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 Z34F-14000
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. 1312294GT
Rev A
July 2021

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

  • Page 1 Service and Repair Manual Serial Number Range -34/22 IC ® This manual includes: from Z34F-14000 Repair procedures Fault Codes Electrical and Hydraulic Schematics For detailed maintenance procedures, refer to the appropriate Maintenance Manual for your machine. Part No. 1312294GT Rev A July 2021...

  • Page 2: Introduction

    Copyright © 2015 by Terex Corporation 1312294GT Rev A, July 2021 Second Edition, First Printing Genie and "Z" are registered trademarks of Terex South Dakota, Inc. in the U.S.A. and many other countries. ® -34/22 IC Part No. 1312294GT...

  • Page 3: Revision History

    July 2021 Service and Repair Manual Introduction Revision History Revision Date Section Procedure / Page / Description 7/2021 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 July 2021 Introduction Serial Number Legend Z34 F - 12345 Model: Serial number: Z34F-12345 Year of manufacture: Electrical schematic number: Machine unladen weight: Rated work load (including occupants): Maximum number of platform occupants: Maximum allowable side force: Maximum allowable inclination of the chassis: 1 Model 4 Serial number (stamped on chassis)

  • Page 5: Safety Rules

    July 2021 Service and Repair Manual Safety Rules Section 1 Safety Rules 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 July 2021 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

    July 2021 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 July 2021 Table of Contents Section 3 Repair Procedures ..................... 16 Introduction ......................16 Platform Controls ....................18 1-1 Drive Joystick ....................18 How to Adjust the Drive Joystick ..............18 1-2 Boom Function Speed Controller Adjustments ..........20 Boom Function Speed Controller Adjustments ..........20 Platform Components ..................
  • Page 9 July 2021 Table of Contents Primary Boom Components ................29 4-1 Cable Track ....................29 How to Repair the Primary Boom Cable Track ..........29 4-2 Primary Boom ....................29 How to Shim the Primary Boom ..............29 How to Remove the Primary Boom ..............30 How to Disassemble the Primary Boom ............
  • Page 10 July 2021 Table of Contents 6-2 Kubota Gasoline / LPG Models ..............45 Choke Adjustment ..................45 Timing Adjustment ..................45 Carburetor Adjustment ..................45 RPM Adjustment ..................... 45 How to Remove the Flex Plate ............... 46 How to Install the Flex Plate ................46 Coolant Temperature and Oil Pressure Switches ..........
  • Page 11 July 2021 Table of Contents Manifolds ......................54 8-1 Function Manifold Components ..............54 8-2 Valve Adjustments - Function Manifold ............58 How to Adjust the System Relief Valve ............58 How to Adjust the Primary Boom Down Relief Valve........58 How to Adjust the Secondary Boom Down Relief Valve .........
  • Page 12 July 2021 Table of Contents Section 4 Fault Codes ......................73 Introduction ......................73 How to Retrieve Engine Fault Codes Perkins 403F-11 Models ..... 74 How to Retrieve Engine Fault - Codes GM .998L Models ........75 Section 5 Schematics ......................81 Introduction ......................

  • Page 13: Specifications

    July 2021 Service and Repair Manual Specifications Section 2 Specifications 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 Hydraulic tank...

  • Page 14: Machine Component Weights

    Service and Repair Manual July 2021 Specifications Machine Component Weights Performance Specifications Drive motor 27 lbs Drive speed, maximum 12 kg Stowed position 3.0 mph Torque hub 113 lbs 5.1 km/h 51 kg 40 ft / 9.1 sec 12.2 m / 9.1 sec Primary boom assembly 647 lbs (including extension boom)

  • Page 15: Hydraulic Oil Specifications

    July 2021 Service and Repair Manual Specifications Hydraulic Oil Specifications Do not top off with incompatible hydraulic fluids. Hydraulic fluids may be incompatible due to the Hydraulic Fluid Specifications differences in base additive Genie specifications require hydraulic oils which are chemistry.
  • Page 16 Service and Repair Manual July 2021 Specifications Chevron Rando HD Premium Oil Chevron 5606A Hydraulic Oil MV Fluid Properties Fluid Properties ISO Grade ISO Grade Viscosity index Viscosity index Kinematic Viscosity Kinematic Viscosity cSt @ 200°F / 100°C cSt @ 200°F / 100°C cSt @ 104°F / 40°C 33.5 cSt @ 104°F / 40°C...
  • Page 17 July 2021 Service and Repair Manual Specifications Petro-Canada Environ MV 46 UCON Hydrolube HP-5046 Fluid Fluid Properties Properties ISO Grade ISO Grade Viscosity index Viscosity index Kinematic Viscosity Kinematic Viscosity cSt @ 200°F / 100°C cSt @ 149°F / 65°C cSt @ 104°F / 40°C 44.4 cSt @ 104°F / 40°C...

