Terex Genie Z-34/22 IC Service And Repair Manual
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Terex Genie Z-34/22 IC Service And Repair Manual

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Service and Repair Manual
Z-34/22 IC
Serial Number Range
from Z3406-4800
This manual includes:
Repair procedures
Fault Codes
Electrical and
Hydraulic Schematics
For detailed maintenance
procedures, refer to the
appropriate Maintenance
Manual for your machine.
Part No. 1268527
Rev A
September 2015

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Summary of Contents for Terex Genie Z-34/22 IC

  • Page 1 Service and Repair Manual Serial Number Range Z-34/22 IC from Z3406-4800 This manual includes: Repair procedures Fault Codes Electrical and Hydraulic Schematics For detailed maintenance procedures, refer to the appropriate Maintenance Manual for your machine. Part No. 1268527 Rev A September 2015...

  • Page 2: Introduction

    Copyright © 2015 by Terex Corporation 1268527 Rev A, September 2015 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.

  • Page 3: Revision History

    September 2015 Service and Repair Manual Introduction Revision History Revision Date Section Procedure / Page / Description 9/2015 Release Reference Examples: Electronic Version Section – Repair Procedure, 4-2 Click on any content or procedure in the Table of Contents to view Section –...

  • Page 4: Serial Number Legend

    Service and Repair Manual September 2015 Introduction Serial Number Legend 1 Model 2 Model year 3 Sequence number 4 Serial number (stamped on chassis) 5 Serial label Z-34/22 IC Part No. 1268527...

  • Page 5: Safety Rules

    September 2015 Service and Repair Manual Safety Rules Section 1 Safety R ules Danger Failure to obey the instructions and safety rules in this manual and the appropriate Operator's Manual on your machine 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 Service and Repair Manual September 2015 Safety Rules Personal Safety Workplace Safety Any person working on or around a machine must Any person working on or around a machine must be aware of all known safety hazards. Personal be aware of all known safety hazards. Personal safety and the continued safe operation of the safety and the continued safe operation of the machine should be your top priority.

  • Page 7: Table Of Contents

    September 2015 Table of Contents Introduction Introduction ......................ii Important Information ..................... ii Find a Manual for this Model .................. ii Revision History..................... iii Serial Number Legend ..................iv Section 1 Safety Rules ......................v General Safety Rules ..................... v Section 2 Specifications .......................
  • Page 8 September 2015 Table of Contents Section 3 Repair Procedures ..................... 13 Introduction ......................13 Platform Controls ....................15 1-1 Drive Joystick ....................15 How to Adjust the Drive Joystick ..............15 1-2 Boom Function Speed Controller Adjustments ..........17 Boom Function Speed Controller Adjustments ..........17 Platform Components ..................
  • Page 9 September 2015 Table of Contents Primary Boom Components ................27 4-1 Cable Track ....................27 How to Repair the Primary Boom Cable Track ..........27 4-2 Primary Boom....................27 How to Shim the Primary Boom ..............27 How to Remove the Primary Boom ..............28 How to Disassemble the Primary Boom ............
  • Page 10 September 2015 Table of Contents 6-2 Kubota Gasoline / LPG Models ..............44 Choke Adjustment ..................44 Timing Adjustment ..................44 Carburetor Adjustment ..................44 RPM Adjustment ..................... 44 How to Remove the Flex Plate ............... 45 How to Install the Flex Plate ................45 Coolant Temperature and Oil Pressure Switches ..........
  • Page 11 September 2015 Table of Contents Manifolds ......................52 8-1 Function Manifold Components ..............52 8-2 Valve Adjustments - Function Manifold ............56 How to Adjust the Primary Boom Down Relief Valve........56 How to Adjust the Secondary Boom Down Relief Valve ......... 56 8-3 Jib Boom and Platform / Jib Boom Rotate Manifold Components ....
  • Page 12 September 2015 Table of Contents Section 4 Schematics ......................69 Introduction ......................69 Electrical Symbol Legend ..................70 Hydraulic Symbols Legend .................. 71 Electrical Component and Wire Color Legends ........... 72 Electrical Schematics - Gasoline/LPG Models ..........75 Electrical Schematic - Gasoline/LPG Models ............76 Ground Control Box Switch Panel Wiring Diagram - Gasoline/LPG Models ..

