi 110 bar K Primary boom down 25 30 ft lbs 34 41 Nm 7 Proportional solenoid valve D System flow regulating circuit 35 40 ft lbs 47 54 Nm 8 Solenoid valve 3 position 4 way E Steer left right 10 12 ft lbs 14 16 Nm 9 Flow regulator valve 0 1 gpm 0 38 L min V Differential sensing circuit 35 40 ft lbs 47 54 Nm 10 Dif...

Page 69: ...Service and Repair Manual September 2016 Manifolds 56 Z 34 22 IC Part No 1274592 ...

Page 70: ...ion 3 way L Platform level up 8 10 ft lbs 11 14 Nm 19 Solenoid valve 2 position 3 way T Primary boom extend 8 10 ft lbs 11 14 Nm 20 Solenoid valve 2 position 3 way S Primary boom down 8 10 ft lbs 11 14 Nm 21 Solenoid valve 2 position 3 way Q Secondary boom down 8 10 ft lbs 11 14 Nm 22 Solenoid valve 2 position 3 way N Turntable rotate right 8 10 ft lbs 11 14 Nm 23 Orifice 0 052 inch 1 32 mm X Turn...

Page 71: ...Service and Repair Manual September 2016 Manifolds 58 Z 34 22 IC Part No 1274592 ...

Page 72: ...zard Do not adjust the relief valve higher than specified 7 Repeat steps 2 through 6 to confirm the relief valve pressure setting 8 Remove the pressure gauge How to Adj ust the Secondary Boom D own R elief Valve How to Adjust the Secondary Boom Down Relief Valve Note Perform this procedure with the boom in the stowed position 1 Connect a 0 to 3000 psi 0 to 206 bar pressure gauge to the test port o...

Page 73: ...ib boom Index No Description Schematic Item Function Torque 1 Solenoid valve 3 position 4 way CH Jib boom up down 8 10 ft lbs 11 14 Nm 2 Solenoid valve 3 position 4 way CI Platform rotate left right 8 10 ft lbs 11 14 Nm 3 Flow regulator valve 0 3 gpm 1 14 L min CG Platform rotate circuit 8 10 ft lbs 11 14 Nm 4 Orifice plug 0 028 inch 0 71 mm located in P port CF Platform rotate and jib boom circui...

Page 74: ... under the drive chassis cover at the non steer end Index No Description Schematic Item Function Torque 1 Check Valve AC Pressure circuit 8 10 ft lbs 10 15 Nm 2 Solenoid valve 2 position 3 way AB 2 speed motor shift 25 30 ft lbs 34 41 Nm 3 Solenoid valve 2 position 3 way AA Brake 25 30 ft lbs 34 41 Nm 4 Orifice Plug 0 025 inch 0 64 mm AD Tank return circuit ...

Page 75: ...Charge pressure circuitthat gets hot oil out of low pressureside of drive pump and allows lowpressure flow path for brakerelease and 2 speed motor shift 10 12 ft lbs 14 16 Nm 2 Relief valve 210 psi 14 5 bar B Charge pressure circuit 35 40 ft lbs 47 54 Nm 3 Diagnostic fitting Testing 4 Flow divider combiner valve C Controls flow to drive motorsin forward and reverse 130 140 ft lbs 176 190 Nm 5 Orif...

Page 76: ... ft lbs 33 9 Nm 8 Orifice plug 0 039 inch 1 mm BQ Equalizes pressure on both sides offlow divider combiner valve BO 9 Check valve BG Drive motor anti cavitation 20 ft lbs 27 1 Nm 10 Orifice plug 0 032 inch 0 8 mm BC Brake circuit 11 Orifice plug 0 079 inch 2 mm BH Equalizes pressure on both sides offlow divider combiner valve BI 12 Check valve BM Drive motor anti cavitation 20 ft lbs 27 1 Nm 13 Ch...

Page 77: ...Service and Repair Manual September 2016 Manifolds 64 Z 34 22 IC Part No 1274592 ...

Page 78: ...lve Result The engine stalls The charge pressure relief valve is set too high Proceed to step 3 to adjust the charge pressure relief valve 3 Turn the engine off Connect a 0 to 600 psi 0 to 40 bar pressure gauge to the test port located on the traction manifold 4 Start the engine from the platform controls Slowly move the drive joystick to full stroke in either direction and observe the pressure re...