  • Page 18: Hydraulic Component Specifications

    Service and Repair Manual July 2021 Specifications Hydraulic Component Auxiliary Pump Specifications Type: fixed displacement gear pump Displacement per revolution 0.5 gpm Drive Pump 1.9 L/min Type: bi-directional variable displacement piston pump Auxiliary pump relief pressure 3400 psi 234.5 bar Displacement per revolution 1.71 cu in 28 cc...

  • Page 19: Machine Torque Specifications

    July 2021 Service and Repair Manual Specifications Machine Torque Specifications Non-steer end drive motors Displacement per revolution 1.53 cu in Platform Rotator 25 cc 3/4-10 center bolt, GR 8, dry 380 ft-lbs Hydraulic Filters 515 Nm 3/4-10 center bolt, GR 8, lubricated Medium pressure filter Beta 3 ˆ...

  • Page 20: Kubota Wg-972 Engine Specifications

    Service and Repair Manual July 2021 Specifications Kubota WG-972 Engine Alternator output 40A @ 12V DC Fan belt deflection 1/4 to 3/8 in Displacement 57.8 cu in 7 to 9 mm 0.96 liters Starter motor Number of cylinders Brush length, new 0.551 in Bore and Stroke 2.93 x 2.90 inches...

  • Page 21: Gm .998L Engine Specifications

    July 2021 Service and Repair Manual Specifications GM .998L Engine Alternator output 70A @ 14V DC Fan belt deflection .3125 in Displacement 60.9 cu in 8 mm 0.99 liters Battery Number of cylinders Type 12V DC Bore and Stroke 2.58 x 2.91 inches Group 34/78 65.5 x 74 mm...

  • Page 22: Kubota D1105 Engine Specifications

    Service and Repair Manual July 2021 Specifications Kubota D1105 Engine Fuel injection system Injection pump make Bosch MD Displacement 68.53 cu in Injection pump pressure, 1991 psi 1.123 liters maximum 137 bar Number of cylinders Injection timing 18° BTDC Bore and Stroke 3.07 x 3.09 inches Fuel requirement 78 x 78.4 mm...

  • Page 23: Perkins 403D-11 Engine Specifications

    July 2021 Service and Repair Manual Specifications Perkins 403D-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 24: Perkins 403F-11 Engine Specifications

    Service and Repair Manual July 2021 Specifications Perkins 403F-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 25: Hydraulic Hose And Fitting Torque Specifications

    July 2021 Service and Repair Manual 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 26: Torque Procedure

    Service and Repair Manual July 2021 Specifications Torque Procedure JIC 37° fittings Align the tube flare (hex nut) against the nose Seal-Lok™ fittings of the fitting body (body hex fitting) and tighten the hex nut to the body hex fitting to Replace the O-ring.
  • Page 27 July 2021 Service and Repair Manual Specifications Working clockwise on the body hex fitting, make a second mark with a permanent ink marker to indicate the proper tightening position. Refer to Illustration 2. Note: Use the JIC 37° Fitting table in this section to determine the correct number of flats, for the proper tightening position.

  • Page 28: Repair Procedures

    Service and Repair Manual July 2021 Repair Procedures Machine Configuration: Section 3 Repair Procedures  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 29 July 2021 Service and Repair Manual 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 30: Platform Controls

    Service and Repair Manual July 2021 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 controller, located under the drive chassis cover at current, should be capable of reading up to...
  • Page 31 July 2021 Service and Repair Manual 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 32: Boom Function Speed Controller Adjustments

    Service and Repair Manual July 2021 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 Function Speed Controller Adjustments 23 Press down the foot switch and raise the Boom Function Speed Controller primary boom approximately 3 feet / 1 m.
  • Page 33 July 2021 Service and Repair Manual 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 34: Platform Components

    Service and Repair Manual July 2021 Platform Components Remove the pin retainer fastener from the rod-end pivot pin. Platform Leveling Slave Cylinder Remove the external snap ring from the barrel-end pivot pin. The slave cylinder and the rotator pivot are the two primary supports for the platform.

