Genie Z-34/22IC Service Manual
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Genie Z-34/22IC Service Manual

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Service Manual
Part No. 128267
Rev A
Refer to inside cover for additional serial number information
July 2007
(from serial number 3242 to 4799)

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Summary of Contents for Genie Z-34/22IC

  • Page 1 Service Manual Part No. 128267 Rev A Refer to inside cover for additional serial number information July 2007 (from serial number 3242 to 4799)

  • Page 2: Introduction

    Technical Publications Genie Industries 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.

  • Page 3: Serial Number Legend

    Model year Country of manufacture: USA This machine complies with: ANSI A92.5 CAN B.354.4 Serial number stamped on chassis Genie Industries 18340 NE 76th Street Serial label (located under cover) Redmond, WA 98052 PN - 77055 Part No. 128267 Z-34/22 IC...
  • Page 4 July 2007 This page intentionally left blank. Z-34/22 IC Part No. 128267...

  • Page 5: Safety Rules

    Danger Failure to obey the instructions and safety rules in this manual and the appropriate Genie Z-34/22 IC Operator’s Manual will result in death or serious injury. Many of the hazards identified in the operator’s manual are also safety hazards when maintenance and repair procedures are performed.
  • Page 6 Section 1 • Safety Rules July 2007 SAFETY RULES Personal Safety Workplace Safety Any person working on or around a machine must Be sure to keep sparks, flames and be aware of all known safety hazards. Personal lighted tobacco away from flammable and safety and the continued safe operation of the combustible materials like battery gases machine should be your top priority.

  • Page 7: Table Of Contents

    July 2007 Table of Contents Introduction Important Information ....................ii Serial Number Information .................... ii Serial Number Legend ....................iii Section 1 Safety Rules General Safety Rules ....................v Section 2 Specifications Machine Specifications ..................2 - 1 Performance Specifications ................... 2 - 2 Hydraulic Oil Specifications ...................
  • Page 8 July 2007 TABLE OF CONTENTS Section 3 Scheduled Maintenance Procedures Introduction ......................3 - 1 Pre-Delivery Preparation ..................3 - 3 Maintenance Inspection Report ................3 - 5 Checklist A Procedures Inspect the Manuals and Decals ..............3 - 7 Perform Pre-operation Inspection ..............
  • Page 9 July 2007 TABLE OF CONTENTS Section 3 Scheduled Maintenance Procedures, continued B-12 Test the Engine Idle Select ................ 3 - 24 B-13 Test the Fuel Select Operation - Gasoline/LPG Models ......3 - 25 B-14 Test the Drive Brakes ................3 - 26 B-15 Test the Drive Speed - Stowed Position .............
  • Page 10 July 2007 TABLE OF CONTENTS Section 4 Repair Procedures Introduction ......................4 - 1 Platform Controls Drive Joystick ....................4 - 2 Boom Function Speed Controller ..............4 - 5 Platform Components Platform Leveling Slave Cylinder ..............4 - 6 Platform Rotator ...................
  • Page 11 July 2007 TABLE OF CONTENTS Section 4 Repair Procedures, continued Kubota DF-752 Engine Choke Adjustments ..................4 - 32 Timing Adjustment ..................4 - 32 Carburetor Adjustment ................4 - 32 RPM Adjustment ..................4 - 32 Flex Plate ....................4 - 32 Coolant Temperature and Oil Pressure Switches ........
  • Page 12 July 2007 TABLE OF CONTENTS Section 4 Repair Procedures, continued Fuel and Hydraulic Tanks 11-1 Fuel Tank ....................4 - 53 11-2 Hydraulic Tank ................... 4 - 54 Turntable Rotation Components 12-1 Rotation Hydraulic Motor ................4 - 55 Axle Components 13-1 Hub and Bearings, 2WD Models ..............
  • Page 13 July 2007 TABLE OF CONTENTS Section 5 Schematics, continued Ground Control Box Wiring Diagram - Diesel Models (from serial number 3242 to 3308) ................ 5 - 17 Ground Control Box Wiring Diagram - Diesel Models (from serial number 3309 to 3577) ................ 5 - 18 Ground Control Box Wiring Diagram - Diesel Models (from serial number 3578 to 4799) ................
  • Page 14 July 2007 This page intentionally left blank. Z-34/22 IC Part No. 128267...

  • Page 15: A Machine Specifications

    125 ft-lbs (lubricated) 170 Nm 170 Nm For operational specifications, refer to the Operator's Manual. Continuous improvement of our products is a Genie policy. Product specifications are subject to change without notice. Part No. 128267 Z-34/22 IC 2 - 1...

  • Page 16: Performance Specifications

    3 to 4 ft on paved surface 0.9 to 1.2 m Gradeability See Operator's Manual Continuous improvement of our products is a Genie policy. Product specifications are subject to change without notice. 2 - 2 Z-34/22 IC Part No. 128267...

  • Page 17: Hydraulic Oil Specifications

    Note: Genie specifications require additional Water content, maximum 200 ppm equipment and special installation instructions for the approved optional fluids. Consult the Genie Chevron Rykon MV oil is fully compatible and Industries Service Department before use. mixable with Shell Donax TG (Dexron III) oils.

  • Page 18: Hydraulic Component Specifications

    (before serial number 3734) 30 cc Displacement per revolution 1.53 cu in (after serial number 3733) 25 cc Continuous improvement of our products is a Genie policy. Product specifications are subject to change without notice. 2 - 4 Z-34/22 IC Part No. 128267...

  • Page 19: Manifold Component Specifications

    6Ω (schematic item E, CH, CI) Proportional solenoid valve, 12V DC 5Ω (schematic item D) Continuous improvement of our products is a Genie policy. Product specifications are subject to change without notice. Part No. 128267 Z-34/22 IC 2 - 5...

  • Page 20: Kubota D-905 Engine Specifications

    Extreme operating temperatures may require the use of alternative engine oils. For oil requirements, refer to the Engine Operator Handbook on your machine. Continuous improvement of our products is a Genie policy. Product specifications are subject to change without notice. 2 - 6 Z-34/22 IC...

  • Page 21: Kubota Df-752 Engine Specifications

    0.125 gpm Output 30A, 14V DC 0.47 L/min Fan belt deflection inch Continuous improvement of our products is a 7 to 9 mm Genie policy. Product specifications are subject to change without notice. Part No. 128267 Z-34/22 IC 2 - 7...

  • Page 22: Perkins 403C-11 Engine Specifications

    Extreme operating temperatures may require the use of Continuous improvement of our products is a alternative engine oils. For oil requirements, refer to the Genie policy. Product specifications are Engine Operator Handbook on your machine. subject to change without notice.

