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1. C52 154 1 UP DOWN TERMINAL BASE TB CIRCUIT DESC cs WIRES FROM TO DESCRIPTION OPTION 2 184 C134PWR KEYSWITCH POWER LS3 RD MH 7 184 RD H6 RD KSI C134PWR KEYSWITCH POWER x 1 cn 3 SONETON DRIVE ENABLE 8 2 BR OPTION 1 52 GND GROUND GR SP IB Up BR OPT 2S _ 52 BR GND STUD GROUND OR C40LS C522 C2B 2 OFF LIMIT SPEED GRIWH 4912 GRWHC2B 7 45 C45GEN GENERATOR OPTION 4 E caa X OPTION 2 6 _ 44 5 C44JD JIB DOWN BL BK C378CW LsspRIMARYBOOM e SUBD CB 39 BL C36SCC MH 10 STEER LEFT UP DOWN ee BUWHCIBHZ Cus WHIBK C31REV C53 1 5 DRIVE REVERSE BK RD CR3 30_ BK RDC1B 9 95 5 BK RD SP C35RPM HIGH RPM DU D a 2 C10 BK WH CR8 86_ BK WHC
2. CHARGE PRESSURE 1 50 psi a B E B D 7 2 rue Li GEN E ed A 4 Ko as 5 ra D 0 5 gpm i OER AD 220 psi AI 51 4 Pi T3 9 5 CHARGE PRESSURE ees Gee Ss Up T2 r a Ti pese 1 1 6 170 psi a M4 J 3 77 Essi REAR L m ALM 7 7 0 025 inch HII M3 _ ui _ _ ooro int EN J 8 ae wa Hor M STEERING TRACTION n L eee ES342WL A TEREX COMPANY 5 30 Z 34 221C Part No 128300 REV
3. i i 151 i PRIMARY BOOM JIB CABLE TO PLATFORM BOX E AM LIMIT SWITCH 8 M 1 E SHOWN WITH BOOM EXTENDED 5 BL JIB UP a 1 E 1 9 1 a ROTATE RIGHT PIN WIRES CKT 13 QU ma 2 8 c 1 OR C17PRL E 9 7 WH JIB 2 22 PIN WIRES 8 5 2 9 5 u OR JIB 7 JIB DOWN ald 218 2 8 PLATFORM 2 BL C18PRR CABLE 7 i BK 2a alg lt ROTATE LEFT Bu 8 8 a kg 28 5 132 IET ai Biz 5 PRIMARY BOOM 5 2 lt a UP DOWN 56 58 9 4 C44JD LIMIT SWITCH 8 23 8 55 5 au S 2 9 5 3 5 8E gt 23 8 a
4. August 2007 Section 5 Schematics 2 2 2 7 Hydraulic Schematic 2WD Models F E D C B A SLAVE CYLINDER SECONDARY BOOM PRIMARY BOOM PRIMARY BOOM JIB BOOM CYLINDER CYLINDER EXTENSION CYLINDER CYLINDER 2 1 0 032 inch i I ES 1 TURNTABLE ROTATE F1 PLATFORM ROTATE 3000 psi FE 4 451 Lj 5 9 CU INJREV it 0 090 inch 0025 1 1 1 r 4 CYLINDER COE RM 3 DD ES E MIE HIN E o OI HD o XP Ee enn x Jee x x psi r TEN Ed 2 4 4 151 Ox TUN aoe cc 1
5. NOTES 0 052 inch orifice before serial number 5745 0 036 inch orifice after serial number 5744 PRIMARY BOOM PRIMARY BOOM JIB BOOM CYLINDER EXTENSION CYLINDER CYLINDER 0 032 inch des LJ z 0 090 inch possum S e E EEE eE Ee i 1 i 1 i E 1 udo umo 3 PE EON EAS ba Q EX Eins iere Lo er 1 2 3 1 3200 3000 psi 2500 psi 3 1 1 5 1 3 1 C5 c7 4 4 4 1600 J1 J2 PR1 PR2 6 R 5 T U m p 1 T I Wilh X 1 CH i AU 2 0 028 inch lt gt CG 039pm sil 7 0 035 inch Genie TEREX COMPANY Part No 128300 Z 34 22 IC 5 35 August 2007 Section 5 Schematics SSS SSS SSS Hydraulic Schematic 4WD Models 36 Genie Scandinavia Phone 46 31 575100 Fax 46 31 579020 Genie France Phone 33 0 2 37 26 09 99 Fax 33 0 2 37 26 09 98 Genie Iberica Phone 34 93 579