  • Page 35: Platform Rotator

    July 2021 Service and Repair Manual Platform Components Support the platform rotator with a suitable lifting device. Do not apply any lifting Platform Rotator pressure. Remove the pin retaining fasteners from the How to Remove the Platform Rotator jib boom and leveling links to platform rotator How to Remove the Platform pivot pins.

  • Page 36: How To Bleed The Platform Rotator

    Service and Repair Manual July 2021 Platform Components How to Bleed the Platform Rotator 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 37: Platform Overload System

    July 2021 Service and Repair Manual Platform Components Note: There may be an approximate 2 second delay before the overload indicator light turns on Platform Overload System and the alarm sounds. How to Calibrate the Platform Overload System (if equipped) How to Calibrate the Platform Note: The platform will need to be moved up and down and allowed to settle between adjustments.

  • Page 38: Jib Boom Components

    Service and Repair Manual July 2021 Jib Boom Components Tag and disconnect the electrical wiring from the jib boom manifold. Jib Boom Attach a lifting strap from an suitable lifting device to the jib boom. How to Remove the Jib Boom How to Remove the Jib Boom Remove the pin retaining fasteners from the Note: Perform this procedure with the boom in the...

  • Page 39: Jib Boom Bell Crank

    July 2021 Service and Repair Manual Jib Boom Components Jib Boom Bell Crank Jib Boom Lift Cylinder How to Remove the Jib Boom Bell Crank How to Remove the Jib Boom How to Remove the Jib Boom Lift Cylinder How to Remove the Jib Boom Lift Bell Crank Cylinder Note: Perform this procedure with the boom in the...
  • Page 40 Service and Repair Manual July 2021 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 41: Primary Boom Components

    July 2021 Service and Repair Manual Primary Boom Components Primary Boom Cable Track The primary boom cable track guides the cables How to Shim the Primary Boom How to Shim the Primary Boom and hoses running up the boom. It can be repaired Extend the boom until the wear pads are link by link without removing the cables and hoses accessible.

  • Page 42: How To Remove The Primary Boom

    Service and Repair Manual July 2021 Primary Boom Components How to Remove 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 43 July 2021 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 it.

  • Page 44: How To Disassemble The Primary Boom

    Service and Repair Manual July 2021 Primary Boom Components Support and slide the extension tube out of How to Disassemble the Primary Boom How to Disassemble the Primary 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 45: Primary Boom Lift Cylinder

    July 2021 Service and Repair Manual Primary Boom Components Attach a lifting strap from an suitable lifting device to the primary boom lift cylinder. Primary Boom Lift Cylinder Remove the rear turntable cover. The primary boom lift cylinder raises and lowers Place a 4x4 inch / 10 x 10 cm block between the primary boom.

  • Page 46: Primary Boom Extension Cylinder

    Service and Repair Manual July 2021 Primary Boom Components 13 Tag, disconnect and plug the primary boom lift cylinder hydraulic hoses. Cap the fittings Primary Boom Extension on the cylinder. Cylinder Bodily injury hazard. Spraying hydraulic oil can penetrate and The primary boom extension cylinder extends and burn skin.
  • Page 47 July 2021 Service and Repair Manual Primary Boom Components Raise the secondary boom until the master 10 Carefully pull out and properly support the extension cylinder from the primary boom cylinder rod-end pivot pin is accessible. using a lifting strap from an suitable lifting Remove the drive speed limit switch from the device.

  • Page 48: Platform Leveling Master Cylinder

    Service and Repair Manual July 2021 Primary Boom Components Secure the upper secondary boom to the pivot end of the primary boom with a strap. Platform Leveling Master Note: Securing the upper secondary boom to the Cylinder pivot will prevent the upper secondary boom from falling when the master cylinder barrel-end pivot The platform leveling master cylinder acts as a pin is removed from the cylinder.