  • Page 23: Hydraulic Hose And Fitting Torque Specifications

    O-rings. They are not standard SAE size O-rings. They are available in the O-ring field service kit (Genie part SAE O-ring Boss Port number 49612). (tube fitting - installed into Aluminum) 2 Lubricate the O-ring before installation.
  • Page 24 Section 2 • Specifications July 2007 SPECIFICATIONS REV A SAE FASTENER TORQUE CHART • This chart is to be used as a guide only unless noted elsewhere in this manual • A574 High Strength Grade 5 Grade 8 SIZE THREAD Black Oxide Bolts LUBED LUBED...
  • Page 25 Repair any machine damage or malfunction injury. before operating the machine. Indicates a potentially hazardous Use only Genie approved replacement parts. situation which, if not avoided, may result in property damage. Machines that have been out of service for a...
  • Page 26 Section 3 • Scheduled Maintenance Procedures July 2007 SCHEDULED MAINTENANCE PROCEDURES Maintenance Symbols Legend Pre-delivery Preparation Report The following symbols have been used in this The pre-delivery preparation report contains manual to help communicate the intent of the checklists for each type of scheduled inspection. instructions.

  • Page 27: Pre-Delivery Preparation

    The Maltings, Wharf Road PO Box 97030 Grantham, Lincolnshire Redmond, WA 98073-9730 NG31- 6BH England (425) 881-1800 (44) 1476-584333 Copyright © 2002 by Genie Industries. Genie® is a registered trademark of Genie Industries. Part No. 128267 Z-34/22 IC 3 - 3 Rev B...
  • Page 28 Section 3 • Scheduled Maintenance Procedures July 2007 This page intentionally left blank. 3 - 4 Z-34/22 IC Part No. 128267...

  • Page 29: Maintenance Inspection Report

    July 2007 Section 3 • Scheduled Maintenance Procedures Maintenance Inspection Report Model Checklist A - Rev A Y N R Checklist B - Rev A Y N R A-1 Manuals and decals B-1 Engine choke - Serial number Gasoline/LPG models A-2 Pre-operation inspection B-2 Exhaust system...
  • Page 30 Section 3 • Scheduled Maintenance Procedures July 2007 MAINTENANCE INSPECTION REPORT Model Checklist C - Rev A Y N R C-1 Grease platform Serial number overload (if equipped) C-2 Test platform overload Date (if equipped) C-3 Clean fuel tank - Hour meter Diesel models Machine owner...

  • Page 31: Checklist A Procedures

    In addition, maintaining all of the safety and Note: Contact your authorized Genie distributor or instructional decals in good condition is mandatory Genie Industries if replacement manuals or decals for safe machine operation. Decals alert operators are needed.

  • Page 32: Perform Pre-Operation Inspection

    Complete information on how to perform this also serves to determine if routine maintenance procedure is available in the appropriate procedures are required. Genie Z-34/22 IC Operator's Manual on your machine. Complete information on how to perform this procedure is available in the appropriate Genie Z-34/22 IC Operator's Manual on your machine.

  • Page 33: Perform Engine Maintenance

    (Perkins part number 100816460). · C-5 Perform Engine Maintenance - Diesel Models Kubota D905 Operator's Manual · D-4 Replace the Hydraulic Filters Genie part number 31743 · D-5 Check the Turnable Rotation Bearing Bolts Kubota DF752 Operator's Manual Genie part number...

  • Page 34: Inspect The Engine Air Filter

    8 Install the gasket and baffle (if equipped), and end cap onto the air cleaner canister. Note: Be sure the dust discharge valve is facing Note: Genie specifications require that this down when installed. procedure be performed every 40 hours or weekly, whichever comes first.

  • Page 35: Perform Engine Maintenance - Kubota Models

    Kubota DF752 Operator's Manual Kubota DF752 Operator's Manual (Kubota part number EG601-8916-1). (Kubota part number EG601-8916-1). Kubota D905 Operator's Manual Kubota D905 Operator's Manual Genie part number 31743 Genie part number 31743 Kubota DF752 Operator's Manual Kubota DF752 Operator's Manual...

  • Page 36: Perform Engine Maintenance - Kubota Models

    Note: The lift cylinder safety chock is available through Genie Service Parts (part number 36555). 2 Locate the grease fitting on the inside of the bearing in the middle of the turntable. 3 Pump grease into the turntable rotation bearing.

  • Page 37: Perform Engine Maintenance - Kubota Models

    Kubota DF752 Operator's Manual turntable rotation bearing. (Kubota part number EG601-8916-1). Grease Specification Kubota D905 Operator's Manual Chevron Ultra-duty grease, EP NLGI 2 (lithium based) Genie part number 31743 or equivalent Kubota DF752 Operator's Manual Genie part number 84250 Part No. 128267...

  • Page 38: Drain The Fuel Filter/Water Separator - Diesel Models

    Separator - Diesel Models Immediately tighten the drain plug. Note: Genie specifications require that this procedure be performed every 200 hours or monthly, whichever comes first. Proper maintenance of the fuel filter/water separator is essential for good engine performance.
  • Page 39 Kubota D905 Operator's Manual, (Kubota part number 16622-8916-5) OR the Perkins 403C-11 User's Handbook (Perkins part number 100816460). Kubota D905 Operator's Manual Genie part number 31743 Perkins 403C-11 User's Handbook Genie part number 97360 Part No. 128267...

  • Page 40: Checklist B Procedures

    Result: The choke solenoid should be fully retracted when the choke switch is activated. Note: Genie requires that this procedure be performed every 250 hours or quarterly, whichever 4 Turn the key switch to platform control. comes first.

  • Page 41: Check The Exhaust System

    REV A CHECKLIST B PROCEDURES Check the Exhaust System Inspect the Battery Note: Genie requires that this procedure be Note: Genie requires that this procedure be performed every 250 hours or quarterly, whichever performed every 250 hours or quarterly, whichever comes first.
  • Page 42 Section 3 • Scheduled Maintenance Procedures July 2007 CHECKLIST B PROCEDURES REV A 5 Remove the battery vent caps and check the 9 Check the ambient air temperature and adjust specific gravity of each battery cell with a the specific gravity reading for each cell as hydrometer.

  • Page 43: Inspect The Electrical Wiring

    CHECKLIST B PROCEDURES Inspect the Electrical Wiring Inspect the Tires, Wheels and Lug Nut Torque Note: Genie requires that this procedure be performed every 250 hours or quarterly, whichever Note: Genie requires that this procedure be comes first. performed every 250 hours or quarterly, whichever comes first.

  • Page 44: Confirm The Proper Brake Configuration

    Confirm the Proper Check the Oil Level in the Brake Configuration Drive Hubs Note: Genie requires that this procedure be Note: Genie requires that this procedure be performed every 250 hours or quarterly, whichever performed every 250 hours or quarterly, whichever comes first.

  • Page 45: Perform Engine Maintenance - Perkins 403C-11 Models

    Check and Adjust the Perkins 403C-11 Models Engine RPM Note: Engine specifications require that this Note: Genie requires that this procedure be procedure be performed every 250 hours or six performed every 250 hours or quarterly, whichever months, whichever comes first.
  • Page 46 Section 3 • Scheduled Maintenance Procedures July 2007 CHECKLIST B PROCEDURES REV A 2 Turn the low idle adjustment screw on the Diesel models: carburetor clockwise to increase rpm or 1 Connect an rpm gauge to the engine, and then counterclockwise to decrease rpm.

  • Page 47: Test The Ground Control Override

    REV A CHECKLIST B PROCEDURES B-10 Test the Ground Control Override Note: Genie requires that this procedure be performed every 250 hours or quarterly, whichever comes first. A properly functioning ground control override is essential to safe machine operation. The ground...