Page 79: ...nd disconnect the wiring from the coil to be tested 2 Test the coil resistance Coils with 2 terminals Connect the leads from the ohmmeter to the valve coil terminals Coils with 1 terminal Connect the positive lead from the ohmmeter to the valve coil terminal then connect the negative lead from the ohmmeter to the internal ring of the valve coil Result The resistance should be within specification ...

Page 80: ... a terminal on the coil Resistor 10Ω Genie part number 27287 Note The battery should read 9V DC or more when measured across the terminals 1 multimeter 2 9V DC battery 3 10Ω resistor 4 coil Note Dotted lines in illustration indicate a reversed connection as specified in step 6 3 Set a multimeter to read DC current Note The multimeter when set to read DC current should be capable of reading up to 8...

Page 81: ... LPG models Remove the LPG hose from the tank and then remove the tank from the machine 4 Gasoline LPG models Remove the mounting fasteners from the LPG bottle bracket then remove the bracket from the machine 5 Turn the manual fuel shutoff valve if equipped to the closed position on the fuel tank 6 Using an approved hand operated pump drain the fuel tank into a suitable container Refer to Specific...

Page 82: ... and Fitting Torque Specifications 1 Place a suitable container under the hydraulic tank Refer to Specifications Machine Specifications 2 Remove the drain plug from the hydraulic tank and completely drain the tank into a container of suitable capacity Refer to Specifications Machine Specifications Bodily injury hazard Spraying hydraulic oil can penetrate and burn skin Loosen hydraulic connections ...

Page 83: ...ly or fitting the O ring if equipped on the fitting and or hose end must be replaced All connections must be torqued to specification during installation Refer to Specifications Hydraulic Hose and Fitting Torque Specifications Note Do not allow the turntable to rotate until the hydraulic motor is installed 1 Tag disconnect and plug the hydraulic hoses from the turntable rotation motor Cap the fitt...

Page 84: ...el bearing both the inner and outer bearings including the pressed in races must be replaced 1 Be sure that both bearings are packed with clean fresh grease 2 Place the large inner bearing into the rear of the hub 3 Install a new bearing grease seal into the hub by pressing it evenly into the hub until it is flush Note Always replace the bearing grease seal when removing the hub 4 Slide the hub on...

Page 85: ...ly disconnected from the machine Boom in the stowed position Turntable secured with the turntable rotation lock Welder disconnected from the machine if equipped with the weld cable to platform option Before Troubleshooting Read understand and obey the safety rules and operating instructions in the appropriate operator s manual on your machine Be sure that all necessary tools and test equipment are...

Page 86: ...on Oil pressure switch disconnected Engine will start but will shut down after 180 seconds Check harness connection 22 Pressure sensor malfunction Pressure sensor disconnected Engine will start but the engine will go into limp home mode Check harness connection 33 Actuator position sensor malfunction Engine will start but the engine will go into limp home mode Check harness connection 04 Actuator ...

Page 87: ...DTC is related to either an engine shutdown fault or an oxygen sensor fault the following statement applies If the machine is not serviced by a technician and the condition causing the DTC no longer exists the DTC will no longer display after the fourth start cycle In the event the DTC is not related to an engine shutdown or oxygen sensor fault the DTC will no longer be shown Use the Up and Down a...

Page 88: ... Injector 5 open or short to ground 655 5 DTC 122 TPS1 voltage low 51 4 DTC 274 Injector 5 coil shorted 655 6 DTC 123 TPS1 voltage high 51 3 DTC 276 Injector 6 open or short to ground 656 5 DTC 127 IAT higher than expected stage 2 105 0 DTC 277 Injector 6 coil shorted 656 6 DTC 129 BP pressure low 108 1 DTC 279 Injector 7 open or short to ground 657 5 DTC 134 EGO1 open lazy 724 10 DTC 280 Injector...

Page 89: ...low 520202 1 DTC 616 Start relay ground short 1321 4 DTC 1163 Adaptive learn NG high 520203 0 DTC 617 Start relay coil short to power 1321 3 DTC 1164 Adaptive learn NG low 520203 1 DTC 627 Fuel pump relay coil open 1348 5 DTC 1165 Catalyst inactive on LPG 520213 10 DTC 628 Fuel pump high side open or short to ground 1347 5 DTC 1166 Catalyst inactive on NG 520214 0 DTC 628 Fuel pump relay control g...

