Terex Z3413-9461 Service And Repair Manual
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Terex Z3413-9461 Service And Repair Manual

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Service and Repair Manual
Z-34/22 IC
Serial Number Range
from Z3413-9461 to
Z3415-10688
from Z3416F-10689 to
Z3416F-11999
from Z34F-12000
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. 1274592
Rev A
September 2016

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Summary of Contents for Terex Z3413-9461

  • Page 1 Service and Repair Manual Serial Number Range Z-34/22 IC This manual includes: from Z3413-9461 to Repair procedures Z3415-10688 Fault Codes from Z3416F-10689 to Electrical and Z3416F-11999 Hydraulic Schematics from Z34F-12000 For detailed maintenance procedures, refer to the appropriate Maintenance Manual for your machine.

  • Page 2: Find A Manual For This Model

    Copyright © 2015 by Terex Corporation 1274592 Rev A, September 2016 First Edition, First Printing Genie is a registered trademark of Terex South Dakota, Inc. in the U.S.A. and many other countries. “Z” is a trademark of Terex South Dakota, Inc.

  • Page 3: Revision History

    September 2016 Service and Repair Manual Introduction Revision History Revision Date Section Procedure / Page / Description 9/2016 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 2016 Introduction Serial Number Legend To August 31, 2016 1 Model 4 Sequence number 2 Model year 5 Serial number (stamped on chassis) 3 Facility code 6 Serial label (located under cover) From September 1, 2016 1 Model 4 Serial number (stamped on chassis) 2 Facility code...

  • Page 5: Safety Rules

    September 2016 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 2016 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 2016 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 2016 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 September 2016 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 September 2016 Table of Contents 6-2 Kubota Gasoline / LPG Models ..............46 Choke Adjustment ..................46 Timing Adjustment ..................46 Carburetor Adjustment ..................46 RPM Adjustment ..................... 46 How to Remove the Flex Plate ............... 47 How to Install the Flex Plate ................47 Coolant Temperature and Oil Pressure Switches ..........
  • Page 11 September 2016 Table of Contents Manifolds ......................55 8-1 Function Manifold Components ..............55 8-2 Valve Adjustments - Function Manifold ............59 How to Adjust the Primary Boom Down Relief Valve........59 How to Adjust the Secondary Boom Down Relief Valve ......... 59 8-3 Jib Boom and Platform / Jib Boom Rotate Manifold Components ....
  • Page 12 Electrical Schematics - Gasoline/LPG Models ..........87 Electrical Schematic - Gasoline/LPG Kubota WG972 Models (from serial number Z3413-9461) ..............88 Ground Control Box Switch Panel Wiring Diagram - Gasoline/LPG Models ..92 Ground Control Box Terminal Strip Wiring Diagram - Gasoline/LPG Models ..93 Platform Control Box Wiring Diagram - Gasoline/LPG Models ......
  • Page 13 Table of Contents Electrical Schematics - Diesel Models ............105 Electrical Schematic - Diesel Models from Z3413-9461 (ANSI / CSA) ....106 Ground Control Box Switch Panel Wiring Diagram - Diesel Models ....110 Ground Control Box Terminal Strip Wiring Diagram - Diesel Models from serial number Z3413-9461 (ANSI / CSA) ....

  • Page 14: Specifications

    September 2016 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 15: Machine Component Weights

    Service and Repair Manual September 2016 Specifications Machine Component Weights Performance Specifications Drive speed, maximum Drive motor 27 lbs 12 kg Stowed position 3.0 mph 5.1 km/h Torque hub 113 lbs 51 kg 40 ft / 6.1 sec 12.2 m / 6.1 sec Primary boom assembly 647 lbs (including extension boom)

  • Page 16: Hydraulic Specification

    September 2016 Service and Repair Manual Specifications Hydraulic Oil Specifications Do not top off with incompatible hydraulic fluids. Hydraulic fluids Hydraulic Fluid Specifications may be incompatible due to the differences in base additive Genie specifications require hydraulic oils which are chemistry.
  • Page 17 Service and Repair Manual September 2016 Specifications Petro-Canada Environ MV 46 Chevron Rando HD Premium Oil Fluid Properties MV 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 44.4 cSt @ 104°F / 40°C...