  • Page 13: Specifications

    September 2015 Service and Repair Manual Specifications Section 2 Specific ati ons Machine Specifications Fuel capacities LPG tank 33.5 pounds Tires and wheels rough industrial 15.2 kg terrain Fuel tank 9.3 gallons Tire size 10-16.5 NHS 9-14.5 LT 35.2 liters Tire ply rating 8 Ply Tread 6...

  • Page 14: Performance Specifications

    Service and Repair Manual September 2015 Specifications Performance Specifications Hydraulic Oil Specifications Drive speed, maximum Hydraulic Fluid Specifications Stowed position 3.0 mph Genie specifications require hydraulic oils which are 5.1 km/h designed to give maximum protection to hydraulic systems, have the ability to perform over a wide 40 ft / 6.1 sec temperature range, and the viscosity index should 12.2 m / 6.1 sec...
  • Page 15 September 2015 Service and Repair Manual Specifications Chevron Rando HD Premium Oil Do not top off with incompatible hydraulic fluids. Hydraulic fluids MV Fluid Properties may be incompatible due to the differences in base additive ISO Grade chemistry. When incompatible Viscosity index fluids are mixed, insoluble materials may form and deposit...

  • Page 16: Hydraulic Component Specifications

    Service and Repair Manual September 2015 Specifications Hydraulic Component Continued use of Chevron 5606A hydraulic fluid, or Specifications equivalent, when ambient temperatures are consistently Drive Pump above 32°F / 0°C may result in Type: bi-directional variable displacement piston pump component damage Displacement per revolution 1.71 cu in 28 cc...
  • Page 17 September 2015 Service and Repair Manual Specifications Auxiliary Pump Non-steer end drive motors Type: fixed displacement gear pump Displacement per revolution 1.53 cu in 25 cc Displacement per revolution 0.5 gpm 1.9 L/min Hydraulic Filters Auxiliary pump relief pressure 3400 psi Medium pressure filter Beta 3 ˆ...

  • Page 18: Machine Torque Specifications

    Service and Repair Manual September 2015 Specifications Machine Torque Specifications Platform Rotator 3/4-10 center bolt, GR 8, dry 380 ft-lbs 515 Nm 3/4-10 center bolt, GR 8, lubricated 280 ft-lbs 379 Nm 3/8-16 outer bolts, GR 8, dry 44 ft-lbs 60 Nm 3/8-16 outer bolts, GR 8, lubricated 33 ft-lbs...

  • Page 19: Kubota D-905 Engine Specifications

    September 2015 Service and Repair Manual Specifications Kubota D-905 Engine Fuel injection system Injection pump make Bosch MD Displacement 54.86 cu in Injection pump pressure, 1991 psi 0.90 liters maximum 137 bar Number of cylinders Injection timing 13° to 25° BTDC Bore and Stroke 2.83 x 2.9 inches Fuel requirement...

  • Page 20: Kubota Df-752 Engine Specifications

    Service and Repair Manual September 2015 Specifications Kubota DF-752 Engine Alternator output 30A @ 12V DC 1/4 to 3/8 in Fan belt deflection Displacement 45 cu in 7 to 9 mm 0.74 liters Starter motor Number of cylinders Brush length, new 0.669 in Bore and Stroke 2.68 x 2.68 inches...

  • Page 21: Perkins 403C-11 Engine Specifications

    September 2015 Service and Repair Manual Specifications Perkins 403C-11 Engine Unit ships with 15W-40. Extreme operating temperatures may require the use of alternative engine oils. For oil requirements, refer to the Engine Operator Displacement 69 cu in Manual for your engine. 1.13 liters Fuel injection system Number of cylinders...

  • Page 22: Hydraulic Hose And Fitting Torque Specifications

    Service and Repair Manual September 2015 Specifications Hydraulic Hose and Fitting SAE O-ring Boss Port Torque Specifications (tube fitting - installed into Aluminum) (all types) Your machine is equipped with Parker Seal-Lok™ SAE Dash Size Torque ORFS or 37° JIC fittings and hose ends. Genie specifications require that fittings and hose ends 14 ft-lbs / 19 Nm be torqued to specification when they are removed...

  • Page 23: Torque Procedure

    September 2015 Service and Repair Manual Specifications Torque Procedure Seal-Lok™ fittings Replace the O-ring. The O-ring must be replaced anytime the seal has been broken. The O-ring cannot be re-used if the fitting or hose end has been tightened beyond finger tight.