Page 90: ...4 4 DTC 1561 AUX analog Pull Down 2 low voltage 0 4 DTC 1423 ERWT1 higher than expected stage 1 443 15 DTC 1611 Sensor supply voltage 1 and 2 out of range 1079 31 DTC 1424 ERWT2 higher than expected stage 1 444 15 DTC 1612 Microprocessor failure RTI 1 629 31 DTC 1425 ERWT1 higher than expected stage 2 443 0 DTC 1613 Microprocessor failure RTI 2 629 31 DTC 1426 ERWT2 higher than expected stage 2 44...

Page 91: ...6 Spark coil 3 primary open or short to ground 1270 5 DTC 1662 PWM6 short to power 925 3 DTC 2307 Spark coil 3 primary shorted 1270 6 DTC 1663 PWM7 open ground short 926 5 DTC 2309 Spark coil 4 primary open or short to ground 1271 5 DTC 1664 PWM7 short to power 926 3 DTC 2310 Spark coil 4 primary shorted 1271 6 DTC 1665 PWM8 open ground short 2646 5 DTC 2312 Spark coil 5 primary open or short to g...

Page 92: ...eater supply high voltage 3222 3 DTC 8912 UEGO pump voltage at high drive limi 3217 3 DTC 8903 UEGO heater supply low voltage 3222 4 DTC 8913 UEGO pump voltage at low drive limit 3217 3 DTC 8904 UEGO cal resistor voltage high 3221 3 DTC 8914 UEGO sense cell slow to warm up 3225 4 DTC 8905 UEGO cal resistor voltage low 3221 4 DTC 8915 UEGO pump cell slow to warm up 3222 4 DTC 8906 UEGO return volta...

Page 93: ...Service and Repair Manual September 2016 Fault Codes 80 Z 34 22 IC Part No 1274592 This page intentionally left blank ...

Page 94: ... safety rules and operating instructions in the appropriate operator s manual on your machine Be sure that all necessary tools and test equipment are available and ready for use About This Section There are two groups of schematics in this section Electrical Schematics Electrocution burn hazard Contact with electrically charged circuits could result in death or serious injury Remove all rings watc...

Page 95: ...minal T circuits connect at terminal Circuits crossing no connection Quick disconnect terminal Circuit breaker with amperage Key switch Toggle switch DPDT Toggle switch SPDT Pump or Motor Tilt sensor Horn button normally open Emergency stop button normally closed Resistor with ohm value Battery seperator Gauge sending unit Oil temperature switch normally open Coolant temperature switch normally op...

Page 96: ...tion 3 way Differential sensing valve Filter with bypass relief valve Relief valve with pressure setting Priority flow regulator valve Solenoid operated proportional valve Directional valve mechanically activated Flow divider combiner valve Pilot operated 3 position 3 way shuttle valve Solenoid operated 2 position 3 way directional valve Counterbalance valve with pressure and pilot ratio Solenoid ...

Page 97: ... option CR17 Hydraulic oil cooling fan option CR23 Drive light enable CR27 Brake circuit relay lift drive option CR30 Limit switch relay lift drive option CR76 Load sense aux recovery AS models CR51 Aircraft package option G Gauge G1 Battery Charge Indicator G2 Engine oil pressure G3 Engine coolant temp G4 Engine oil temp G6 Hour meter Item Description H Horn or Alarm H1 Tilt load sense alarm H4 D...

Page 98: ...el select switch ford efi only TS4 Hi low rpm switch TS6 Glow plug switch TS7 Platform rotate switch TS8 Jib rotate switch jib option TS9 Platform level switch TS13 Primary boom extend retract switch TS14 Drive speed switch TS15 Drive enable switch TS43 Heater switch option TS46 Proximity kill switch option TS47 Generator switch option TS51 Auxiliary pump toggle switch TS52 Engine start toggle swi...

Page 99: ...or X101 ALC500 input out connectors X102 ALC500 input out connectors X103 ALC500 input out connectors X104 ALC500 input out connectors X105 ALC500 input out connectors X106 ALC500 input out connectors X107 ALC500 input out connectors X108 ALC500 input out connectors X109 ALC500 input out connectors X1 4 Circuit splice Wire Color Legend Item Description BL Blue BK Black BR Brown GN Green OR Orange ...

Page 100: ...September 2016 Service and Repair Manual 87 Electrical Schematic Gasoline LPG Kubota WG972 Models from serial number Z3413 9461 ...

Page 101: ...Service and Repair Manual September 2016 88 Z 34 22 IC Part No 1274592 Electrical Schematic Gasoline LPG Kubota WG972 Models from serial number Z3413 9461 ...