6. C7P 3 GNDBAT BR C7B 3 chouio C3P 12 C12FTS C3B 12 C12FTS BLWH u V 1 C13DEL BURD C4B 1 BURD 4 WHS amp 8 BR 5 C82 8 DRIVE ENABLE ol 1 5 4 4 160 OR RD 4 4 8 1 0 5 5 M 5 LIMIT SWITCH a 2 1 C12FTS gt y 8 4 C30FWD WH C1B 4 5 2 C30FWD WH E gt 4 WH BK CP 083 5 g 1 6 C32BRK WH RD C1B 6 05 4 C32BRK WH RD SHAKE RELEASE 5 gt bes sles sss r r gt WH RD TRAVEL ALARM 1 9 1 1 10 C36SCC BL 1 10 BL 36 MH rl cda 1 11 C37SCW C1B 11 BL BK 37 MH i STEER RIGHT 3 9 E coe 1 5 C29MS RD WH C29MS RD WH C1B 3 C5 1 il motor sTROKE 8 ak C12FTS BK C10 1 BK 7 ES 2 5 EXTEND RETRACT C10 2 WH 7 Ce LIMIT SWITCH C11 4 WH 6 152 aye PRIMARY BOOM 5 Een UP DOWN
7. 0 0 a function speed controller b drive joystick Genie REV A 3 Locate and disconnect the wire connected to terminal A on the drive joystick circuit board 4 Seta multimeter to read DC current Note The multimeter when set to read DC current should be capable of reading up to 1200 mA 5 Connect the black lead from the multimeter to the wire that was just disconnected Connect the red lead of the multimeter to terminal A on the joystick D UJ gt d gt _ 1 low range potentiometer terminal R activates low range terminal B drive reverse terminal X brake release terminal ground terminal positive terminal A drive forward threshold potentiometer high range potentiometer 6 keyswitch to platform controls and pull out the red Emergency Stop button out to the on position at both the ground and platform controls Do not start the engine 4 2 Z 34 22 IC Part No 128300 August 2007 Section 4 Repair Procedures REVA Set the threshold Note The drive joystick adjustments are not final adjustments Final adjustments will need to be made to meet drive speed specifications Refer to Section 2 Specifications 7 Press down the foot switch Move the drive joystick off center in either directio
8. lt LABEL DESCRIPTION TILT ALARM 48 PLATFORM OVERLOAD LED CE OPTION 318 PLATFORM OVERLOAD CE OPTION P2 EMERGENCY STOP BUTTON TS2 ENGINE START TOGGLE SWITCH 7547 GENERATOR TOGGLE SWITCH OPTION 7548 DRIVE LIGHT TOGGLE SWITCH OPTION PLATFORM 1949 WORK LIGHT TOGGLE SWITCH OPTION OVERLOAD CE OPTION JIB d E WORK 5 LIGHT a 5 zz xx 0 5 E 8 C GRAY BLACK BROWN S 0 C133PLA OR RD 2 4 6 t h C n tc 1 GENERATOR lt 515 TS12 TS10 547 O OUO i O R L O OOO ODO TS2 TS6 TS7 TS11 TS8 OUO OUO R L ODO ODO TS14 lt gt TS9 TS13 gt L1 L48 OUO ORO A B D A O WY ODO OEO PLATFORM OVERLOAD ul 9 2 z H 3 x 2 y o ss 1 1 lt ES 29 O O O 5 NO NC NC NC 104 9 P3 P2 a ES34DV ES34GPW a 2 34 221 G 5 25 Part No 128300 August 2007 Section 5 Schematics p M i Platform Control Box Wiring Diagram Options 26 August 2007 Section 6 Schematics Manifold and Limit Switch Wiring Diagram M L K J H G D C B A