  • Page 24: Sae And Metric Fasteners Torque Charts

    Service and Repair Manual September 2015 Specifications Z-34/22 IC Part No. 1268527...

  • Page 25: Repair Procedures

    September 2015 Service and Repair Manual Repair Procedures Machine Configuration: Section 3 Repair Pr oc edures  Unless otherwise specified, perform each repair procedure with the machine in the following configuration: • Machine parked on a firm, level surface • Key switch in the off position with the key Observe and Obey: removed ...

  • Page 26: About This Section

    Service and Repair Manual September 2015 Repair Procedures About This Section Most of the procedures in this section should only be performed by trained service professional in a suitably equipped workshop. Select the appropriate repair procedure after troubleshooting the problem. Perform disassembly procedures to the point where repairs can be completed.

  • Page 27: Platform Controls

    September 2015 Service and Repair Manual Platform Controls Locate and disconnect the wire connected to terminal "A" on the drive joystick circuit board. Drive Joystick Set a multimeter to read DC current. The drive joystick is connected to the drive motor Note: The multimeter, when set to read DC current, controller, located under the drive chassis cover at should be capable of reading up to 1200 mA.
  • Page 28 Service and Repair Manual September 2015 Platform Controls Set the threshold: Set the stowed drive speed: Note: The drive joystick adjustments are not final Note: Select a test area that is firm, level and free adjustments. Final adjustments will need to be of obstructions.

  • Page 29: Boom Function Speed Controller Adjustments

    September 2015 Service and Repair Manual Platform Controls Set the raised drive speed: Boom Function Speed Controller Note: Select a test area that is firm, level and free of obstructions. Boom F unction Speed Contr oller Adj ustm ents 23 Press down the foot switch and raise the Boom Function Speed Controller primary boom approximately 3 feet / 1 m.
  • Page 30 Service and Repair Manual September 2015 Platform Controls Locate the diode between the black wire from the boom function speed controller and the white/red wire. Connect the red (+) lead from a volt meter to the wire connector of the white/red wire next to the diode.

  • Page 31: Platform Components

    September 2015 Service and Repair Manual Platform Components Remove the pin retainer fastener from the rod-end pivot pin. Platform Leveling Slave Cylinder Remove the external snap ring from the The slave cylinder and the rotator pivot are the two barrel-end pivot pin. primary supports for the platform.

  • Page 32: Platform Rotator

    Service and Repair Manual September 2015 Platform Components Support the platform rotator with a suitable lifting device. Do not apply any lifting Platform Rotator pressure. How to R emove the Pl atform Rotator Remove the pin retaining fasteners from the jib boom and leveling links to platform rotator How to Remove the Platform pivot pins.

  • Page 33: How To Bleed The Platform Rotator

    September 2015 Service and Repair Manual Platform Components How to Bleed the Pl atform R otator How to Bleed the Platform Move the function enable toggle switch to either side and hold the platform rotate toggle Rotator switch to the left position until the platform is fully rotated to the left.

  • Page 34: Platform Overload System

    Service and Repair Manual September 2015 Platform Components Determine the limit switch trigger point: Platform Overload System 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 How to C alibr ate the Pl atform Overl oad System (if equi pped) settle.
  • Page 35 September 2015 Service and Repair Manual Platform Components Confirm the setting: Turn the key switch to platform control. Lift the test weight off the platform floor using a suitable lifting device. Place the test weight back onto the center of the platform floor using a suitable lifting device.

  • Page 36: Jib Boom Components

    Service and Repair Manual September 2015 Jib Boom Components Tag, disconnect and plug the hydraulic hoses from ports "T" and "P" of the jib boom Jib Boom manifold. Cap the fittings on the manifold. How to R emove the Jib Boom Bodily injury hazard.

  • Page 37: Jib Boom Bell Crank

    September 2015 Service and Repair Manual Jib Boom Components Jib Boom Bell Crank Jib Boom Lift Cylinder How to R emove the Jib Boom Bell Crank How to R emove the Jib Boom Lift Cylinder How to Remove the Jib Boom How to Remove the Jib Boom Lift Bell Crank Cylinder...
  • Page 38 Service and Repair Manual September 2015 Jib Boom Components Use a soft metal drift to tap the rod-end pivot pin half way out and lower one of the leveling links to the ground. Tap the pin the other direction and lower the opposite leveling link. Do not remove the pin.