  • Page 48: Test The Platform Self-Leveling

    REV A B-11 B-12 Test the Platform Self-leveling Test the Engine Idle Select Note: Genie requires that this procedure be performed every 250 hours or quarterly, whichever comes first. Note: Genie requires that this procedure be Automatic platform self-leveling throughout...

  • Page 49: Test The Fuel Select Operation - Gasoline/Lpg Models

    7 Move the engine idle control switch to foot switch activated high idle (rabbit and foot switch symbol). Note: Genie requires that this procedure be Result: The engine should not change to performed every 250 hours or quarterly, whichever high idle.

  • Page 50: Test The Drive Brakes

    6 Restart the engine and allow it to run at low idle. 7 Press down the foot switch to allow the engine Note: Genie requires that this procedure be to run at high idle. performed every 250 hours or quarterly, whichever Result: The engine should start promptly and comes first.

  • Page 51: Test The Drive Speed - Stowed Position

    Release the drive joystick when your reference point on the machine crosses the test line. Note: Genie requires that this procedure be 8 Measure the distance between the test line and performed every 250 hours or quarterly, whichever your machine reference point.

  • Page 52: Test The Drive Speed - Raised Or Extended Position

    9 Choose a point on the machine; i.e., contact patch of a tire, as a visual reference for use Note: Genie requires that this procedure be when crossing the start and finish lines. performed every 250 hours or quarterly, whichever comes first.

  • Page 53: Inspect The Fuel And Hydraulic Tank Cap Venting Systems

    Result: If air does not pass through the cap, clean or replace the cap. Proceed to step 3. Note: When checking for positive tank cap venting, Note: Genie requires that this procedure be air should pass freely through the cap. performed every 250 hours or quarterly, whichever 3 Using a mild solvent, carefully wash the cap comes first.

  • Page 54: Perform Hydraulic Oil Analysis

    B-19 Perform Hydraulic Oil Analysis Test the Alarm Package (if equipped) Note: Genie requires that this procedure be Note: Genie requires that this procedure be performed every 250 hours or quarterly, whichever performed every 250 hours or quarterly, whichever comes first.

  • Page 55: Replace The Diesel Fuel Filter/Water Separator Element - Diesel Models

    July 2007 Section 3 • Scheduled Maintenance Procedures REV A CHECKLIST B PROCEDURES 4 At the platform controls pull out the red B-20 Emergency Stop button to the on position. Replace the Diesel Fuel Filter/ Result: The flashing beacon should be on Water Separator Element - and flashing.
  • Page 56 5 Apply a thin layer of oil to the bowl gasket and Kubota D905 Operator's Manual then install the new filter element onto the bowl. Genie part number 31743 6 Tighten the drain plug and fill the bowl and filter assembly with clean diesel fuel.

  • Page 57: Perform Engine Maintenance - Kubota D905 Models

    400 hours. Required maintenance procedures and additional engine information is available in the Kubota D905 Operator's Manual (Kubota part number 16622-8916-5). Kubota D905 Operator's Manual Genie part number 31743 Part No. 128267 Z-34/22 IC 3 - 33...

  • Page 58: Checklist C Procedures

    Grease the Platform Overload Test the Platform Overload Mechanism (if equipped) System (if equipped) Note: Genie specifications require that this Note: Genie specifications require that this procedure be performed every 500 hours or 6 procedure be performed every 500 hours or six months, whichever comes first.
  • Page 59 July 2007 Section 3 • Scheduled Maintenance Procedures REV A CHECKLIST C PROCEDURES The platform support subassembly utilizes two load 4 Using a suitable lifting device, place a test support arms that are opposed in a full weight equal to that of the available capacity parallelogram link.
  • Page 60 Section 3 • Scheduled Maintenance Procedures July 2007 CHECKLIST C PROCEDURES REV A 6 Using a suitable lifting device, place an 8 Test all machine functions from the platform additional 10 lbs / 4.5 kg of weight onto the controls. platform.

  • Page 61: Clean The Fuel Tank - Diesel Models

    Note: Genie requires that this procedure be Note: Be sure to only use a hand operated pump performed every 500 hours or six months, suitable for use with gasoline and/or diesel fuel.

  • Page 62: Perform Engine Maintenance - Diesel Models

    Kubota D905 Operator's Manual (Kubota part number 16622-8916-5) OR the (Kubota part number 16622-8916-5). Perkins 403C-11 User's Handbook (Perkins part number 100816460). Kubota D905 Operator's Manual Genie part number 31743 Kubota D905 Operator's Manual Genie part number 31743 Perkins 403C-11 User's Handbook...

  • Page 63: Checklist D Procedures

    REV A Check the Primary Boom Check the Free-wheel Wear Pads Configuration Note: Genie requires that this procedure be Note: Genie requires that this procedure be performed every 1000 hours or annually, performed every 1000 hours or annually, whichever comes first.

  • Page 64: Replace The Drive Hub Oil

    6 Re-engage the torque hubs by turning over the hub disconnect caps. Carefully remove Note: Genie requires that this procedure be the jack stands, lower the machine and remove the jack. performed every 1000 hours or annually, whichever comes first.

  • Page 65: Replace The Hydraulic Filters

    Contact with hot oil may cause severe burns. Note: The medium pressure filter is mounted in the Note: Genie requires that this procedure be engine compartment. performed every 1000 hours or annually, 5 Place a suitable container under the medium whichever comes first.

  • Page 66: Check The Turntable Rotation Bearing Bolts

    Check the Turntable Rotation 180 ft-lbs / 244 Nm. Bearing Bolts Note: Genie requires that this procedure be performed every 1000 hours or annually, whichever comes first. Maintaining proper torque on the turntable bearing bolts is essential to safe machine operation.

  • Page 67: Inspect For Turntable Bearing Wear

    Note: To obtain an accurate measurement, place the dial indicator no more than 1 inch / 2.5 cm from the turntable rotation bearing. Note: Genie requires that this procedure be performed every 1000 hours or annually, whichever comes first. Periodic inspection of turntable bearing wear is essential to safe machine operation, good machine performance and service life.

  • Page 68: Perform Engine Maintenance

    12 Remove the dial indicator from the machine. Kubota DF752 Operator's Manual (Kubota part number EG601-8916-1) OR the Perkins 403C-11 User's Handbook (Perkins part number 100816460). Kubota D905 Operator's Manual Genie part number 31743 Kubota DF752 Operator's Manual Genie part number 84250 Perkins 403C-11 User's Handbook...

  • Page 69: Checklist E Procedures

    Component damage hazard. The engine must not be started with the hydraulic tank shut-off valves Note: Genie requires that this procedure be in the closed position or performed every 2000 hours or two years, component damage will occur. If whichever comes first.

  • Page 70: Grease The Steer Axle Wheel Bearings, 2Wd Models

    10 Rinse out the inside of the tank using a mild solvent. Note: Genie requires that this procedure be 11 Install the suction strainers using a pipe thread performed every 2000 hours or every two years, whichever comes first.
  • Page 71 July 2007 Section 3 • Scheduled Maintenance Procedures REV A CHECKLIST E PROCEDURES 6 Remove the dust cap from the hub. Remove the 14 Place the large inner bearing into the rear of the cotter pin from the castle nut. hub.