9. 3 24 B 13 Test the Fuel Select Operation Gasoline LPG Models 3 25 B 14 Test the Drive Brakes 3 26 B 15 Test the Drive Speed Stowed Position 3 27 B 16 Test the Drive Speed Raised or Extended Position 3 28 B 17 Inspect the Fuel and Hydraulic Tank Cap Venting Systems 3 29 B 18 Perform Hydraulic Oil 3 30 B 19 Test the Alarm Package if 3 30 B 20 Replace the Diesel Fuel Filter Water Separator Element Diesel 5 3 31 B 21 Perform Engine Maintenance Kubota D905 Models 3 33 Checklist Procedures C 1 Grease the Platform Overload Mechanism if equipped 3 34 C 2 Test the Platform Overload System if equipped 3 34 C 3 Clean the Fuel Tank Diesel Models 3 37 C 4 Perform Engine Maintenance Diesel Models 3 38 C 5 Perform Engine Maintenance Kubota D905 Models 3 38 A Checklist D Procedures D 1 Check the Primary Boom Wear 3 39 D 2 Check the Free w
10. RN Hydraulic Schematic 4WD Models A B C D E F G H 5 me xx aa DRIVE MANIFOLD 1 ee OO gt BL 5 SLEW RING i i T T 4 4 4 _ 3 50 50 BC ae L1 1 1 Pem ______ 0 039 inch 0 039 inch TERN fe S as e BR BS 2 079 inch T i FUNCTION 8 7 gpm 22 mM 7 4 m B SEE FO tsp eus 3625 psi ____ 3625 psi BR Y Y s 5096 50 I d ge gt e 2 BN M
11. 4 56 Section5 Rev Schematics E 5 1 A Electrical Symbols Legend issia pa eu 5 2 A Hydraulic Symbols 5 3 A Electrical Schematic Gasoline LPG Models 5 6 A Ground Control Box Switch Panel Wiring Diagram Gasoline LPG Models 5 10 A Ground Control Box Terminal Strip Wiring Diagram Gasoline LPG Models 5 11 A Platform Control Box Wiring Diagram Gasoline LPG Models 5 14 Xil 2 34 22 IC Part No 128300 August 2007 TABLE OF CONTENTS Section5 Rev Schematics continued A Electrical Schematic Diesel 5 16 A Ground Control Box Switch Panel Wiring Diagram Diesel Models 5 20 A Ground Control Box Terminal Strip Wiring Diagram Diesel Models 5 21 A Platform Control Box Wiring Diagram Diesel Models 5 24 A Platform Control Box Wiring Diagram Options 5 25 A Manifold and Limit Switch Wiring 5 27 A Hydraulic Schematic 2WD 5 30 A Hydraulic Schematic 4WD 5 34 Part 128300 Z 34 22 IC xill August 2007 a This page intentionally left blank xvi Z 34 22 IC Part No 128300 2011 Section 2 Specification