  • Page 49: Secondary Boom Components

    July 2021 Service and Repair Manual 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 Part No. 1312294GT ® -34/22 IC...

  • Page 50: Secondary Boom

    Service and Repair Manual July 2021 Secondary Boom Components Tag and disconnect each wire from the cables in the platform control box. Secondary Boom Electrocution/burn hazard. Contact with electrically charged How to Disassemble the Secondary Boom How to Disassemble the circuits could result in death or Secondary Boom serious injury.
  • Page 51 July 2021 Service and Repair Manual Secondary Boom Components 18 Tag, disconnect and plug the primary boom 25 Carefully remove the entire primary boom lift cylinder and master cylinder hydraulic assembly from the machine (primary boom hoses. Cap the fittings on the cylinders. assembly, jib boom assembly, platform, master cylinder, primary lift cylinder and upper Bodily injury hazard.
  • Page 52 Service and Repair Manual July 2021 Secondary Boom Components 32 Remove the pin retaining fasteners from the 43 Tag, disconnect and plug the hydraulic hoses rod end of the secondary boom lift cylinder. from the secondary boom lift cylinder. Cap the Use a soft metal drift to remove the pin.

  • Page 53: Secondary Boom Lift Cylinders

    July 2021 Service and Repair Manual Secondary Boom Components 49 Attach a lifting strap from an suitable lifting device to the control box side lower Secondary Boom Lift Cylinder compression arm. 50 Remove the pin retaining fasteners from the The secondary boom lift cylinder raises and lowers lower compression arm to turntable pivot pins.
  • Page 54 Service and Repair Manual July 2021 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 55: Engines

    July 2021 Service and Repair Manual Engines How to Check the Glow Plugs Glow Plugs Kubota Diesel Models How to Check the Glow Plugs Timing Adjustment 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-1105 Workshop Manual.

  • Page 56: How To Remove The Flex Plate

    Service and Repair Manual July 2021 Engines How to Remove the Flex Plate Flex Plate How to Install the Flex 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 57: Coolant Temperature And Oil Pressure Switches

    July 2021 Service and Repair Manual Engines Coolant Temperature and Oil Pressure Switches Kubota Gasoline / LPG Models The engine coolant temperature switch is a Choke Adjustment 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 58: How To Remove The Flex Plate

    Service and Repair Manual July 2021 Engines How to Remove the Flex Plate Flex Plate How to Install the Flex 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 59: Coolant Temperature And Oil Pressure Switches

    July 2021 Service and Repair Manual Engines Coolant Temperature and Oil Pressure Switches Perkins Diesel Models The engine coolant temperature switch is a Timing Adjustment 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 403D-11 Workshop...

  • Page 60: How To Remove The Flex Plate

    Service and Repair Manual July 2021 Engines How to Remove the Flex Plate Flex Plate How to Install the Flex 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 61: Coolant Temperature And Oil Pressure Switches

    July 2021 Service and Repair Manual Engines Coolant Temperature and Oil Pressure Switches GM .998L Models The engine coolant temperature switch is a Timing Adjustment 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 GM .998L Service Manual.

  • Page 62: How To Remove The Flex Plate

    Service and Repair Manual July 2021 Engines How to Remove the Flex Plate Flex Plate How to Install the Flex 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 63: Hydraulic Pumps

    July 2021 Service and Repair Manual Hydraulic Pumps How to Remove the Auxiliary Pump Auxiliary Pump Note: When removing a hose assembly or fitting, How to Test 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 64: Function Pump

    Service and Repair Manual July 2021 Hydraulic Pumps Function Pump How to Removet the Function Pump How to Remove the Function Pump Note: When removing a hose assembly 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.

  • Page 65: Drive Pump

    July 2021 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 66: Manifolds

    Service and Repair Manual July 2021 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, 3000 psi / Platform level up 25-30 ft-lbs / 34-41 Nm 207 bar Counterbalance valve, 3000 psi / Platform level down...
  • Page 67 July 2021 Service and Repair Manual Manifolds Part No. 1312294GT ® -34/22 IC...
  • Page 68 Service and Repair Manual July 2021 Manifolds Function Manifold Components, continued Index Description Schematic Item Function Torque 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 69 July 2021 Service and Repair Manual Manifolds Part No. 1312294GT ® -34/22 IC...