  • Page 72: Perform Engine Maintenance

    (Kubota part number 16622-8916-5) OR the (Perkins part number 100816460). Kubota DF752 Operator's Manual (Kubota part number EG601-8916-1) OR the Perkins 403C-11 User's Handbook Perkins 403C-11 User's Handbook Genie part number 97360 (Perkins part number 100816460). Kubota D905 Operator's Manual Genie part number 31743...
  • Page 73 Read, understand and obey the safety rules result in death or serious injury. and operating instructions in the appropriate Indicates a potentially hazardous Genie Z-34/22 IC Operator's Manual on your situation which, if not avoided, machine. could result in death or serious Be sure that all necessary tools and parts are injury.

  • Page 74: Platform Controls

    Section 4 • Repair Procedures July 2007 Platform Controls REV A 3 Locate and disconnect the wire connected to terminal "A" on the drive joystick circuit board. Drive Joystick 4 Set a multimeter to read DC current. How to Adjust the Drive Joystick Note: The multimeter, when set to read DC current, should be capable of reading up to Note: Perform this procedure with the engine off.
  • Page 75 July 2007 Section 4 • Repair Procedures REV A PLATFORM CONTROLS Set the threshold: Set the low range: Note: The drive joystick adjustments are not final 11 Start the engine from the platform controls and adjustments. Final adjustments will need to be raise the primary boom approximately made to meet drive speed specifications.
  • Page 76 Section 4 • Repair Procedures July 2007 PLATFORM CONTROLS REV A 21 Bring the machine to top drive speed before 26 Continue at full speed and note the time when reaching the start line. Begin timing when your the machine reference point passes over the reference point on the machine crosses the finish line.

  • Page 77: Boom Function Speed Controller

    July 2007 Section 4 • Repair Procedures REV A PLATFORM CONTROLS 3 Locate the diode between the black wire from the boom function speed controller and the Boom Function Speed white/red wire. Controller 4 Connect the red (+) lead from a volt meter to the wire connector of the white/red wire next to the Boom Function Speed diode.

  • Page 78: Platform Components

    Section 4 • Repair Procedures July 2007 Platform Components REV A 5 Use a soft metal drift to remove the rod-end pivot pin. Platform Leveling Slave Cylinder 6 Use a soft metal drift to remove the barrel-end pivot pin. The slave cylinder and the rotator pivot are the two primary supports for the platform.

  • Page 79: Platform Rotator

    July 2007 Section 4 • Repair Procedures REV A PLATFORM COMPONENTS 5 Support the platform rotator with a suitable lifting device. Do not apply any lifting pressure. Platform Rotator 6 Remove the pin retaining fasteners from the jib boom and leveling links to platform rotator pivot The platform rotator is a hydraulically-activated pins.
  • Page 80 Section 4 • Repair Procedures July 2007 PLATFORM COMPONENTS REV A How to Bleed the Platform 5 Hold the platform rotate toggle switch in the left direction for approximately 5 seconds, then Rotator release it. 1 Connect a clear hose to the top bleed screw. 6 Fully rotate the platform to the left and continue Place the other end of the hose in a container holding the platform rotate toggle switch until air...

  • Page 81: Platform Overload System (If Equipped)

    July 2007 Section 4 • Repair Procedures REV A PLATFORM COMPONENTS Determine the limit switch trigger point: Platform Overload System 4 Gently move the platform up and down by hand, so it bounces approximately 1 to 2 inches / 2.5 to 5 cm. Allow the platform to settle. How to Calibrate the Platform Overload System (if equipped) Result: The overload indicator light and the...
  • Page 82 Section 4 • Repair Procedures July 2007 PLATFORM COMPONENTS REV A Confirm the setting: 5 Turn the key switch to platform control. 6 Lift the test weight off the platform floor using a suitable lifting device. 7 Place the test weight back onto the center of the platform floor using a suitable lifting device.

  • Page 83: Jib Boom Components

    July 2007 Section 4 • Repair Procedures Jib Boom Components REV A 5 Tag, disconnect and plug the hydraulic hoses from ports "T" and "P" of the jib boom manifold. Jib Boom Cap the fittings on the manifold. Bodily injury hazard. Spraying How to Remove the Jib Boom hydraulic oil can penetrate and burn skin.

  • Page 84: Jib Boom Bell Crank

    Section 4 • Repair Procedures July 2007 JIB BOOM COMPONENTS REV A Jib Boom Bell Crank Jib Boom Lift Cylinder How to Remove the Jib Boom How to Remove the Jib Boom Bell Crank Lift Cylinder Note: Perform this procedure with the boom in the Note: Perform this procedure with the boom in the stowed position.
  • Page 85 July 2007 Section 4 • Repair Procedures REV A JIB BOOM COMPONENTS 2 Tag, disconnect and plug the jib boom lift cylinder hydraulic hoses. Cap the fittings on the jib boom lift cylinder. Bodily injury hazard. Spraying hydraulic oil can penetrate and burn skin.

  • Page 86: Primary Boom Components

    Section 4 • Repair Procedures July 2007 Primary Boom Components REV A Plastic Cable Track Primary Boom The primary boom cable track guides the cables How to Shim the Primary Boom and hoses running up the boom. It can be repaired Note: Measure each wear pad.
  • Page 87 July 2007 Section 4 • Repair Procedures REV A PRIMARY BOOM COMPONENTS How to Remove the 6 Tag and disconnect the hydraulic hoses to the slave cylinder and connect them together using Primary Boom a connector. Plug the slave cylinder hoses from the cable track.
  • Page 88 Section 4 • Repair Procedures July 2007 PRIMARY BOOM COMPONENTS REV A 15 Tag, disconnect and plug the extension cylinder 23 Remove the hose clamp from the side of the hydraulic hoses. Cap the fittings on the primary boom. cylinder. 24 Remove the limit switch cam mounting Bodily injury hazard.
  • Page 89 July 2007 Section 4 • Repair Procedures REV A PRIMARY BOOM COMPONENTS How to Disassemble 7 Support and slide the extension tube out of the outer primary boom tube. Place the extension the Primary Boom boom tube on blocks for support. Note: Complete disassembly of the boom is only Crushing hazard.

  • Page 90: Primary Boom Lift Cylinder

    Section 4 • Repair Procedures July 2007 PRIMARY BOOM COMPONENTS REV A 4 Place a block of wood across the upper secondary boom to support the cylinder when Primary Boom Lift Cylinder the rod-end pivot pin is removed. 5 Attach a lifting strap from a second overhead The lift cylinder raises and lowers the primary crane or other similar lifting device to the boom.

  • Page 91: Extension Cylinder

    July 2007 Section 4 • Repair Procedures REV A PRIMARY BOOM COMPONENTS 11 Place a rod through the compression arm pivot pin and twist to remove the pin. Extension Cylinder 12 Swing the compression arm up out of the way and secure it from moving.
  • Page 92 Section 4 • Repair Procedures July 2007 PRIMARY BOOM COMPONENTS REV A 3 Remove the rear turntable cover. 10 Carefully pull out and properly support the extension cylinder from the primary boom using 4 Raise the secondary boom until the master a lifting strap from an overhead crane.