12. MANIFOLDS 10 5 2WD Traction Manifold Components The 2WD traction is mounted inside the drive chassis at the non steer end Index Schematic No Description Item Function Torque 1 Shuttle valve 3 position 3 way Bus Charge pressure circuit that gets hot oil out of low pressure side of drive pump and allows low pressure flow path for brake release and 2 speed motor shift 10 12 ft lbs 14 16 Nm 2 Relief valve 210 psi 14 5 bar Bassus Charge pressure circuit 35 40 ft lbs 47 54 Nm 3 Diagnostic 0 0 Testing Flow divider combiner valve Quin Controls flow to drive motors in forward and reverse 130 140 ft Ibs 176 190 Nm 5 Orifice 0 070 inch 1 78 mm Equalizes pressure on both sides divider combiner valve C 0 Genie TEREX COMPANY Part No 128300 Z 34 22 IC 4 47 Section 4 Repair Procedures August 2007 SSS MANIFOLDS REV 10 6 4WD Traction Manifold Components The 4WD traction manifold is mounted inside the drive chassis at the non steer end Index Schematic No Description Item Function Torque 1 Solenoid valve 2 position 3 way Brake iibi enti dete 20 ft lbs 27 1 Nm Check valve BL Drive motor anti cavitation 20 ft lbs 27 1 Nm Shuttle valve 3 position
13. 25 30 ft lbs 34 41 Nm 5 Relief valve 1600 psi 110 bar Jae Secondary boom down 25 30 ft lbs 34 41 Nm 6 Relief valve 1600 psi 110 bar Kiani Primary boom down 25 30 ft lbs 34 41 Nm 7 Proportional solenoid valve Diss System flow regulating circuit 35 40 ft lbs 47 54 Nm 8 Solenoid valve 3 position 4 way Steer 10 12 ft Ibs 14 16 Nm 9 Flow regulator valve 0 1 gpm 0 38 L MIN M uc Differential sensing circuit 35 40 ft lbs 47 54 Nm 10 Differential sensing valve All 35 40 ft lbs 47 54 Nm 11 Diagnostic fitting 2 2 Testing 12 Priority flow regulator valve 1 3 8 L MIN 34 40 ft lbs 47 54 Nm 13 Relief valve 3200 psi 221 System relief 25 30 ft lbs 34 41 Nm 14 Solenoid valve 2 position 3 way Primary boom retract 8 10 ft lbs 11 14 Nm 15 Solenoid valve 2 position way Buses Primary boom 8 10 ft lbs 11 14 Nm This list continues Please turn the page TEREX COMPANY 4 40 Z 34 22 IC Part No 128300 Section 4 Repair Pro
14. E cete EERTE taa Core EG Let ri a t La acere Nee ote neo n vd ded eser St erate ak 13 14 C52 PART OF ENGINE HARNESS WH 8 21 22 BK 8 ES34DV y T 1 1 PIN WIRES i WH RD C32BRK i CABLE 8 i BRN GND ENGINE BLOCK 1 7 1 I NOTE WHIBK C31REV ALL LIMIT SWITCHES SHOWN WITH THE MACHINE 2 WH i IN THE STOWED POSITION EXCEPT AS NOTED 1 1 H H snake RELEASE BRN GND C5 2 SPEED BRAKE PIN amp WIRES CIRCUIT DRIVE PUMP 1 RD WH C29MS i m HIGH LOW DRIVE REAR VIEW WH C30FWD 2 WH C30FWD T BRN GND 8 RD WH 29 5 C31REV LL 4 WHRD 2 BRN GND i 1 Mr 1 1 enie A TEREX COMPANY Part No 128300 Z 34 221C 5 27 August 2007 Section 5 Schematics p s Manifold and Limit Switch Wiring Diagram 28 Section 5 Schematics August 2007 e Hydraulic Schematic 2WD Models Section 5 Schematics August 2007 Hydraulic Schematic 2WD Models REV A A B C D E F G H K