  • Page 18: Hydraulic Component Specifications

    September 2016 Service and Repair Manual 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

    Service and Repair Manual September 2016 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 20: Kubota Wg-972 Engine Specifications

    September 2016 Service and Repair Manual 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

    Service and Repair Manual September 2016 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

    September 2016 Service and Repair Manual 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

    Service and Repair Manual September 2016 Specifications Perkins 403D-11 Engine Unit ships with 15W-40. Extreme operating temperatures may require the use of alternative engine Displacement oils. For oil requirements, refer to the Engine Operator 69 cu in Manual for your engine. 1.13 liters Fuel injection system Number of cylinders...

  • Page 24: Perkins 403F-11 Engine Specifications

    September 2016 Service and Repair Manual Specifications Perkins 403F-11 Engine Unit ships with 15W-40. Extreme operating temperatures may require the use of alternative engine Displacement oils. For oil requirements, refer to the Engine Operator 69 cu in Manual for your engine. 1.13 liters Fuel injection system Number of cylinders...

  • Page 25: Hydraulic Hose And Fitting Torque Specifications

    Service and Repair Manual September 2016 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 14 ft-lbs / 19 Nm specifications require that fittings and hose ends be torqued to specification when they are removed...

  • Page 26: Torque Procedure

    September 2016 Service and Repair Manual 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 hand tight, Replace the O-ring.
  • Page 27 Service and Repair Manual September 2016 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: Sae And Metric Fasteners Torque Charts

    September 2016 Service and Repair Manual Specifications Part No. 1274592 Z-34/22 IC...

  • Page 29: Repair Procedures

    Service and Repair Manual September 2016 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 30 September 2016 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 31: Platform Controls

    Service and Repair Manual September 2016 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 32 September 2016 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 33: Boom Function Speed Controller Adjustments

    Service and Repair Manual September 2016 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 34 September 2016 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 35: Platform Components

    Service and Repair Manual September 2016 Platform Components Remove the pin retainer fastener from the Platform Leveling Slave Cylinder rod-end pivot pin. 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 36: Platform Rotator

    September 2016 Service and Repair Manual Platform Components Support the platform rotator with a suitable Platform Rotator lifting device. Do not apply any lifting pressure. Remove the pin retaining fasteners from the How to R emove the Pl atform Rotator jib boom and leveling links to platform rotator How to Remove the Platform pivot pins.

  • Page 37: How To Bleed The Platform Rotator

    Service and Repair Manual September 2016 Platform Components How to Bleed the Platform Rotator How to Bleed the Pl atform R otator Move the function enable toggle switch to either side and hold the platform rotate toggle Note: This procedure will require two people. switch to the left position until the platform is fully rotated to the left.

  • Page 38: Platform Overload System

    September 2016 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 C alibr ate the Pl atform Overl oad System (if equipped) Note: The platform will need to be moved up and How to Calibrate the Platform down and allowed to settle between adjustments.

  • Page 39: Jib Boom Components

    Service and Repair Manual September 2016 Jib Boom Components Tag, disconnect and plug the hydraulic hoses Jib Boom from ports "T" and "P" of the jib boom manifold. Cap the fittings on the manifold. How to R emove the Jib Boom Bodily injury hazard.

  • Page 40: Jib Boom Bell Crank

    September 2016 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 Bell How to Remove the Jib Boom Lift Crank Cylinder...
  • Page 41 Service and Repair Manual September 2016 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 42: Primary Boom Components

    September 2016 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 43: How To Remove The Primary Boom

    Service and Repair Manual September 2016 Primary Boom Components How to Remove the Primary How to R emove the Primary Boom Tag and disconnect the hydraulic hoses to the Boom slave cylinder and connect them together using a connector. Plug the slave cylinder hoses from the cable track.
  • Page 44 September 2016 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 45: How To Disassemble The Primary Boom

    Service and Repair Manual September 2016 Primary Boom Components How to Disassemble the Primary How to Dis ass embl e the Primary Boom Support and slide the extension tube out of the Boom outer primary boom tube. Place the extension boom tube on blocks for support.

  • Page 46: Primary Boom Lift Cylinder

    September 2016 Service and Repair Manual Primary Boom Components Attach a lifting strap from a second overhead Primary Boom Lift Cylinder crane or other similar lifting device to the primary boom lift cylinder. The primary boom lift cylinder raises and lowers Remove the rear turntable cover.