  • Page 70: Valve Adjustments - Function Manifold

    Service and Repair Manual July 2021 Manifolds 8-2 Valve Adjustments - Function Manifold How to Adjust the System Relief Valve How to Adjust the System Relief Valve Note: Perform this procedure with the boom in the stowed position. Note: Refer to Function Manifold Component list to locate the system relief valve.

  • Page 71: How To Adjust The Secondary Boom Down Relief Valve

    July 2021 Service and Repair Manual Manifolds How to Adjust the Primary Boom How to Adjust the Secondary Boom Down Relief Valve Down Relief Valve Note: Perform this procedure with the boom in the stowed position. Connect a 0 to 3000 psi / 0 to 206 bar pressure gauge to the test port on the function manifold.
  • Page 72 Service and Repair Manual July 2021 Manifolds How to Adjust the Secondary Boom Down Relief Valve Note: Perform this procedure with the boom in the stowed position. Connect a 0 to 3000 psi / 0 to 206 bar pressure gauge to the test port on the function manifold.

  • Page 73: Jib Boom And Platform / Jib Boom Rotate Manifold Components

    July 2021 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 74: Brake/Two-Speed Manifold Components

    Service and Repair Manual July 2021 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 75: Traction Manifold Components, 2Wd

    July 2021 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, 3 position Charge pressure circuitthat gets hot oil out of 10-12 ft-lbs / 3 way low pressureside of drive pump and allows...

  • Page 76: Traction Manifold Components, 4Wd

    Service and Repair Manual July 2021 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 77 July 2021 Service and Repair Manual Manifolds Part No. 1312294GT ® -34/22 IC...

  • Page 78: Valve Adjustments, 4Wd Traction Manifold

    Service and Repair Manual July 2021 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 /...

  • Page 79: Valve Coils

    July 2021 Service and Repair Manual Manifolds Valve Coil Resistance Specification Valve Coil Resistance Valve Coils Specifications Note: The following coil resistance specifications How to Test a Coil 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...

  • Page 80: How To Test A Coil Diode

    Service and Repair Manual July 2021 Manifolds How to Test a Coil Diode 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 81: Fuel And Hydraulic Tanks

    July 2021 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. Using an approved hand-operated pump, How to Remove the Fuel Tank drain the fuel tank into a suitable container. How to Remove the Fuel Tank Refer to Specifications, Machine Specifications.

  • Page 82: Hydraulic Tank

    Service and Repair Manual July 2021 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 83: Turntable Rotation Components

    July 2021 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 84: Axle Components

    Service and Repair Manual July 2021 Axle Components How to Install the Hub 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 Remove the Hub and Bearings How to Remove the Hub and inner and outer bearings including the pressed-in Bearings, 2WD Models...

  • Page 85: Fault Codes

    July 2021 Service and Repair Manual Fault Codes Before Troubleshooting: Section 4 Fault Codes  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 available and ready for use.

  • Page 86: How To Retrieve Engine Fault Codes Perkins 403F-11 Models

    Service and Repair Manual July 2021 Fault Codes Flash Codes with Key ON (Engine not in Operation) How to Retrieve Engine Fault Codes Perkins 403F-11 Models How to Retrieve Engine Fault Flash Description Status Action Codes - Perkins 403F-11 Models code Oil pressure Engine will...