  • Page 93: Platform Leveling Master Cylinder

    July 2007 Section 4 • Repair Procedures REV A PRIMARY BOOM COMPONENTS 2 Raise the secondary boom until the master cylinder barrel-end pivot pin is above the Platform Leveling Master turntable counterweights. Cylinder 3 Raise the primary boom until the master cylinder rod-end pivot pin is accessible.
  • Page 94 Section 4 • Repair Procedures July 2007 PRIMARY BOOM COMPONENTS REV A 9 Remove the pin retaining fasteners from the master cylinder 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.
  • Page 95 July 2007 Section 4 • Repair Procedures This page intentionally left blank. Part No. 128267 Z-34/22 IC 4 - 23...

  • Page 96: Secondary Boom Components

    Section 4 • Repair Procedures July 2007 Secondary Boom Components REV A Secondary Boom upper pivot upper compression arm mid-pivot compression link lower secondary boom lower compression arm turntable pivot upper secondary boom 4 - 24 Z-34/22 IC Part No. 128267...

  • Page 97: Secondary Boom

    July 2007 Section 4 • Repair Procedures REV A SECONDARY BOOM COMPONENTS 6 Locate the cables from the primary boom cable track to the platform control box. Number each Secondary Boom cable and its entry location at the platform control box. How to Disassemble the 7 Open the platform control box.
  • Page 98 Section 4 • Repair Procedures July 2007 SECONDARY BOOM COMPONENTS REV A 14 Remove the primary boom extend drive speed 21 Position a lifting strap from the overhead crane limit switch mounted on the side of the primary approximately 2 feet / 60 cm from the platform boom at the pivot end.
  • Page 99 July 2007 Section 4 • Repair Procedures REV A SECONDARY BOOM COMPONENTS 27 Remove the pin retaining fasteners from the 35 Remove the pin retaining fasteners from the upper secondary compression arm pivot pins. mid-pivot to upper secondary boom pivot pin. Do not remove the pins.
  • Page 100 Section 4 • Repair Procedures July 2007 SECONDARY BOOM COMPONENTS REV A 42 Attach a lifting strap from an overhead crane to 48 Remove the mid-pivot from the machine. the lug on the rod-end of the secondary boom Crushing hazard. The mid-pivot lift cylinder.

  • Page 101: Secondary Boom Lift Cylinder

    July 2007 Section 4 • Repair Procedures REV A SECONDARY BOOM COMPONENTS 4 Open the engine side turntable cover. Pull up on the engine tray lock pin and swing the engine Secondary Boom Lift Cylinder tray out and away from the machine. Secure the engine tray from moving.

  • Page 102: Kubota D-905 Engine

    Kubota D-905 Workshop Manual Adjust the Engine RPM. (Kubota part number: 97897-02432). Kubota D905 Workshop Manual Genie part number 31742 Flex Plate The flex plate acts as a coupler between the engine and the pump. It is bolted to the engine flywheel and has a splined center to drive the pump.

  • Page 103: Coolant Temperature And Oil Pressure Switches

    July 2007 Section 4 • Repair Procedures REV A KUBOTA D-905 ENGINE How to Install the Flex Plate Coolant Temperature and 1 Install the flex plate onto the flywheel with the Oil Pressure Switches raised spline away from the flywheel. The engine coolant temperature switch is a normally open switch.

  • Page 104: Kubota Df752 Engine

    Section 4 • Repair Procedures July 2007 Kubota DF752 Engine REV A Choke Adjustments RPM Adjustment The choke is solenoid-operated and functions only Refer to maintenance procedure B-9, Check and in the gasoline mode. This choke will not operate in Adjust the Engine RPM .

  • Page 105: Coolant Temperature And Oil Pressure Switches

    July 2007 Section 4 • Repair Procedures REV A KUBOTA DF752 ENGINE How to Install the Flex Plate Coolant Temperature and 1 Install the flex plate onto the flywheel with the Oil Pressure Switches raised spline against the flywheel. The engine coolant temperature switch is a normally open switch.

  • Page 106: Perkins 403C-11 Engine

    Perkins 403C-11 Workshop Manual How to Remove the Flex Plate Genie part number 84817 1 Support the drive pump with a suitable lifting device. 2 Remove all of the pump mounting plate to engine fasteners.

  • Page 107: Coolant Temperature And Oil Pressure Switches

    July 2007 Section 4 • Repair Procedures REV A PERKINS 403C-11 ENGINE How to Install the Flex Plate Coolant Temperature and Oil 1 Install the flex plate onto the flywheel with the Pressure Switches raised spline against the flywheel. The engine coolant temperature switch is a normally open switch.

  • Page 108: Hydraulic Pumps

    Section 4 • Repair Procedures July 2007 Hydraulic Pumps REV A How to Remove the Auxiliary Auxiliary Pump Pump Note: When removing a hose assembly or fitting, How to Test the Auxiliary Pump the O-ring on the fitting and/or hose end must be replaced and then torqued to specification during Note: When removing a hose assembly or fitting, installation.

  • Page 109: Function Pump

    July 2007 Section 4 • Repair Procedures REV A HYDRAULIC PUMPS 5 Observe the pressure gauge while cranking the engine. Immediately stop if the pressure Function Pump reaches or exceeds 3000 psi / 206 bar. Result: The pressure gauge reads 3000 psi / 206 How to Test the Function Pump bar, immediately stop cranking the engine.

  • Page 110: Drive Pump

    Section 4 • Repair Procedures July 2007 HYDRAULIC PUMPS REV A Before serial number 3364: Drive Pump 1 Close the two hydraulic tank shut-off valves at the hydraulic tank. The drive pump is a bi-directional variable Component damage hazard. The displacement piston pump.
  • Page 111 July 2007 Section 4 • Repair Procedures REV A HYDRAULIC PUMPS All models: 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.

  • Page 112: Function Manifold Components

    Section 4 • Repair Procedures July 2007 Manifolds REV A 10-1 Function Manifold Components The function manifold is mounted to the turntable under the ground control box. Index Schematic Description Item Function Torque Counterbalance valve, 3000 psi / 207 bar ......F ... Platform level up ....... 25-30 ft-lbs / 34-41 Nm Counterbalance valve, 3000 psi / 207 bar ......
  • Page 113 July 2007 Section 4 • Repair Procedures REV A MANIFOLDS Part No. 128267 Z-34/22 IC 4 - 41...
  • Page 114 Section 4 • Repair Procedures July 2007 MANIFOLDS REV A Function Manifold Components, continued The function manifold is mounted to the turntable under the ground control box. Index Schematic Description Item Function Torque Solenoid valve, 2 position 3 way ..P ... Secondary boom up ......8-10 ft-lbs / 11-14 Nm Solenoid valve, 2 position 3 way ..
  • Page 115 July 2007 Section 4 • Repair Procedures REV A MANIFOLDS Part No. 128267 Z-34/22 IC 4 - 43...