  • Page 47: Primary Boom Extension Cylinder

    Service and Repair Manual September 2016 Primary Boom Components 13 Tag, disconnect and plug the primary boom lift Primary Boom Extension Cylinder cylinder hydraulic hoses. Cap the fittings on the cylinder. The primary boom extension cylinder extends and Bodily injury hazard. Spraying retracts the primary boom extension tube.
  • Page 48 September 2016 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 49: Platform Leveling Master Cylinder

    Service and Repair Manual September 2016 Primary Boom Components Remove the rear turntable cover. Platform Leveling Master Cylinder Raise the secondary boom until the master cylinder barrel-end pivot pin is above the The platform leveling master cylinder acts as a turntable counterweights.
  • Page 50 September 2016 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 51: Secondary Boom Components

    Service and Repair Manual September 2016 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. 1274592...

  • Page 52: Secondary Boom

    September 2016 Service and Repair Manual Secondary Boom Components Tag and disconnect each wire from the cables Secondary Boom in the platform control box. Electrocution/burn hazard. How to Dis ass embl e the Secondary Boom Contact with electrically charged How to Disassemble the circuits could result in death or serious injury.
  • Page 53 Service and Repair Manual September 2016 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 54 September 2016 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 55: Secondary Boom Lift Cylinders

    Service and Repair Manual September 2016 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 56 September 2016 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 57: Engines

    Service and Repair Manual September 2016 Engines Glow Plugs How to C heck the Glow Plugs Kubota Diesel Models How to Check the Glow Plugs Timing Adjustment Timing Adjustm ent 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 58: How To Remove The Flex Plate

    September 2016 Service and Repair Manual Engines Flex Plate How to R emove the Flex Pl ate How to Ins tall the Fl ex Plate How to Install the Flex Plate The flex plate acts as a coupler between the engine and the pump.

  • Page 59: Coolant Temperature And Oil Pressure Switches

    Service and Repair Manual September 2016 Engines Coolant Temperature and Oil Pressure Switches Kubota Gasoline / LPG Models Choke Adjustment Chok e Adjus tment The engine coolant temperature switch is a 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 60: How To Remove The Flex Plate

    September 2016 Service and Repair Manual Engines Flex Plate How to Install the Flex Plate How to R emove the Flex Pl ate How to Ins tall the Fl ex Plate Install the flex plate onto the flywheel with the The flex plate acts as a coupler between the engine raised spline away from the flywheel.

  • Page 61: Coolant Temperature And Oil Pressure Switches

    Service and Repair Manual September 2016 Engines Coolant Temperature and Oil Pressure Switches Perkins Diesel Models Timing Adjustment Timing Adjustm ent The engine coolant temperature switch is a 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 62: How To Remove The Flex Plate

    September 2016 Service and Repair Manual Engines Flex Plate How to Install the Flex Plate How to R emove the Flex Pl ate How to Ins tall the Fl ex Plate Install the flex plate onto the flywheel with the The flex plate acts as a coupler between the engine raised spline away from the flywheel.

  • Page 63: Coolant Temperature And Oil Pressure Switches

    Service and Repair Manual September 2016 Engines Coolant Temperature and Oil Pressure Switches GM .998L Models Timing Adjustment Timing Adjustm ent The engine coolant temperature switch is a 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 Workshop Manual.

  • Page 64: How To Remove The Flex Plate

    September 2016 Service and Repair Manual Engines Flex Plate How to Install the Flex Plate How to R emove the Flex Pl ate How to Ins tall the Fl ex Plate Install the flex plate onto the flywheel with the The flex plate acts as a coupler between the engine raised spline away from the flywheel.

  • Page 65: Hydraulic Pumps

    Service and Repair Manual September 2016 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 the O-ring (if equipped) on the fitting and/or hose How to Test the Auxiliary Pump end must be replaced.

  • Page 66: Function Pump

    September 2016 Service and Repair Manual Hydraulic Pumps Observe the pressure gauge while cranking Function Pump the engine. Immediately stop if the pressure reaches or exceeds 3000 psi / 206 bar. How to T est the Func tion Pum p Result: The pressure gauge reads 3000 psi / How to Test the Function Pump 206 bar, immediately stop cranking the engine.