  • Page 39: Primary Boom Components

    September 2015 Service and Repair Manual Primary Boom Components Primary Boom Cable Track How to Shim the Primary Boom The primary boom cable track guides the cables and hoses running up the boom. It can be repaired How to Shim the Primary Boom link by link without removing the cables and hoses that run through it.

  • Page 40: How To Remove The Primary Boom

    Service and Repair Manual September 2015 Primary Boom Components How to R emove the Primary Boom How to Remove the Primary Tag and disconnect the hydraulic hoses to the slave cylinder and connect them together Boom using a connector. Plug the slave cylinder hoses from the cable track.
  • Page 41 September 2015 Service and Repair Manual Primary Boom Components 15 Tag, disconnect and plug the extension 24 Remove the limit switch cam mounting cylinder hydraulic hoses. Cap the fittings on fastener (if equipped). the cylinder. Note: Note the position of the cam before removing Bodily injury hazard.

  • Page 42: How To Disassemble The Primary Boom

    Service and Repair Manual September 2015 Primary Boom Components How to Dis ass embl e the Primary Boom How to Disassemble the Primary Support and slide the extension tube out of the outer primary boom tube. Place the Boom extension boom tube on blocks for support. Note: Complete disassembly of the boom is only Crushing hazard.

  • Page 43: Primary Boom Lift Cylinder

    September 2015 Service and Repair Manual Primary Boom Components Attach a lifting strap from a second overhead crane or other similar lifting device to the Primary Boom Lift Cylinder primary boom lift cylinder. The primary boom lift cylinder raises and lowers Remove the rear turntable cover.

  • Page 44: Primary Boom Extension Cylinder

    Service and Repair Manual September 2015 Primary Boom Components 13 Tag, disconnect and plug the primary boom lift cylinder hydraulic hoses. Cap the fittings on Primary Boom Extension the cylinder. Cylinder Bodily injury hazard. Spraying hydraulic oil can penetrate and The primary boom extension cylinder extends and burn skin.
  • Page 45 September 2015 Service and Repair Manual Primary Boom Components Remove the drive speed limit switch from the 10 Carefully pull out and properly support the pivot end of the primary boom. Do not extension cylinder from the primary boom disconnect the wiring. using a lifting strap from an overhead crane.

  • Page 46: Platform Leveling Master Cylinder

    Service and Repair Manual September 2015 Primary Boom Components Remove the rear turntable cover. Platform Leveling Master Raise the secondary boom until the master Cylinder cylinder barrel-end pivot pin is above the turntable counterweights. The platform leveling master cylinder acts as a Raise the primary boom until the master pump for the slave cylinder.
  • Page 47 September 2015 Service and Repair Manual Primary Boom Components Remove the pin retaining fasteners from the master cylinder rod-end pivot pin. Use a soft metal drift to remove the pin. 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.

  • Page 48: Secondary Boom Components

    Service and Repair Manual September 2015 Secondary Boom Components Secondary Boom components lower secondary boom upper pivot turntable pivot upper compression arm lower compression arm mid-pivot upper secondary boom compression link Z-34/22 IC Part No. 1268527...

  • Page 49: Secondary Boom

    September 2015 Service and Repair Manual Secondary Boom Components Tag and disconnect each wire from the cables in the platform control box. Secondary Boom Electrocution/burn hazard. How to Dis ass embl e the Secondary Boom Contact with electrically charged circuits could result in death or How to Disassemble the serious injury.
  • Page 50 Service and Repair Manual September 2015 Secondary Boom Components 17 Remove the cable covers from the top of the 25 Carefully remove the entire primary boom upper secondary boom. assembly from the machine (primary boom assembly, jib boom assembly, platform, 18 Tag, disconnect and plug the primary boom lift master cylinder, primary lift cylinder and upper cylinder and master cylinder hydraulic hoses.
  • Page 51 September 2015 Service and Repair Manual Secondary Boom Components 31 Remove the plastic plug in the bulkhead to 40 Remove the battery hold down and battery. access the secondary boom lift cylinder 41 Remove the pin retaining fasteners from the rod-end pivot pin.