  • Page 87: How To Retrieve Engine Fault - Codes Gm .998L Models

    July 2021 Service and Repair Manual Fault Codes How to Retrieve Engine Fault Codes - GM .998L Models The emissions control system utilizes a diagnostic display located on the ground control box. A fault condition will be displayed for one of the following: The fault caused the engine to shut down or the fault is related to the exhaust gas oxygen (EGO) sensors.
  • Page 88 Service and Repair Manual July 2021 Fault Codes DTC Set 2 DTC Set 2 Description Description SPN-2/FMI-2 SPN-2/FMI-2 DTC 11: Intake cam / distributor position DTC 221: TPS1-2 higher than expected 520800 / 7 653/6 error DTC 16: Crank and/or cam no sync during DTC 222: TPS2 voltage low 636 / 8 520251 / 4...
  • Page 89 July 2021 Service and Repair Manual Fault Codes DTC Set 2 DTC Set 2 Description Description SPN-2 / FMI-2 SPN-2 / FMI-2 DTC 420: Catalyst inactive on gasoline (Bank DTC 1111: RPM above fuel rev limit level 520211 / 10 515 / 16 DTC 430: Catalyst inactive on gasoline (Bank DTC 1112: RPM above spark rev limit level...
  • Page 90 Service and Repair Manual July 2021 Fault Codes DTC Set 2 DTC Set 2 Description Description SPN-2 / FMI-2 SPN-2 / FMI-2 DTC 1315: Cylinder 5 misfire detected 1327 / 11 DTC 1543: AUX analog Pull-Up/Down 2 high voltage 520220 / 3 DTC 1316: Cylinder 6 misfire detected 1328 / 11 DTC 1544: AUX analog Pull-Up/Down 2 low voltage...
  • Page 91 July 2021 Service and Repair Manual Fault Codes DTC Set 2 DTC Set 2 Description Description SPN-2 / FMI-2 SPN-2 / FMI-2 DTC 1517: AUX analog Pull-Up 3 high voltage 520218 / 3 DTC 1626: CAN-J1939 Tx fault 639 / 12 DTC 1518: AUX analog Pull-Up 3 low voltage 520218 / 4 DTC 1627: CAN-J1939 Rx fault...
  • Page 92 Service and Repair Manual July 2021 Fault Codes DTC Set 2 DTC Set 2 Description Description SPN-2 / FMI-2 SPN-2 / FMI-2 DTC 2123: FPP1 voltage low 91 / 4 DTC 2328: Spark coil 10 primary shorted 1277 / 6 DTC 2125: FPP2 invalid voltage and 520250 / 31 DTC 2428: EGT temperature high...

  • Page 93: Schematics

    July 2021 Service and Repair Manual Schematics About This Section Section 5 Schematics 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. Remove all rings, ...

  • Page 94: Electrical Symbol Legend

    Service and Repair Manual July 2021 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 Connection - no T-circuits connect at Circuits crossing no...

  • Page 95: Hydraulic Symbols Legend

    July 2021 Service and Repair Manual Hydraulic Symbols Legend Orifice with size Check valve Shut off valve Brake Pump, bi-directional Motor, 2 speed bi- Pump, fixed displacement Motor, bi-directional variable displacement directional Pump, prime mover Shuttle valve. 2 position, Cylinder, double acting Differential sensing valve (engine or motor) 3 way...

  • Page 96: Electrical Component And Wire Color Legends

    Service and Repair Manual July 2021 Electrical Component and Wire Color Legends Item Fuse Description Fuse, VSW 5A Battery Fuse, ECM 10A Engine Start - 12V DC Fuse, fuel pump 15A Connector Fuse, ignition 20A 2 speed/brake manifold/drive pump connector Fuse, 5A Power to platform, 12v cable connector Fuse, starter 25A...
  • Page 97 July 2021 Service and Repair Manual Electrical Component and Wire Color Legends Item Description Item Description Horn or Alarm Motor Tilt/load sense alarm Auxiliary pump Service horn Engine starter Travel alarm Fuel pump Descent (ground) Button Load sense (ground) Red emergency stop button Joystick Emergency stop button Boom proportional joystick: secondary...
  • Page 98 Service and Repair Manual July 2021 Electrical Component and Wire Color Legends Item Description Wire Color Legend Toggle Switch Item Description Auxiliary pump switch Blue Start engine switch Black Fuel select switch (ford efi only) Brown Engine speed Green Glow plug switch Orange Platform rotate switch Purple...

  • Page 99: Electrical Schematics - Gasoline/Lpg Models

    July 2021 Service and Repair Manual Electrical Schematic - Gasoline/LPG Models...

  • Page 100: Electrical Schematic - Gasoline/Lpg Models

    Service and Repair Manual July 2021 Electrical Schematic - Gasoline/LPG Models CR24 TILT LOAD SENSE AUX ALARM RECOVERY RELAY TB134 TB134 TB134 C47FE RD TB28 ES34GP AL ® -34/22 IC Part No. 1312294GT...