  • Page 67: Drive Pump

    Service and Repair Manual September 2016 Hydraulic Pumps Tag,disconnect and plug the hydraulic hoses Drive Pump from the 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 68: Manifolds

    September 2016 Service and Repair Manual 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 / 34-41 207 bar Counterbalance valve, 3000 psi / Platform level down...
  • Page 69 Service and Repair Manual September 2016 Manifolds Z-34/22 IC Part No. 1274592...
  • Page 70 September 2016 Service and Repair Manual 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 Solenoid valve, 2 position 3 way Turntable rotate left 8-10 ft-lbs / 11-14 Solenoid valve, 2 position 3 way Platform level up 8-10 ft-lbs / 11-14...
  • Page 71 Service and Repair Manual September 2016 Manifolds Z-34/22 IC Part No. 1274592...

  • Page 72: Valve Adjustments - Function Manifold

    September 2016 Service and Repair Manual Manifolds 8-2 Valve Adjustments - Function How to Adjust the Secondary How to Adj ust the Sec ondary Boom D own R elief Valv e 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 73: Jib Boom And Platform / Jib Boom Rotate Manifold Components

    Service and Repair Manual September 2016 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

    September 2016 Service and Repair Manual 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

    Service and Repair Manual September 2016 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 low 10-12 ft-lbs / 14-16 3 way pressureside of drive pump and allows...

  • Page 76: Traction Manifold Components, 4Wd

    September 2016 Service and Repair Manual 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 Service and Repair Manual September 2016 Manifolds Z-34/22 IC Part No. 1274592...

  • Page 78: Valve Adjustments, 4Wd Traction Manifold

    September 2016 Service and Repair Manual Manifolds Start the engine from the platform controls. Valve Adjustments, 4WD Traction Slowly move the drive joystick to full stroke in 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 Pressure Relief Valve...

  • Page 79: Valve Coils

    Service and Repair Manual September 2016 Manifolds Valve Coil Resistance Valv e C oil Resistanc e Speci ficati on 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 80: How To Test A Coil Diode

    September 2016 Service and Repair Manual Manifolds How to Test a Coil Diode How to T est a Coil Di ode 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

    Service and Repair Manual September 2016 Fuel and Hydraulic Tanks Turn the manual fuel shutoff valve (if Fuel Tank equipped) to the closed position on the fuel tank. How to R emove the Fuel T ank Using an approved hand-operated pump, How to Remove the Fuel Tank drain the fuel tank into a suitable container.

  • Page 82: Hydraulic Tank

    September 2016 Service and Repair Manual Fuel and Hydraulic Tanks Tag, disconnect and plug the hoses from the Hydraulic Tank return filter. Cap the fittings on the return filter. 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

    Service and Repair Manual September 2016 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

    September 2016 Service and Repair Manual Axle Components How to Ins tall the H ub and Bearings 11-1 How to Install the Hub and Hub and Bearings, 2WD Models Bearings, 2WD Models How to R emove the Hub and Bearings Note: When replacing a wheel bearing, both the How to Remove the Hub and inner and outer bearings including the pressed-in...

  • Page 85: Fault Codes

    Service and Repair Manual September 2016 Fault Codes Before Troubleshooting: Section 4 Faul t 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

    September 2016 Service and Repair Manual Fault Codes How to Retrieve Engine Fault Flash Codes with Key ON (Engine not in Operation) Flash Description Status Action Codes - Perkins 403F-11 Models code Oil pressure Engine will Check harness The electronic engines can perform a switch start, but will connection...
  • Page 87 Service and Repair Manual September 2016 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: Gm Fault Code Chart