  • Page 116: Valve Adjustments - Function Manifold

    Section 4 • Repair Procedures July 2007 MANIFOLDS REV A 10-2 How to Adjust the Secondary Valve Adjustments - Boom Down Relief Valve Function Manifold 1 Connect a 0 to 3000 psi / 0 to 206 bar pressure gauge to the test port on the function manifold. How to Adjust the Primary Boom 2 Start the engine from the ground controls.

  • Page 117: Jib Boom / Platform Rotate Manifold Components

    July 2007 Section 4 • Repair Procedures REV A MANIFOLDS 10-3 Jib Boom / Platform Rotate Manifold Components The jib boom/platform rotate manifold is mounted to the jib boom. Index Schematic Description Item Function Torque Solenoid valve, 3 position 4 way ..CH ..Jib boom up/down ....... 8-10 ft-lbs / 11-14 Nm Solenoid valve, 3 position 4 way ..

  • Page 118: Brake / 2-Speed Manifold Components, 2Wd Models

    Section 4 • Repair Procedures July 2007 MANIFOLDS REV A 10-4 Brake / 2-speed Manifold Components, 2WD Models The brake / 2-speed manifold is located under the drive chassis cover at the non-steer end. Index Schematic Description Item Function Torque Check Valve ........

  • Page 119: 2Wd Traction Manifold Components

    July 2007 Section 4 • Repair Procedures REV A MANIFOLDS 10-5 2WD Traction Manifold Components The 2WD traction is mounted inside the drive chassis at the non-steer end. Index Schematic Description Item Function Torque Shuttle valve, 3 position 3 way ..A ... Charge pressure circuit that gets hot oil out of low pressure side of drive pump and allows low pressure flow path for brake...

  • Page 120: 4Wd Traction Manifold Components

    Section 4 • Repair Procedures July 2007 MANIFOLDS REV A 10-6 4WD Traction Manifold Components The 4WD traction manifold is mounted inside the drive chassis at the non-steer end. Index Schematic Description Item Function Torque Solenoid valve, 2 position 3 way ..BB ..Brake ............20 ft-lbs / 27.1 Nm Check valve ........
  • Page 121 July 2007 Section 4 • Repair Procedures REV A MANIFOLDS Part No. 128267 Z-34/22 IC 4 - 49...

  • Page 122: Valve Adjustments - Traction Manifold

    Section 4 • Repair Procedures July 2007 MANIFOLDS REV A 10-7 3 Turn the engine off. Connect a 0 to 600 psi / 0 to 40 bar pressure gauge to the test port Valve Adjustments - located on the traction manifold. Traction Manifold 4 Start the engine from the platform controls.

  • Page 123: Valve Coils

    July 2007 Section 4 • Repair Procedures REV A MANIFOLDS 10-8 Valve Coil Resistance Valve Coils Specification Note: The following coil resistance specifications How to Test a Coil are at an ambient temperature of 68°F / 20°C. As valve coil resistance is sensitive to changes in air A properly functioning coil provides an temperature, the coil resistance will typically electromotive force which operates the solenoid...
  • Page 124 How to Test a Coil Diode 3 Set a multimeter to read DC current. Note: The multimeter, when set to read DC current, Genie incorporates spike suppressing diodes in all should be capable of reading up to of its valve coils. Properly functioning coil diodes 800 mA.

  • Page 125: Fuel And Hydraulic Tanks

    July 2007 Section 4 • Repair Procedures Fuel and Hydraulic Tanks REV A 11-1 7 Tag, disconnect and plug the fuel hoses from the fuel tank. Cap the fittings on the fuel tank. Fuel Tank Clean up any fuel that may have spilled. 8 Remove the fuel tank retaining plate fasteners How to Remove the Fuel Tank at the bulkhead.

  • Page 126: Hydraulic Tank

    Section 4 • Repair Procedures July 2007 FUEL AND HYDRAULIC TANKS REV A 11-2 3 Remove the drain plug from the hydraulic tank and completely drain the tank into a container Hydraulic Tank of suitable capacity. Refer to Section 2, Specifications .

  • Page 127: Turntable Rotation Components

    July 2007 Section 4 • Repair Procedures Turntable Rotation Components REV A 12-1 Rotation Hydraulic Motor The turntable rotation hydraulic motor is the only serviceable component of the turntable rotation assembly. The worm gear may not be removed from the housing. In order to remove the housing, the entire turntable assembly has to be removed.

  • Page 128: Axle Components

    Section 4 • Repair Procedures July 2007 Axle Components REV A 13-1 How to Install the Hub and Hub and Bearings, 2WD Models Bearings Note: When replacing a wheel bearing, both the How to Remove the Hub and inner and outer bearings, including the pressed-in Bearings races, must be replaced.
  • Page 129 Do not allow oil to squirt Read, understand and obey the safety rules or spray. and operating instructions printed in the appropriate Genie Z-34/22 IC Operator's General Repair Process Manual on your machine. Be sure that all necessary tools and test...

  • Page 130: Electrical Symbols Legend

    Section 5 • Schematics June 2007 Electrical Symbols Legend REV A TB17 15AMP. Foot switch Circuit breaker Spark plug PLAT Wire color with cable number GRND Key switch Solenoid or Ground TB20 relay coil supression circuit Terminal Water temperature HORN switch, normally open Horn button Horn or alarm...

  • Page 131: Hydraulic Symbols Legend

    June 2007 Section 5 • Schematics Hydraulic Symbols Legend REV A N.O. N.C. Double acting Pressure gauge cylinder Pressure switch 0.035 Solenoid operated Orifice with size proportional valve Filter Brake Check valve Solenoid operated 2 pos., 3 way, directional valve Fixed displacement Variable orifice or pump...
  • Page 132 Section 5 • Schematics June 2007 5 - 4 Z-34/22 IC Part No. 128267...

  • Page 134: Electrical Schematic - Diesel Models (From Serial Number 3242 To 3577)

    Section 5 • Schematics July 2007 Electrical Schematic - Diesel Models (from serial number 3242 to 3577) REV A WHT-FS TS47 TS12 FS-HI HORN TB22 PLAT GRND TS51 AUXILIARY TS52 TS56 TS54 PUMP Added after serial number 2266 TS62 TB28 TB27 TB33 TB34...
  • Page 135 July 2007 Section 5 • Schematics Electrical Schematic - Diesel Models REV A (from serial number 3242 to 3577) WHT-FS JP1 (REMOVE FOR CE VERSION) TS15 TS10 TS11 TS13 ORG/RED ROTARY FLOW LIFT CONTROL TS14 BRK REL OFF LIMIT HIGH DRIVE DRIVE ENABLE...
  • Page 136 July 2007 Section 5 • Schematics Electrical Schematic - Diesel Models (from serial number 3242 to 3577)

  • Page 138: Electrical Schematic - Diesel Models (From Serial Number 3578 To 4799)