  • Page 101: Electrical Schematic, Functions - Gasoline/Lpg Models

    July 2021 Service and Repair Manual Electrical Schematic, Functions - Gasoline/LPG Models C54A-9 WH P24BAT TURNTABLE SECONDARY PRIMARY PRIMARY PLATFORM PLATFORM ROTATE BOOM BOOM BOOM LEVEL TS12 TS10 TS11 TS13 ROTATE 87A 30 DRIVE ENABLE BATTERY NEGATIVE FORWARD PUMP VALVE 1.5A REVERSE PUMP VALVE 1.5A BRAKE VALVE OFF LIMIT...
  • Page 102 Service and Repair Manual July 2021 Electrical Schematic, Functions - Gasoline/LPG Models...
  • Page 103 July 2021 Service and Repair Manual Electrical Schematic, PSI DF Engine - Gasoline/LPG Models...

  • Page 104: Electrical Schematic, Psi Df Engine - Gasoline/Lpg Models

    Service and Repair Manual July 2021 Electrical Schematic, PSI DF Engine - Gasoline/LPG Models PGL PINNING ® -34/22 IC Part No. 1312294GT...

  • Page 105: Electrical Schematics - Diesel Models

    July 2021 Service and Repair Manual Electrical Schematic - Diesel Models (ANSI / CSA)

  • Page 106: Electrical Schematic - Diesel Models (Ansi / Csa)

    Service and Repair Manual July 2021 Electrical Schematic - Diesel Models (ANSI / CSA) LOAD SENSE AUX RECOVERY RELAY CR24 TILT ALARM TB134 TB134 TB134 TB134 TB134 TB28 C21IGN ES34D AR ® -34/22 IC Part No. 1312294GT...

  • Page 107: Electrical Schematic, Functions - Diesel Models Ansi / Csa

    July 2021 Service and Repair Manual Electrical Schematic, Functions - Diesel Models (ANSI / CSA) WH P24BAT C28TTA RD/BK C28TTA C54A-9 PLATFORM SECONDARY PRIMARY TURNTABLE PLATFORM PRIMARY BOOM LEVEL BOOM ROTATE ROTATE BOOM TS12 TS10 TS11 TS13 DRIVE ENABLE BATTERY NEGATIVE FORWARD PUMP VALVE 1.5A REVERSE PUMP VALVE 1.5A BRAKE VALVE...
  • Page 108 Service and Repair Manual July 2021 Electrical Schematic, Functions - Diesel Models (ANSI / CSA)
  • Page 109 July 2021 Service and Repair Manual Electrical Schematic - Diesel Models (CE / AS)

  • Page 110: Electrical Schematic - Diesel Models (Ce / As)

    Service and Repair Manual July 2021 Electrical Schematic - Diesel Models (CE / AS) LOAD SENSE AUX RECOVERY RELAY 86 CR24 TILT ALARM TB134 TB134 TB134 TB134 TB134 C21IGN ® -34/22 IC Part No. 1312294GT...
  • Page 111 July 2021 Service and Repair Manual Electrical Schematic, Functions - Diesel Models (CE / AS) WH P24BAT C28TTA RD/BK C28TTA PLATFORM TURNTABLE PRIMARY SECONDARY PRIMARY LEVEL PLATFORM ROTATE BOOM BOOM BOOM TS12 TS10 TS11 TS13 ROTATE DRIVE ENABLE BATTERY NEGATIVE FORWARD PUMP VALVE 1.5A REVERSE PUMP VALVE 1.5A BRAKE VALVE...
  • Page 112 Service and Repair Manual July 2021 Electrical Schematic, Functions - Diesel Models (CE / AS)

  • Page 113: Electrical Schematics - Options

    July 2021 Service and Repair Manual Kubota D1105 Engine Schematic...

  • Page 114: Kubota D1105 Engine Schematic, Options

    Service and Repair Manual July 2021 Kubota D1105 Engine Schematic, Options PRESSURE SWITCH C27AUX C49-1 C24SEN N.C. C49-2 C25PSR WH/BK C49-3 WATER C26TSR WH/RD C49-4 TEMP. SWITCH C21IGN C49-5 R33STR BK \14 N.O. C49-6 R34SA BK/WH \14 C49-7 R35RPM BK/RD \14 C49-8 C41RPM OR/BK...