    September 2016 Service and Repair Manual Fault Codes GM Fault Code Chart DTC Set 2 DTC Set 2 Description Description SPN-2/FMI-2 SPN-2/FMI-2 DTC 11: Intake cam / distributor position error 520800 / 7 DTC 221: TPS1-2 higher than expected 653/6 DTC 16: Crank and/or cam no sync during start 636 / 8 DTC 222: TPS2 voltage low...
  • Page 89 Service and Repair Manual September 2016 Fault Codes GM Fault Code Chart DTC Set 2 DTC Set 2 Description Description SPN-2 / FMI-2 SPN-2 / FMI-2 DTC 420: Catalyst inactive on gasoline (Bank 1) 520211 / 10 DTC 1111: RPM above fuel rev limit level 515 / 16 DTC 430: Catalyst inactive on gasoline (Bank 2) 520212 / 10 DTC 1112: RPM above spark rev limit level 515 / 0...
  • Page 90 September 2016 Service and Repair Manual Fault Codes GM Fault Code Chart DTC Set 2 DTC Set 2 Description Description SPN-2 / SPN-2 / FMI-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 Service and Repair Manual September 2016 Fault Codes GM Fault Code Chart DTC Set 2 DTC Set 2 Description Description SPN-2 / FMI-2 SPN-2 / FMI-2 DTC 1634: PWM2-Gauge2 short to power 698 / 6 DTC 2126: FPP1-2 higher than expected 91 / 16 DTC 1635: PWM3-Gauge3 open / ground short 699 / 6...
  • Page 92 September 2016 Service and Repair Manual Fault Codes GM Fault Code Chart DTC Set 2 DTC Set 2 Description Description SPN-2 / FMI-2 SPN-2 / FMI-2 DTC 2618: Tach output ground short 645 / 4 DTC 8909: UEGO pump voltage shorted low 3218 / 3 DTC 2619: Tach output short to power 645 / 3...
  • Page 93 Service and Repair Manual September 2016 Fault Codes This page intentionally left blank Z-34/22 IC Part No. 1274592...

  • Page 94: Schematics

    September 2016 Service and Repair Manual Schematics About This Section Section 5 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 95: Electrical Symbol Legend

    Service and Repair Manual September 2016 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 96: Hydraulic Symbols Legend

    September 2016 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 97: Electrical Component And Wire Color Legends

    Service and Repair Manual September 2016 Electrical Component and Wire Color Legends Item Description Item Description Battery Horn or Alarm Engine Start - 12V DC Tilt/load sense alarm Connector Descent (ground) Load sense (ground) 2 speed/brake manifold/drive pump connector Joystick Power to platform, 12v cable connector Boom proportional joystick: secondary Footswitch input connector...
  • Page 98 September 2016 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) Button Hi/low rpm switch Glow plug switch Red emergency stop button Platform rotate switch...
  • Page 99 Service and Repair Manual September 2016 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 100: Electrical Schematics - Gasoline/Lpg Models

    September 2016 Service and Repair Manual Electrical Schematic - Gasoline/LPG Kubota WG972 Models (from serial number Z3413-9461)

  • Page 101: Electrical Schematic - Gasoline/Lpg Kubota Wg972 Models (From Serial Number Z3413-9461)

    Service and Repair Manual September 2016 Electrical Schematic - Gasoline/LPG Kubota WG972 Models (from serial number Z3413-9461) Z-34/22 IC Part No. 1274592...
  • Page 102 September 2016 Service and Repair Manual Electrical Schematic - Gasoline/LPG Kubota WG972 Models (from serial number Z3413-9461) Part No. 1274592 Z-34/22 IC...
  • Page 103 Service and Repair Manual September 2016 Electrical Schematic - Gasoline/LPG Kubota WG972 Models (from serial number Z3413-9461)
  • Page 104 September 2016 Service and Repair Manual Ground Control Box Switch Panel Wiring Diagram - Gasoline/LPG Kubota WG972 Models (from serial number Z3413-9461)

  • Page 105: Ground Control Box Switch Panel Wiring Diagram - Gasoline/Lpg Models

    Service and Repair Manual September 2016 Ground Control Box Switch Panel Wiring Diagram - Gasoline/LPG Kubota WG972 Models (from serial number Z3413-9461) Z-34/22 IC Part No. 1274592...

  • Page 106: Ground Control Box Terminal Strip Wiring Diagram - Gasoline/Lpg Models

    September 2016 Service and Repair Manual Ground Control Box Terminal Strip Wiring Diagram - Gasoline/LPG Kubota WG972 Models (from serial number Z3413-9461) Part No. 1274592 Z-34/22 IC...
  • Page 107 Service and Repair Manual September 2016 Ground Control Box Terminal Strip Wiring Diagram - Gasoline/LPG Kubota WG972 Models (from serial number Z3413-9461)
  • Page 108 September 2016 Service and Repair Manual Platform Control Box Wiring Diagram - Gasoline/LPG Kubota WG972 Models (from serial number Z3413-9461)

  • Page 109: Platform Control Box Wiring Diagram - Gasoline/Lpg Models

    Service and Repair Manual September 2016 Platform Control Box Wiring Diagram - Gasoline/LPG Kubota WG972 Models (from serial number Z3413-9461) Z-34/22 IC Part No. 1274592...
  • Page 110 September 2016 Service and Repair Manual Electrical Schematic - Gasoline/LPG GM .998L Models (from serial number Z3416F-10967)