    Section 5 • Schematics July 2007 Electrical Schematic - Diesel Models (from serial number 3578 to 4799) REV A TB134 RED-FS BLK-FS WHT-FS WHT-FS TB22 PLAT GRND TS47 TS12 TILT LS18 ALARM AUXILIARY FS-HI PUMP HORN ORG/RED-1 TS51 TS52 TS56 TS54 TS62 AUXILIARY...
  • Page 139 July 2007 Section 5 • Schematics Electrical Schematic - Diesel Models REV A (from serial number 3578 to 4799) WHT-FS JP1 (REMOVE FOR CE VERSION) TS15 TS10 TS11 TS13 ORG/RED ROTARY FLOW LIFT CONTROL TS14 BRK REL OFF LIMIT HIGH DRIVE DRIVE ENABLE...
  • Page 140 July 2007 Section 5 • Schematics Electrical Schematic - Diesel Models (from serial number 3578 to 4799)

  • Page 142: Electrical Schematic - Gasoline/Lpg Models (From Serial Number 3242 To 3577)

    Section 5 • Schematics July 2007 Electrical Schematic - Gasoline/LPG Models (from serial number 3242 to 3577) REV A WHT-FS AUXILIARY TS47 TS12 POWER FS-HI HORN TB22 PLAT GRND TS52 TS56 TS53 TS54 TS51 AUXILIARY POWER TB39 TS62 TB28 TB33 TB34 TB38 TB27...
  • Page 143 July 2007 Section 5 • Schematics Electrical Schematic - Gasoline/LPG Models REV A (from serial number 3242 to 3577) WHT-FS JP1 (REMOVE FOR CE VERSION) TS15 TS10 TS11 TS13 ORG/RED ROTARY FLOW LIFT CONTROL TS14 BRK REL OFF LIMIT HIGH DRIVE DRIVE ENABLE...
  • Page 144 July 2007 Section 5 • Schematics Electrical Schematic - Gasoline/LPG Models (from serial number 3242 to 3577)

  • Page 146: Electrical Schematic - Gasoline/Lpg Models (From Serial Number 3578 To 4799)

    Section 5 • Schematics July 2007 Electrical Schematic - Gasoline/LPG Models (from serial number 3578 to 4799) REV A WHT-FS AUXILIARY TS47 TS12 POWER FS-HI HORN TB22 PLAT GRND TS52 TS56 TS53 TS54 TS51 AUXILIARY POWER TB39 TS62 TB28 TB34 TB38 TB33 TB27...
  • Page 147 July 2007 Section 5 • Schematics Electrical Schematic - Gasoline/LPG Models REV A (from serial number 3578 to 4799) WHT-FS JP1 (REMOVE FOR CE VERSION) TS15 TS10 TS11 TS13 ORG/RED ROTARY FLOW LIFT CONTROL TS14 BRK REL OFF LIMIT DRIVE HIGH DRIVE ENABLE...
  • Page 148 July 2007 Section 5 • Schematics Electrical Schematic - Gasoline/LPG Models (from serial number 3578 to 4799)

  • Page 149: Ground Control Box Wiring Diagram - Diesel Models (From Serial Number 3242 To 3308)

    Section 5 • Schematics July 2007 Ground Control Box Wiring Diagram - Diesel Models (from serial number 3242 to 3308)
  • Page 150 Section 5 • Schematics July 2007 Ground Control Box Wiring Diagram - Diesel Models (from serial number 3242 to 3308) REV A VOLTAGE OIL PRESSURE COOLANT TEMPERATURE SPARE WIRE LIST OPTION NUMBERS BRN-5 BRN [OPTION 1] GROUND BRN-2 BRN [OPT. 2/3] BRN-GND.

  • Page 151: Ground Control Box Wiring Diagram - Diesel Models (From Serial Number 3309 To 3577)

    July 2007 Section 5 • Schematics Ground Control Box Wiring Diagram - Diesel Models REV A (from serial number 3309 to 3577) SPARE WIRE LIST OPTION NUMBERS VOLTAGE OIL PRESSURE COOLANT TEMPERATURE GRN/WHT-1 1 - PLATFORM LEVEL CUTOUT BRN-5 BRN [OPTION 1] GROUND ORG/RED-1 2 - FLASHING BEACON...
  • Page 152 July 2007 Section 5 • Schematics Ground Control Box Wiring Diagram - Diesel Models (from serial number 3309 to 3577)

  • Page 153: Ground Control Box Wiring Diagram - Diesel Models (From Serial Number 3578 To 4799)

    Section 5 • Schematics July 2007 Ground Control Box Wiring Diagram - Diesel Models (from serial number 3578 to 4799)
  • Page 154 Section 5 • Schematics July 2007 Ground Control Box Wiring Diagram - Diesel Models (from serial number 3578 to 4799) REV A VOLTAGE OIL PRESSURE COOLANT TEMP. [OPTION 2] 134A KEYSWITCH POWER GRN/WHT-3 RED/WHT-MH RED-A6 RED-KSI KEYSWITCH POWER BRN [OPTION 1] GROUND BRN-5 BRN [OPT.
  • Page 155 July 2007 Section 5 • Schematics Ground Control Box Wiring Diagram - REV A Gasoline/LPG Models (from serial number 3242 to 3308) VOLTAGE OIL PRESSURE COOLANT TEMPERATURE BRN-5 BRN [OPTION 1] GROUND BRN [OPT. 2/3] BRN-GND. STUD GROUND BRN-2 WHT-6 WHT-8 LS2-LS4 JUNCTION WHT-21A...

  • Page 156: Ground Control Box Wiring Diagram - Gasoline/Lpg Models (From Serial Number 3242 To 3308)

    July 2007 Section 5 • Schematics Ground Control Box Wiring Diagram - Gasoline/LPG Models (from serial number 3242 to 3308)

  • Page 157: Ground Control Box Wiring Diagram - Gasoline/Lpg Models (From Serial Number 3309 To 3577)

    Section 5 • Schematics July 2007 Ground Control Box Wiring Diagram - Gasoline/LPG Models (from serial number 3309 to 3577)
  • Page 158 Section 5 • Schematics July 2007 Ground Control Box Wiring Diagram - Gasoline/LPG Models REV A (from serial number 3309 to 3577) VOLTAGE OIL PRESSURE COOLANT TEMPERATURE BRN-5 BRN [OPTION 1] GROUND SPARE WIRE LIST OPTION NUMBERS BRN-2 BRN [OPT. 2/3] BRN-GND.
  • Page 159 July 2007 Section 5 • Schematics Ground Control Box Wiring Diagram - REV A Gasoline/LPG Models (from serial number 3578 to 4799) VOLTAGE OIL PRESSURE COOLANT TEMPERATURE SPARE WIRE LIST OPTION NUMBERS BRN-5 BRN [OPTION 1] GROUND GRN/WHT-1 * 1 - PLATFORM LEVEL CUTOUT BRN-2 BRN [OPT.