  • Page 115: Perkins 403F-11 Engine Schematic, Options

    July 2021 Service and Repair Manual Perkins 403F-11 Engine Schematic, Options WATER TEMP. SWITCH C27AUX C49-1 J1-A1 KEY SWITCH PWR. (+12V) N.O. C24SEN C65-2 C65-1 BR C49-2 J1-A2 FUEL RACK ACTUATOR (PWR) C25PSR WH/BK C49-3 J1-A3 FUEL RACK ACTUATOR (SIG) C26TSR WH/RD WH/RD...
  • Page 116 Service and Repair Manual July 2021 Perkins 403F-11 Engine Schematic, Options...
  • Page 117 July 2021 Service and Repair Manual Manifold and Limit Switch Wiring Diagram - Diesel Models, Options...

  • Page 118: Manifold And Limit Switch Wiring Diagram - Diesel Models, Options

    Service and Repair Manual July 2021 Manifold and Limit Switch Wiring Diagram - Diesel Models, Options JIB MANIFOLD (TOP VIEW) WH-JIB DOWN BR-GND PIN# WIRES CKT# BK-JIB UP C17PRL PIN# WIRES BR-GND C18PRR C43JU C44JD OR-PLAT ROTATE L BR-GND PLUG PLUG PLUG PIN#...

  • Page 119: Manifold And Limit Switch Wiring Diagram - Gasoline/Lpg Models, Options

    July 2021 Service and Repair Manual Manifold and Limit Switch Wiring Diagram - Gasoline/LPG Models, Options JIB MANIFOLD (TOP VIEW) JIB CABLE TO PLATFORM BOX (SHOWN WITH BOOM EXTENDED) BK-JIB BL-JIB (JIB UP) (PLAT R) PIN# WIRES CKT# C17PRL WH-JIB PIN# WIRES OR-JIB...
  • Page 120 Service and Repair Manual July 2021 Manifold and Limit Switch Wiring Diagram - Gasoline/LPG Models, Options...
  • Page 121 July 2021 Service and Repair Manual Lift Guard Contact Alarm Wiring Diagram, Options...

  • Page 122: Lift Guard Contact Alarm Wiring Diagram, Options

    Service and Repair Manual July 2021 Lift Guard Contact Alarm Wiring Diagram, Options J110 C111A-2 C111B-2 OR/BK L18B L18A C111A-1 C111B-1 R24BAT BK/RD R24BAT BK/RD BK/WH BK/WH CR81 C9P-1 C9A-2 C9A-1 P24BAT WH P24FS WH C9P-2 HORN ® -34/22 IC Part No.

  • Page 123: Fuel Level Telematics Wiring Diagram, Options

    July 2021 Service and Repair Manual Fuel Level Telematics Wiring Diagram, Options TELEMATICS READY CONNECTOR 4 CAN- 3 CAN+ POWER GROUND SENSOR INPUT GROUND CONTROL BOX FUEL TANK FUEL LEVEL TELEMATICS Part No. 1312294GT ® -34/22 IC...
  • Page 124 Service and Repair Manual July 2021 Fuel Level Telematics Wiring Diagram, Options...

  • Page 125: Hydraulic Schematics

    July 2021 Service and Repair Manual Hydraulic Schematic, 2WD Models...

  • Page 126: Hydraulic Schematic, 2Wd Models

    Service and Repair Manual July 2021 Hydraulic Schematic, 2WD Models ® -34/22 IC Part No. 1312294GT...
  • Page 127 July 2021 Service and Repair Manual Hydraulic Schematic, 2WD Models Part No. 1312294GT ® -34/22 IC...
  • Page 128 Service and Repair Manual July 2021 Hydraulic Schematic, 2WD Models...
  • Page 129 July 2021 Service and Repair Manual Hydraulic Schematic, 4WD Models...

  • Page 130: Hydraulic Schematic, 4Wd Models

    Service and Repair Manual July 2021 Hydraulic Schematic, 4WD Models ® -34/22 IC Part No. 1312294GT...
  • Page 131 July 2021 Service and Repair Manual Hydraulic Schematic, 4WD Models Part No. 1312294GT ® -34/22 IC...
  • Page 132 Service and Repair Manual July 2021 Hydraulic Schematic, 4WD Models Z®-34/22 IC Part No. 1312294GT Service and Repair Manual July 2021...

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Z34f-14000

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