  • Page 52: Secondary Boom Lift Cylinders

    Service and Repair Manual September 2015 Secondary Boom Components 48 Remove the mid-pivot from the machine. Secondary Boom Lift Cylinder Crushing hazard. The mid-pivot could become unbalanced and The secondary boom lift cylinder raises and lowers fall when removed from the the secondary boom.
  • Page 53 September 2015 Service and Repair Manual Secondary Boom Components Remove the pin retaining fasteners from the secondary boom lift cylinder barrel-end pivot pins. Use a slide hammer to remove the barrel-end pivot pins. Note: Access the pins using the access holes located in the bulkheads, one on each side.

  • Page 54: Engines

    Service and Repair Manual September 2015 Engines How to C heck the Glow Plugs Glow Plugs Kubota Diesel Models How to Check the Glow Plugs Timing Adjustm ent Timing Adjustment Connect the leads from an ohmmeter between the far left glow plug and ground. Complete information to perform this procedure is available in the Kubota D-905 Workshop Manual.

  • Page 55: How To Remove The Flex Plate

    September 2015 Service and Repair Manual Engines How to R emove the Flex Pl ate Flex Plate How to Ins tall the Fl ex Plate How to Install the Flex Plate Install the flex plate onto the flywheel with the The flex plate acts as a coupler between the raised spline away from the flywheel.

  • Page 56: Coolant Temperature And Oil Pressure Switches

    Service and Repair Manual September 2015 Engines Coolant Temperature and Oil Pressure Switches Kubota Gasoline / LPG Models The engine coolant temperature switch is a Chok e Adjus tment Choke Adjustment normally open switch. The switch contacts close at approximately 225°F / 107°C. If the coolant The choke is solenoid-operated and functions only temperature rises above the switch point, the in the gasoline mode.

  • Page 57: How To Remove The Flex Plate

    September 2015 Service and Repair Manual Engines How to R emove the Flex Pl ate Flex Plate How to Ins tall the Fl ex Plate How to Install the Flex Plate Install the flex plate onto the flywheel with the The flex plate acts as a coupler between the raised spline away from the flywheel.

  • Page 58: Coolant Temperature And Oil Pressure Switches

    Service and Repair Manual September 2015 Engines Coolant Temperature and Oil Pressure Switches Perkins Diesel Models The engine coolant temperature switch is a Timing Adjustm ent Timing Adjustment normally open switch. The switch contacts close at approximately 225°F / 107°C. If the coolant Complete information to perform this procedure is temperature rises above the switch point, the available in the Perkins 403C-11 Workshop...

  • Page 59: How To Remove The Flex Plate

    September 2015 Service and Repair Manual Engines How to R emove the Flex Pl ate Flex Plate How to Ins tall the Fl ex Plate How to Install the Flex Plate Install the flex plate onto the flywheel with the The flex plate acts as a coupler between the raised spline away from the flywheel.

  • Page 60: Coolant Temperature And Oil Pressure Switches

    Service and Repair Manual September 2015 Engines Coolant Temperature and Oil Pressure Switches The engine coolant temperature switch is a normally open switch. The switch contacts close at approximately 225°F / 107°C. If the coolant temperature rises above the switch point, the switch contacts close and the engine will shut off to prevent damage.

  • Page 61: Hydraulic Pumps

    September 2015 Service and Repair Manual Hydraulic Pumps How to Remove the Auxiliary Pump Auxiliary Pump Note: When removing a hose assembly or fitting, How to T est the Auxiliary Pump How to Test the Auxiliary Pump the O-ring (if equipped) on the fitting and/or hose end must be replaced.

  • Page 62: Function Pump

    Service and Repair Manual September 2015 Hydraulic Pumps Observe the pressure gauge while cranking the engine. Immediately stop if the pressure Function Pump reaches or exceeds 3000 psi / 206 bar. How to T est the Func tion Pum p How to Test the Function Pump Result: The pressure gauge reads 3000 psi / 206 bar, immediately stop cranking the engine.

  • Page 63: Drive Pump

    September 2015 Service and Repair Manual Hydraulic Pumps Tag,disconnect and plug the hydraulic hoses from the pump. Drive Pump Bodily injury hazard. Spraying The drive pump is a bi-directional variable hydraulic oil can penetrate and displacement piston pump. The pump output is burn skin.