Page 102: ...September 2016 Service and Repair Manual Part No 1274592 Z 34 22 IC 89 Electrical Schematic Gasoline LPG Kubota WG972 Models from serial number Z3413 9461 ...

Page 103: ...Service and Repair Manual September 2016 90 Electrical Schematic Gasoline LPG Kubota WG972 Models from serial number Z3413 9461 ...

Page 104: ...September 2016 Service and Repair Manual 91 Ground Control Box Switch Panel Wiring Diagram Gasoline LPG Kubota WG972 Models from serial number Z3413 9461 ...

Page 105: ...Service and Repair Manual September 2016 92 Z 34 22 IC Part No 1274592 Ground Control Box Switch Panel Wiring Diagram Gasoline LPG Kubota WG972 Models from serial number Z3413 9461 ...

Page 106: ...September 2016 Service and Repair Manual Part No 1274592 Z 34 22 IC 93 Ground Control Box Terminal Strip Wiring Diagram Gasoline LPG Kubota WG972 Models from serial number Z3413 9461 ...

Page 107: ...Service and Repair Manual September 2016 94 Ground Control Box Terminal Strip Wiring Diagram Gasoline LPG Kubota WG972 Models from serial number Z3413 9461 ...

Page 108: ...September 2016 Service and Repair Manual 95 Platform Control Box Wiring Diagram Gasoline LPG Kubota WG972 Models from serial number Z3413 9461 ...

Page 109: ...Service and Repair Manual September 2016 96 Z 34 22 IC Part No 1274592 Platform Control Box Wiring Diagram Gasoline LPG Kubota WG972 Models from serial number Z3413 9461 ...

Page 110: ...September 2016 Service and Repair Manual 97 Electrical Schematic Gasoline LPG GM 998L Models from serial number Z3416F 10967 ...

Page 111: ...Service and Repair Manual September 2016 98 Z 34 22 IC Part No 1274592 Electrical Schematic Gasoline LPG GM 998L Models from serial number Z3416F 10967 ...

Page 112: ...September 2016 Service and Repair Manual Part No 1274592 Z 34 22 IC 99 Electrical Schematic Gasoline LPG GM 998L Models from serial number Z3416F 10967 ...

Page 113: ...Service and Repair Manual September 2016 100 Electrical Schematic Gasoline LPG GM 998L Models from serial number Z3416F 10967 ...

Page 114: ...September 2016 Service and Repair Manual 101 Ground Control Box Switch Panel Wiring Diagram Gasoline LPG GM 998L Models from serial number Z3416F 10967 ...

Page 115: ...Service and Repair Manual September 2016 102 Z 34 22 IC Part No 1274592 Ground Control Box Switch Panel Wiring Diagram Gasoline LPG GM 998L Models from serial number Z3416F 10967 ...

Page 116: ...September 2016 Service and Repair Manual 103 Platform Control Box Wiring Diagram Gasoline LPG GM 998L Models from serial number Z3416F 10967 ...

Page 117: ...Service and Repair Manual September 2016 104 Z 34 22 IC Part No 1274592 Platform Control Box Wiring Diagram Gasoline LPG GM 998L Models from serial number Z3416F 10967 ...

Page 118: ...September 2016 Service and Repair Manual 105 Electrical Schematic Diesel Models from serial number Z3413 9461 ANSI CSA ...

Page 119: ...Service and Repair Manual September 2016 106 Z 34 22 IC Part No 1274592 Electrical Schematic Diesel Models ANSI CSA from serial number Z3413 9461 ...

Page 120: ...September 2016 Service and Repair Manual Part No 1274592 Z 34 22 IC 107 Electrical Schematic Diesel Models ANSI CSA from serial number Z3413 9461 ...

Page 121: ...Service and Repair Manual September 2016 108 Electrical Schematic Diesel Models from serial number Z3413 9461 ANSI CSA ...

Page 122: ...September 2016 Service and Repair Manual 109 Ground Control Box Switch Panel Wiring Diagram Diesel Models from serial Z3413 9461 ANSI CSA ...

Page 123: ...Service and Repair Manual September 2016 110 Z 34 22 IC Part No 1274592 Ground Control Box Switch Panel Wiring Diagram Diesel Models ANSI CSA ...

Page 124: ...September 2016 Service and Repair Manual Part No 1274592 Z 34 22 IC 111 Ground Control Box Terminal Strip Wiring Diagram Diesel Models ANSI CSA from serial number Z3413 9461 ...

Page 125: ...Service and Repair Manual September 2016 112 Ground Control Box Terminal Strip Wiring Diagram Diesel Models ANSI CSA ...