  • Page 160: Ground Control Box Wiring Diagram - Gasoline/Lpg Models (From Serial Number 3578 To 4799)

    July 2007 Section 5 • Schematics Ground Control Box Wiring Diagram - Gasoline/LPG Models (from serial number 3578 to 4799)

  • Page 161: Platform Control Box Wiring Diagram - Diesel Models (From Serial Number 3242 To 3577)

    Section 5 • Schematics July 2007 Platform Control Box Wiring Diagram - Diesel Models (from serial number 3242 to 3577)

  • Page 162: Platform Control Box Wiring Diagram - Diesel Models (From Serial Number 3578 To 4799)

    Section 5 • Schematics July 2007 Platform Control Box Wiring Diagram - Diesel Models (from serial number 3242 to 3577) REV A NOTES: REMOVE JUMPER JP1 FOR CE VERSION. REMOVE THIS WIRE WHEN LOAD SENSE OPTION IS REQUIRED. SPARE WIRES GRN/WHT-1 ORG/RED-1 ORG/BLK-1...
  • Page 163 July 2007 Section 5 • Schematics Platform Control Box Wiring Diagram - Diesel Models REV A (from serial number 3578 to 4799) NOTES: REMOVE JUMPER JP1 FOR CE VERSION. SPARE WIRES GRN/WHT-1 ORG/RED-1 ORG/BLK-1 BLU/RED-1 BLU/WHT-1 GRN/WHT-3 RED/WHT-3 LABEL DESCRIPTION EMERGENCY STOP BUTTON HORN BUTTON DRIVE CONTROLLER...
  • Page 164 July 2007 Section 5 • Schematics Platform Control Box Wiring Diagram - Diesel Models (from serial number 3578 to 4799)

  • Page 165: Platform Control Box Wiring Diagram - Gasoline/Lpg Models (From Serial Number 3242 To 3577)

    Section 5 • Schematics July 2007 Platform Control Box Wiring Diagram - Gasoline/LPG Models (from serial number 3242 to 3577)
  • Page 166 Section 5 • Schematics July 2007 Platform Control Box Wiring Diagram - Gasoline/LPG Models REV A (from serial number 3242 to 3577) NOTES: REMOVE JUMPER JP1 FOR CE VERSION. REMOVE THIS WIRE WHEN LOAD SENSE OPTION IS REQUIRED. SPARE WIRES GRN/WHT-1 ORG/RED-1 ORG/BLK-1...

  • Page 167: Platform Control Box Wiring Diagram - Gasoline/Lpg Models (From Serial Number 3578 To 4799)

    July 2007 Section 5 • Schematics Platform Control Box Wiring Diagram - REV A Gasoline/LPG Models (from serial number 3578 to 4799) NOTES: REMOVE JUMPER JP1 FOR CE VERSION. REMOVE THIS WIRE WHEN LOAD SENSE OPTION IS REQUIRED. SPARE WIRES GRN/WHT-1 ORG/RED-1 ORG/BLK-1...
  • Page 168 July 2007 Section 5 • Schematics Platform Control Box Wiring Diagram - Gasoline/LPG Models (from serial number 3578 to 4799)

  • Page 169: Generator Option Wiring Diagram (From Serial Number 3242 To 4081)

    Section 5 • Schematics July 2007 Generator Option Wiring Diagram (from serial number 3242 to 4081)
  • Page 170 Section 5 • Schematics July 2007 Generator Option Wiring Diagram (from serial number 3242 to 4081) REV A GRN/WHT-1 ES34D4S 5 - 27 Z-34/22 IC Part No. 128267...

  • Page 171: Generator Option Wiring Diagram (From Serial Number 4082 To 4799)

    July 2007 Section 5 • Schematics Generator Option Wiring Diagram REV A (from serial number 4082 to 4799) ES34D4T Part No. 128267 Z-34/22 IC 5 - 28...
  • Page 172 July 2007 Section 5 • Schematics Generator Option Wiring Diagram (from serial number 4082 to 4799)

  • Page 173: Load Sense Option Wiring Diagram (From Serial Number 3242 To 3577)

    Section 5 • Schematics July 2007 Load Sense Option Wiring Diagram (from serial number 3242 to 3577)
  • Page 174 Section 5 • Schematics July 2007 Load Sense Option Wiring Diagram (from serial number 3242 to 3577) REV A LABEL DESCRIPTION EMERGENCY STOP BUTTON HORN BUTTON DRIVE CONTROLLER BOOM FUNCTION SPEED CONTROLLER AUXILIARY SWITCH START ENGINE SWITCH RPM SWITCH GLOW PLUG SWITCH RED/BLK PLATFORM ROTATE SWITCH JIB UP/DOWN SWITCH...

  • Page 175: Manifold And Limit Switch Wiring

    July 2007 Section 5 • Schematics Manifold and Limit Switch Wiring REV A WHT#30 (FWD) WHT/BLK#31 (REV) EXTEND/RETRACT LIMIT SWITCH (SHOWN WITH BOOM EXTENDED) WHT-7 BLK-7 CABLE 7 PRIMARY LIFT DRIVE PUMP (REAR VIEW) LIMIT SWITCH RED-6 ORG-6 WHT-6 BLK-6 CABLE 6 TILT SENSOR DRIVE ENABLE...
  • Page 176 July 2007 Section 5 • Schematics Manifold and Limit Switch Wiring...

  • Page 178: Hydraulic Schematic, 2Wd Models

    Section 5 • Schematics July 2007 Hydraulic Schematic, 2WD Models REV A CHARGE PRESSURE 50 psi GENERATOR OPTION 3500 psi 3 gpm 3500 psi AUXILIARY 3200 psi 2000 psi PUMP FUNCTION 0.5 gpm PUMP 3 gpm 220 psi DRIVE PUMP TANK CHARGE PRESSURE A PORT...
  • Page 179 July 2007 Section 5 • Schematics Hydraulic Schematic, 2WD Models REV A SLAVE CYLINDER PRIMARY BOOM PRIMARY BOOM JIB BOOM SECONDARY BOOM CYLINDER EXTENSION CYLINDER CYLINDER CYLINDER 0.032 inch TURNTABLE ROTATE PLATFORM ROTATE 3000 psi 4.5:1 5.9 CU. IN./REV 0.025 inch Orifice added after 0.090 inch serial number 3327...
  • Page 180 July 2007 Section 5 • Schematics Hydraulic Schematic, 2WD Models...

  • Page 182: Hydraulic Schematic, 4Wd Models

    Section 5 • Schematics July 2007 Hydraulic Schematic, 4WD Models REV A FRONT REAR 0.035 inch RIGHT RIGHT DRIVE MANIFOLD 3 MICRON 50 psi SLEW RING 0.079 inch 0.032 inch DRIVE PUMP 0.039 inch 0.039 inch 0.079 inch 150 psi 0.039 inch 0.039 inch FUNCTION...
  • Page 183 July 2007 Section 5 • Schematics Hydraulic Schematic, 4WD Models REV A SLAVE CYLINDER JIB BOOM SECONDARY BOOM PRIMARY BOOM PRIMARY BOOM CYLINDER CYLINDER CYLINDER EXTENSION CYLINDER 0.032 inch TURNTABLE ROTATE PLATFORM ROTATE 3000 psi 4.5:1 5.9 CU. IN./REV Orifice added after 0.025 inch 0.090 inch serial number 3327...
  • Page 184 July 2007 Section 5 • Schematics Hydraulic Schematic, 4WD Models...
  • Page 185 Genie North America Phone 425.881.1800 Toll Free USA and Canada 800.536.1800 Fax 425.883.3475 Genie Australia Pty Ltd. Phone +61 7 3375 1660 Fax +61 7 3375 1002 Genie Scandinavia Genie China Phone +46 31 575100...

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