  • Page 64: Manifolds

    Service and Repair Manual September 2015 Manifolds 8-1 Function Manifold Components The function manifold is mounted to the turntable under the ground control box. Index Schematic Description Function Torque Item Counterbalance valve, Platform level up 25-30 ft-lbs / 34-41 Nm 3000 psi / 207 bar Counterbalance valve, Platform level down...
  • Page 65 September 2015 Service and Repair Manual Manifolds Part No. 1268527 Z-34/22 IC...
  • Page 66 Service and Repair Manual September 2015 Manifolds Function Manifold Components, continued Index Schematic Description Function Torque Item Solenoid valve, 2 position 3 way Secondary boom up 8-10 ft-lbs / 11-14 Nm Solenoid valve, 2 position 3 way Turntable rotate left 8-10 ft-lbs / 11-14 Nm Solenoid valve, 2 position 3 way Platform level up...
  • Page 67 September 2015 Service and Repair Manual Manifolds Part No. 1268527 Z-34/22 IC...

  • Page 68: Valve Adjustments - Function Manifold

    Service and Repair Manual September 2015 Manifolds 8-2 Valve Adjustments - Function How to Adj ust the Sec ondary Boom Down R elief Valv e How to Adjust the Secondary Manifold Boom Down Relief Valve Note: Perform this procedure with the boom in the How to Adj ust the Primary Boom Dow n R elief Valv e stowed position.

  • Page 69: Jib Boom And Platform / Jib Boom Rotate Manifold Components

    September 2015 Service and Repair Manual Manifolds Jib Boom and Platform / Jib Boom Rotate Manifold Components The jib boom/platform rotate manifold is mounted to the jib boom. Index Schematic Description Function Torque Item Solenoid valve, 3 position 4 way Jib boom up/down 8-10 ft-lbs / 11-14 Nm Solenoid valve, 3 position 4 way...

  • Page 70: Brake/Two-Speed Manifold Components

    Service and Repair Manual September 2015 Manifolds Brake/Two-Speed Manifold Components The brake / 2-speed manifold is located under the drive chassis cover at the non-steer end. Index Schematic Description Function Torque Item Check Valve Pressure circuit 8-10 ft-lbs / 10-15 Nm Solenoid valve, 2 position 3 way 2-speed motor shift 25-30 ft-lbs / 34-41 Nm...

  • Page 71: Traction Manifold Components, 2Wd

    September 2015 Service and Repair Manual Manifolds Traction Manifold Components, 2WD The 2WD traction is mounted inside the drive chassis at the non-steer end. Index Schematic Description Function Torque Item Shuttle valve, Charge pressure circuitthat gets hot oil out 10-12 ft-lbs / 14-16 Nm 3 position 3 way of low pressureside of drive pump and allows lowpressure flow path for...

  • Page 72: Traction Manifold Components, 4Wd

    Service and Repair Manual September 2015 Manifolds Traction Manifold Components, 4WD The 4WD traction manifold is mounted inside the drive chassis at the non-steer end. Index Schematic Description Function Torque Item Solenoid valve, 2 position 3 way Brake 20 ft-lbs / 27.1 Nm Check valve Drive motor anti-cavitation 20 ft-lbs / 27.1 Nm...
  • Page 73 September 2015 Service and Repair Manual Manifolds Part No. 1268527 Z-34/22 IC...

  • Page 74: Valve Adjustments, 4Wd Traction Manifold

    Service and Repair Manual September 2015 Manifolds Start the engine from the platform controls. Slowly move the drive joystick to full stroke in Valve Adjustments, 4WD Traction either direction and observe the pressure Manifold reading on the pressure gauge. Result: When the charge pressure relief valve How to Adjust the Charge is set correctly, the pressure reading on the gauge should be between 135 to 180 psi / 9 to...

  • Page 75: Valve Coils

    September 2015 Service and Repair Manual Manifolds Valv e C oil Resistanc e Speci ficati on Valve Coil Resistance Valve Coils Specifications Note: The following coil resistance specifications How to T est a Coil are at an ambient temperature of 68°F / 20°C. As How to Test a Coil valve coil resistance is sensitive to changes in air temperature, the coil resistance will typically...

  • Page 76: How To Test A Coil Diode

    Service and Repair Manual September 2015 Manifolds How to T est a Coil Di ode How to Test a Coil Diode Properly functioning coil diodes protect the electrical circuit by suppressing voltage spikes. Voltage spikes naturally occur within a function circuit following the interruption of electrical current to a coil.