15. B 4 34 8 4 Coolant Temperature and Pressure Switches 4 35 Hydraulic Pumps 9 1 Auxiliary PUlTID rese E 4 36 9 2 Function Pump 2 4 37 9 3 Dwe PUMP E EE 4 38 Manifolds 10 1 Function Manifold Components 4 40 10 2 Valve Adjustments Function 4 44 10 3 Jib Boom Platform Rotate Manifold 4 45 10 4 Brake 2 Manifold Components 2WD 4 46 10 5 2WD Traction Manifold 4 47 10 6 4WD Traction Manifold Components 4 48 10 7 Valve Adjustments Traction 4 50 10 8 Valve pedes hatin 4 51 Part No 128300 Z 34 22 IC Xi August 2007 TABLE OF CONTENTS Section4 Rev Repair Procedures continued Fuel and Hydraulic Tanks 11 1 Fuel ect tee sempe abun e ce tun Pee era 4 53 1152 Hydraulic Tank m 4 54 Turntable Rotation Components 12 1 Rotation Hydraulic de 4 55 Axle Components 13 1 Hub and Bearings 2WD
16. C2PBD RD BK C3P 2 RD 1 OR 4 2 Ts9 TS13 1 BDE Ou amp Va i i 2 oot E C15PLD OR BK C4P 3 C8PBR BK WH C3P 8 i i C7PBE BK C3P 7 i C13DEL C4P 1 4015 OR C2P 2 RD C31REV WH BK 5 i m C32BRK WH RD 6 OR RD i 1 RD TS1 BE IE C30FWD WH 4 1 C36SCC 10 c C37SCW BUBK 11 NC NC NC P24BAT WH 9 2 i Q Q RD P2 i m i P23BAT WH 7 2 WH MES ese ees Sees Se ae goes SR He AS a 1 26 9 1 P22BAT 7 1 C9HRN BK RD C3P 9 C27AUX RD 1 1 C18PRR GR BK 47 2 C17PRL GR 47 1 C44JD GR BK C47 4 C43JU GR 47 3 Platform Control Box Wiring Diagram Diesel Models Section 5 Schematics 5 24 Section 5 Schematics August 2007 Platform Control Box Wiring Diagram Options REVA C
17. Ground Control Box Switch Panel Wiring Diagram Gasoline LPG Models VOLTAGE OIL PRESSURE WATER TEMPERATURE GAUGE GAUGE GAUGE WH 21A WHIRD C49 4 GAUGE 2 OPTION al PS BR GND WH BK C49 3 BK 22A RD 134A WH RD 32A P1 BD 7951 NC ON RD 27A 3 LABEL DESCRIPTION NC 1 gt WH 23A KEY SWITCH RD TS51 AUXILIARY SWITCH TS52 ENGINE START TOGGLE SWITCH BR RD C50 1 12GA TS53 FUEL SELECT TOGGLE SWITCH m Ium RD CR1 12GA TS54 FUNCTION ENABLE ENGINE RPM TOGGLE SWITCH E TS56 ENGINE CHOKE TOGGLE SWITCH 4 7557 PLATFORM ROTATE TOGGLE SWITCH T OR BK 15A TS58 JIB BOOM UP DOWN TOGGLE SWITCH TS63 TS59 WH RD 6A TS59 PLATFORM LEVEL TOGGLE SWITCH TS60 SECONDARY BOOM UP DOWN TOGGLE SWITCH R E TS61 PRIMARY BOOM UP DOWN TOGGLE SWITCH Ou TS62 TURNTABLE ROTATE TOGGLE SWITCH A 5 TS63 PRIMARY BOOM EXTEND RETRACT TOGGLE SWITCH TS58 TS61 TS57 5 CB1 CIRCUIT BREAKER ENGINE 15A D 9 GR BK C4B 6 CB2 CIRCUIT BREAKER