Page 126: ...September 2016 Service and Repair Manual 113 Platform Control Box Wiring Diagram Diesel Models from serial number Z3413 9461 ANSI CSA ...

Page 127: ...Service and Repair Manual September 2016 114 Z 34 22 IC Part No 1274592 Platform Control Box Wiring Diagram Diesel Models ANSI CSA from serial number Z3413 9461 ...

Page 128: ...September 2016 Service and Repair Manual 115 Electrical Schematic Diesel Models from serial number Z3413 9461 CE AS ...

Page 129: ...Service and Repair Manual September 2016 116 Z 34 22 IC Part No 1274592 Electrical Schematic Diesel Models CE AS from serial number Z3413 9461 ...

Page 130: ...September 2016 Service and Repair Manual Part No 1274592 Z 34 22 IC 117 Electrical Schematic Diesel Models CE AS from serial number Z3413 9461 ...

Page 131: ...Service and Repair Manual September 2016 118 Electrical Schematic Diesel Models from serial number Z3413 9461 CE AS ...

Page 132: ...September 2016 Service and Repair Manual 119 Ground Control Box Switch Panel Wiring Diagram Diesel Models from serial Z3413 9461 CE AS ...

Page 133: ...Service and Repair Manual September 2016 120 Z 34 22 IC Part No 1274592 Ground Control Box Switch Panel Wiring Diagram Diesel Models CE AS ...

Page 134: ...September 2016 Service and Repair Manual Part No 1274592 Z 34 22 IC 121 Ground Control Box Terminal Strip Wiring Diagram Diesel Models CE AS from serial number Z3413 9461 ...

Page 135: ...Service and Repair Manual September 2016 122 Ground Control Box Terminal Strip Wiring Diagram Diesel Models CE AS ...

Page 136: ...September 2016 Service and Repair Manual 123 Platform Control Box Wiring Diagram Diesel Models from serial number Z3413 9461 CE AS ...

Page 137: ...Service and Repair Manual September 2016 124 Z 34 22 IC Part No 1274592 Platform Control Box Wiring Diagram Diesel Models CE AS from serial number Z3413 9461 ...

Page 138: ...September 2016 Service and Repair Manual 125 GM 998 Engine Schematic ...

Page 139: ...Service and Repair Manual September 2016 126 Z 34 22 IC Part No 1274592 GM 998 Engine Schematic ...

Page 140: ...September 2016 Service and Repair Manual Part No 1274592 Z 34 22 IC 127 GM Engine Harness Diagram ...

Page 141: ...Service and Repair Manual September 2016 128 GM Engine Harness Diagram ...

Page 142: ...September 2016 Service and Repair Manual 129 Kubota D1105 Engine Schematic ...

Page 143: ...Service and Repair Manual September 2016 130 Z 34 22 IC Part No 1274592 Kubota D1105 Engine Schematic ...

Page 144: ...September 2016 Service and Repair Manual Part No 1274592 Z 34 22 IC 131 Perkins 403F 11 Engine Schematic ...

Page 145: ...Service and Repair Manual September 2016 132 Perkins 403F 11 Engine Schematic ...

Page 146: ...September 2016 Service and Repair Manual 133 Manifold and Limit Switch Wiring Diagram ...

Page 147: ...Service and Repair Manual September 2016 134 Manifold and Limit Switch Wiring Diagram ...

Page 148: ...September 2016 Service and Repair Manual 135 Hydraulic Schematic 2WD Models ...

Page 149: ...Service and Repair Manual September 2016 136 Z 34 22 IC Part No 1274592 Hydraulic Schematic 2WD Models ...

Page 150: ...September 2016 Service and Repair Manual Part No 1274592 Z 34 22 IC 137 Hydraulic Schematic 2WD Models ...

Page 151: ...Service and Repair Manual September 2016 138 Hydraulic Schematic 2WD Models ...

Page 152: ...September 2016 Service and Repair Manual 139 Hydraulic Schematic 4WD Models ...

Page 153: ...Service and Repair Manual September 2016 140 Z 34 22 IC Part No 1274592 Hydraulic Schematic 4WD Models ...

Page 154: ...September 2016 Service and Repair Manual Part No 1274592 Z 34 22 IC 141 Hydraulic Schematic 4WD Models ...

Page 155: ...Service and Repair Manual September 2016 142 Hydraulic Schematic 4WD Models Z 34 22 IC Part No 1274592 Service and R epair M anual September 2016 ...

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