  • Page 77: Fuel And Hydraulic Tanks

    September 2015 Service and Repair Manual Fuel and Hydraulic Tanks Turn the manual fuel shutoff valve (if equipped) to the closed position on the fuel Fuel Tank tank. How to R emove the Fuel T ank Using an approved hand-operated pump, drain the fuel tank into a suitable container.

  • Page 78: Hydraulic Tank

    Service and Repair Manual September 2015 Fuel and Hydraulic Tanks Tag, disconnect and plug the hoses from the return filter. Cap the fittings on the return filter. Hydraulic Tank Tag, disconnect and plug the suction hoses The primary functions of the hydraulic tank are to from the bottom of the tank.

  • Page 79: Turntable Rotation Components

    September 2015 Service and Repair Manual Turntable Rotation Components 10-1 Turntable 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 80: Axle Components

    Service and Repair Manual September 2015 Axle Components How to Ins tall the H ub and Bearings How to Install the Hub and 11-1 Bearings, 2WD Models Hub and Bearings, 2WD Models Note: When replacing a wheel bearing, both the How to R emove the H ub and Bearings inner and outer bearings including the pressed-in How to Remove the Hub and...

  • Page 81: Schematics

    September 2015 Service and Repair Manual Schematics About This Section Section 4 Schem atics There are two groups of schematics in this section. Electrical Schematics Electrocution/burn hazard. Contact with electrically charged Observe and Obey: circuits could result in death or serious injury.

  • Page 82: Electrical Symbol Legend

    Service and Repair Manual September 2015 Electrical Symbol Legend Battery Coil, solenoid or relay Horn or alarm Flashing beacon Gauge Diode Hour meter Fuse with amperage Foot switch T-circuits connect Limit Switch Power relay Coil with suppression Fuel or RPM solenoid T-circuits connect at Circuits crossing - no Quick disconnect...

  • Page 83: Hydraulic Symbols Legend

    September 2015 Service and Repair Manual Hydraulic Symbols Legend Orifice with size Check valve Shut off valve Brake Pump, bi-directional Motor, 2 speed Pump, fixed displacement Motor, bi-directional variable displacement bi-directional Pump, prime mover (engine Shuttle valve. 2 position, Double acting cylinder Differential sensing valve or motor) 3 way...

  • Page 84: Electrical Component And Wire Color Legends

    Service and Repair Manual September 2015 Electrical Component and Wire Color Legends Item Description Item Description Battery Horn or Alarm Engine Start - 12V DC Tilt/load sense alarm Descent (ground) Connector Load sense (ground) Power to platform, 12v cable connector Footswitch input connector Joystick Options connector...
  • Page 85 September 2015 Service and Repair Manual Electrical Component and Wire Color Legends Item Description Item Description Motor Toggle Switch Auxiliary pump Auxiliary pump switch Engine starter Start engine switch Fuel pump Fuel select switch (ford efi only) Hi/low rpm switch Button Glow plug switch Red emergency stop button...
  • Page 86 Service and Repair Manual September 2015 Electrical Component and Wire Color Legends Item Description Wire Color Legend Module Item Description Ignition start module Blue EDC - drive pump Black Alc 500 joystick controller card Brown Control module Green Load sense module Orange Time delay relay - 2 seconds, 10A Purple...

  • Page 87: Electrical Schematics - Gasoline/Lpg Models

    September 2015 Service and Repair Manual Electrical Schematic - Gasoline/LPG Models...

  • Page 88: Electrical Schematic - Gasoline/Lpg Models

    Service and Repair Manual September 2015 Electrical Schematic - Gasoline/LPG Models Z-34/22 IC Part No. 1268527...
  • Page 89 September 2015 Service and Repair Manual Electrical Schematic - Gasoline/LPG Models Part No. 1268527 Z-34/22 IC...
  • Page 90 Service and Repair Manual September 2015 Electrical Schematic - Gasoline/LPG Models...
  • Page 91 September 2015 Service and Repair Manual Ground Control Box Switch Panel Wiring Diagram - Gasoline/LPG Models...

  • Page 92: Ground Control Box Switch Panel Wiring Diagram - Gasoline/Lpg Models

    Service and Repair Manual September 2015 Ground Control Box Switch Panel Wiring Diagram - Gasoline/LPG Models Z-34/22 IC Part No. 1268527...