  • Page 111: Electrical Schematic - Gasoline/Lpg Kubota Wg972 Models (From Serial Number Z3413-9461)

    Service and Repair Manual September 2016 Electrical Schematic - Gasoline/LPG GM .998L Models (from serial number Z3416F-10967) Z-34/22 IC Part No. 1274592...
  • Page 112 September 2016 Service and Repair Manual Electrical Schematic - Gasoline/LPG GM .998L Models (from serial number Z3416F-10967) Part No. 1274592 Z-34/22 IC...
  • Page 113 Service and Repair Manual September 2016 Electrical Schematic - Gasoline/LPG GM .998L Models (from serial number Z3416F-10967)
  • Page 114 September 2016 Service and Repair Manual Ground Control Box Switch Panel Wiring Diagram - Gasoline/LPG GM .998L Models (from serial number Z3416F-10967)

  • Page 115: Ground Control Box Switch Panel Wiring Diagram - Gasoline/Lpg Gm .998L Models

    Service and Repair Manual September 2016 Ground Control Box Switch Panel Wiring Diagram - Gasoline/LPG GM .998L Models (from serial number Z3416F-10967) Z-34/22 IC Part No. 1274592...
  • Page 116 September 2016 Service and Repair Manual Platform Control Box Wiring Diagram - Gasoline/LPG GM .998L Models (from serial number Z3416F-10967)

  • Page 117: Platform Control Box Wiring Diagram - Gasoline/Lpg Models

    Service and Repair Manual September 2016 Platform Control Box Wiring Diagram - Gasoline/LPG GM .998L Models (from serial number Z3416F-10967) Z-34/22 IC Part No. 1274592...

  • Page 118: Electrical Schematics - Diesel Models

    September 2016 Service and Repair Manual Electrical Schematic - Diesel Models from serial number Z3413-9461 (ANSI / CSA)

  • Page 119: Electrical Schematic - Diesel Models From Z3413-9461 (Ansi / Csa)

    Service and Repair Manual September 2016 Electrical Schematic - Diesel Models (ANSI / CSA) (from serial number Z3413-9461) Z-34/22 IC Part No. 1274592...
  • Page 120 September 2016 Service and Repair Manual Electrical Schematic - Diesel Models ANSI / CSA (from serial number Z3413-9461) Part No. 1274592 Z-34/22 IC...
  • Page 121 Service and Repair Manual September 2016 Electrical Schematic - Diesel Models from serial number Z3413-9461 (ANSI / CSA)
  • Page 122 September 2016 Service and Repair Manual Ground Control Box Switch Panel Wiring Diagram - Diesel Models from serial Z3413-9461 (ANSI / CSA)

  • Page 123: Ground Control Box Switch Panel Wiring Diagram - Diesel Models

    Service and Repair Manual September 2016 Ground Control Box Switch Panel Wiring Diagram - Diesel Models (ANSI / CSA) Z-34/22 IC Part No. 1274592...

  • Page 124: Ground Control Box Terminal Strip Wiring Diagram

    September 2016 Service and Repair Manual Ground Control Box Terminal Strip Wiring Diagram - Diesel Models (ANSI / CSA) (from serial number Z3413-9461) Part No. 1274592 Z-34/22 IC...
  • Page 125 Service and Repair Manual September 2016 Ground Control Box Terminal Strip Wiring Diagram - Diesel Models (ANSI / CSA)
  • Page 126 September 2016 Service and Repair Manual Platform Control Box Wiring Diagram - Diesel Models from serial number Z3413-9461 (ANSI / CSA)

  • Page 127: Platform Control Box Wiring Diagram

    Service and Repair Manual September 2016 Platform Control Box Wiring Diagram - Diesel Models (ANSI / CSA) (from serial number Z3413-9461) Z-34/22 IC Part No. 1274592...
  • Page 128 September 2016 Service and Repair Manual Electrical Schematic -Diesel Models from serial number Z3413-9461 (CE / AS)

  • Page 129: Electrical Schematic - Diesel Models From Z3413-9461 (Ce / As)

    Service and Repair Manual September 2016 Electrical Schematic - Diesel Models (CE / AS) (from serial number Z3413-9461) Z-34/22 IC Part No. 1274592...
  • Page 130 September 2016 Service and Repair Manual Electrical Schematic - Diesel Models CE / AS (from serial number Z3413-9461) Part No. 1274592 Z-34/22 IC...
  • Page 131 Service and Repair Manual September 2016 Electrical Schematic - Diesel Models from serial number Z3413-9461 (CE / AS)
  • Page 132 September 2016 Service and Repair Manual Ground Control Box Switch Panel Wiring Diagram - Diesel Models from serial Z3413-9461 (CE / AS)

  • Page 133: Ground Control Box Switch Panel Wiring Diagram - Diesel Models

    Service and Repair Manual September 2016 Ground Control Box Switch Panel Wiring Diagram - Diesel Models (CE / AS) Z-34/22 IC Part No. 1274592...

  • Page 134: Ground Control Box Terminal Strip Wiring Diagram

    September 2016 Service and Repair Manual Ground Control Box Terminal Strip Wiring Diagram - Diesel Models (CE / AS) (from serial number Z3413-9461) Part No. 1274592 Z-34/22 IC...
  • Page 135 Service and Repair Manual September 2016 Ground Control Box Terminal Strip Wiring Diagram - Diesel Models (CE / AS)
  • Page 136 September 2016 Service and Repair Manual Platform Control Box Wiring Diagram - Diesel Models from serial number Z3413-9461 (CE / AS)

  • Page 137: Platform Control Box Wiring Diagram - Diesel Models From Serial Number

    Service and Repair Manual September 2016 Platform Control Box Wiring Diagram - Diesel Models (CE / AS) (from serial number Z3413-9461) Z-34/22 IC Part No. 1274592...

  • Page 138: Electrical Schematics - Options

    September 2016 Service and Repair Manual GM .998 Engine Schematic...

  • Page 139: Gm .998L Engine Schematic

    Service and Repair Manual September 2016 GM .998 Engine Schematic Z-34/22 IC Part No. 1274592...

  • Page 140: Gm Engine Harness Diagram

    September 2016 Service and Repair Manual GM Engine Harness Diagram Part No. 1274592 Z-34/22 IC...
  • Page 141 Service and Repair Manual September 2016 GM Engine Harness Diagram...
  • Page 142 September 2016 Service and Repair Manual Kubota D1105 Engine Schematic...

  • Page 143: Kubota D1105 Engine Schematic

    Service and Repair Manual September 2016 Kubota D1105 Engine Schematic Z-34/22 IC Part No. 1274592...

  • Page 144: Perkins 403F-11 Engine Schematic

    September 2016 Service and Repair Manual Perkins 403F-11 Engine Schematic Part No. 1274592 Z-34/22 IC...
  • Page 145 Service and Repair Manual September 2016 Perkins 403F-11 Engine Schematic...
  • Page 146 September 2016 Service and Repair Manual Manifold and Limit Switch Wiring Diagram...

  • Page 147: Manifold And Limit Switch Wiring Diagram

    Service and Repair Manual September 2016 Manifold and Limit Switch Wiring Diagram...

  • Page 148: Hydraulic Schematics

    September 2016 Service and Repair Manual Hydraulic Schematic, 2WD Models...

  • Page 149: Hydraulic Schematic, 2Wd Models

    Service and Repair Manual September 2016 Hydraulic Schematic, 2WD Models Z-34/22 IC Part No. 1274592...
  • Page 150 September 2016 Service and Repair Manual Hydraulic Schematic, 2WD Models Part No. 1274592 Z-34/22 IC...
  • Page 151 Service and Repair Manual September 2016 Hydraulic Schematic, 2WD Models...
  • Page 152 September 2016 Service and Repair Manual Hydraulic Schematic, 4WD Models...

  • Page 153: Hydraulic Schematic, 4Wd Models

    Service and Repair Manual September 2016 Hydraulic Schematic, 4WD Models Z-34/22 IC Part No. 1274592...
  • Page 154 September 2016 Service and Repair Manual Hydraulic Schematic, 4WD Models Part No. 1274592 Z-34/22 IC...
  • Page 155 Service and Repair Manual September 2016 Hydraulic Schematic, 4WD Models Z-34/22 IC Part No. 1274592 Servic e and R epair M anual September 2016...

This manual is also suitable for:

Genie z-34/22 icZ3415-10688Z3416f-10689Z3416f-11999Z34f-12000

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