  • Page 93: Ground Control Box Terminal Strip Wiring Diagram - Gasoline/Lpg Models

    September 2015 Service and Repair Manual Ground Control Box Terminal Strip Wiring Diagram - Gasoline/LPG Models Part No. 1268527 Z-34/22 IC...
  • Page 94 Service and Repair Manual September 2015 Ground Control Box Terminal Strip Wiring Diagram - Gasoline/LPG Models...
  • Page 95 September 2015 Service and Repair Manual Platform Control Box Wiring Diagram - Gasoline/LPG Models...

  • Page 96: Platform Control Box Wiring Diagram - Gasoline/Lpg Models

    Service and Repair Manual September 2015 Platform Control Box Wiring Diagram - Gasoline/LPG Models Z-34/22 IC Part No. 1268527...

  • Page 97: Electrical Schematics - Diesel Models

    September 2015 Service and Repair Manual Electrical Schematic - Diesel Models...

  • Page 98: Electrical Schematic - Diesel Models

    Service and Repair Manual September 2015 Electrical Schematic - Diesel Models Z-34/22 IC Part No. 1268527...
  • Page 99 September 2015 Service and Repair Manual Electrical Schematic - Diesel Models Part No. 1268527 Z-34/22 IC...
  • Page 100 Service and Repair Manual September 2015 Electrical Schematic - Diesel Models...
  • Page 101 September 2015 Service and Repair Manual Ground Control Box Switch Panel Wiring Diagram - Diesel Models...

  • Page 102: Ground Control Box Switch Panel Wiring Diagram - Diesel Models

    Service and Repair Manual September 2015 Ground Control Box Switch Panel Wiring Diagram - Diesel Models Z-34/22 IC Part No. 1268527...

  • Page 103: Ground Control Box Terminal Strip Wiring Diagram - Diesel Models

    September 2015 Service and Repair Manual Ground Control Box Terminal Strip Wiring Diagram - Diesel Models Part No. 1268527 Z-34/22 IC...
  • Page 104 Service and Repair Manual September 2015 Ground Control Box Terminal Strip Wiring Diagram - Diesel Models...
  • Page 105 September 2015 Service and Repair Manual Platform Control Box Wiring Diagram - Diesel Models...

  • Page 106: Platform Control Box Wiring Diagram - Diesel Models

    Service and Repair Manual September 2015 Platform Control Box Wiring Diagram - Diesel Models Z-34/22 IC Part No. 1268527...

  • Page 107: Electrical Schematics - Options

    September 2015 Service and Repair Manual Platform Control Box Wiring Diagram - Options...

  • Page 108: Platform Control Box Wiring Diagram - Options

    Service and Repair Manual September 2015 Platform Control Box Wiring Diagram - Options Z-34/22 IC Part No. 1268527...

  • Page 109: Manifold And Limit Switch Wiring Diagram

    September 2015 Service and Repair Manual Manifold and Limit Switch Wiring Diagram Part No. 1268527 Z-34/22 IC...
  • Page 110 Service and Repair Manual September 2015 Manifold and Limit Switch Wiring Diagram...

  • Page 111: Hydraulic Schematics

    September 2015 Service and Repair Manual Hydraulic Schematic, 2WD Models...

  • Page 112: Hydraulic Schematic, 2Wd Models

    Service and Repair Manual September 2015 Hydraulic Schematic, 2WD Models Z-34/22 IC Part No. 1268527...
  • Page 113 September 2015 Service and Repair Manual Hydraulic Schematic, 2WD Models Part No. 1268527 Z-34/22 IC...
  • Page 114 Service and Repair Manual September 2015 Hydraulic Schematic, 2WD Models...
  • Page 115 September 2015 Service and Repair Manual Hydraulic Schematic, 4WD Models...

  • Page 116: Hydraulic Schematic, 4Wd Models

    Service and Repair Manual September 2015 Hydraulic Schematic, 4WD Models Z-34/22 IC Part No. 1268527...
  • Page 117 September 2015 Service and Repair Manual Hydraulic Schematic, 4WD Models Part No. 1268527 Z-34/22 IC...
  • Page 118 Service and Repair Manual September 2015 Hydraulic Schematic, 4WD Models Z-34/22 IC Part No. 1268527 Servic e and R epair M anual Sept emb er 2015...

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