18. 52 1 BK 8 Serr 154 C2P 2 C40LS OR C2B 2 C522 amp 9 SECONCARVBOOM J UP DOWN tO Ow WH RD C3P 6 WH RD C3B 6 C6MFV WH RD 4 FLOW CONTROL A BRN 4 E RD BK RD lt JIB BOOM UP gt 9 2 JIB BOOM DOWN foro C47 8 GND BR UP C2P 5 C43JU GR C2B 5 9 C2P 6 C44JD GR BK C2B 6 Y PLATFORM LEVEL DOWN m E 42 CUT OUT OPTION a C474 WH 4 6 38 c47 3 C43JU BK l 5 z 1 2 RIGHT 9 4 ROTATE RIGHT s mE lA g z 5 5 0 do EL ROTATE LEFT x C47 2 18PRR BL ii F4 5 89 mer 6 6 C18PRR GR BK 4 6 9 5 C17PRL GR 5 UP 4 PLATFORM 4 4 LEVEL UP o 4 OR BK ni PLATFORM 5 gt DOWN LEVEL DOWN a F elo gt 84 uP 4 2 C14PLU OR 1 he 4 C15PLD OR BK C4B 3 KS EXTEND F BK iA 4 PRIMARY BOOM 4 BKWH lA 4 PRIMARY BOOM o 29 3 RETRACT na 7 C3B 7 8 C8PBR BK WH C3B 8 UP RD eil 4 PRIMARY BOOM uP 4 RD BK Ui 4 PRIMARY BOOM zo DOWN g DOWN gt BE g 28 EE 1 C1PBU RD C3B 1 a 1 2 C2PBD RD BK C3B 2 S BE e 1 m E UP ie SEC
19. 88 OR BK MH OR MH 8 EM OR 6 H6 CONTROL BOX GROUND La OR BKC4B 8 15 10 OR BK SP PLATFORM LEVEL DOWN cho ssa C4B 2 14 OR CR9 OR SP PLATFORM LEVEL UP PTT RD 134B ES34DV enie A TEREX COMPANY Part No 128300 Z 34 221C 5 21 August 2007 Section 5 Schematics Ground Control Box Terminal Strip Wiring Diesel Models Section 5 Schematics August 2007 e M i Platform Control Box Wiring Diagram Diesel Models ES34DV August 2007 C Part No 128300 A TEREX COMPANY Z 34 221C G SPARE WIRES RD WH 3 LABEL DESCRIPTION P2 EMERGENCY STOP BUTTON HORN BUTTON DP1 DRIVE CONTROLLER BP1
20. VOLT METER GAUGE CHOKE WH C49 4 C26TSR WH RD WATER TEMPERATURE GAUGE 064 IGNITION START MODULE WH C49 3 C25PSR WH BK OIL PRESSURE GAUGE TS56 Ir C1P 7 C33STR C1B 7 TS6 WH EH P25BAT RD P24BAT WH C9P 3 C9P 2 RD FS WH FS T FS1 9 1 BK August 2007 P26BAT BK 21 START WATER TEMPERATURE SWITCH 1 START RELAY 2 TACHOMETER 3 START INPUT 4 AUX ON 5 GROUND 6 BATTERY 7 KEY PWR 8 IGNJFUEL ON 10 ENG FAULT WTS1 ENGINE START 1 KEV BYPASS TS52 49 2 245 WH OIL PRESSURE SWITCH D OPS1 BRN TB33 WH HOUR METER TB21 49 7 R34SA BK WH CHOKE SOLENOID C21IGN WH CR1 RD C49 6 R33STR BK 49 5 STARTER MOTOR RD WH OR BK RD WH AUXILIARY qs IGNITION SYSTEM 21 AUXILIARY PUMP PUMP gt 4 M C27AUX RD C1B 1 27 DISTRIBUTOR Dee COIL RD 2 L4 C49 1 C27AUX RD n AUXILIARY POWER RELAY AUXILIARY PUMP 7 C134PWR GR WH 4 7 TILT A
21. 0 5 Checkthe Turnable Rotation Bearing Kubota DF752 Operator s Manual Bolts Genie part number 84250 Perkins models Perkins 403C 11 User s Handbook 5 Inspect the Tires Wheels and Genie part number 97360 Lug Nut Torque B 8 Perform Engine Maintenance Perkins 403C 11 Models D 4 Replace the Hydraulic Filters 0 5 Check the Turnable Rotation Bearing Bolts Genie Part No 128300 Z 34 22 IC 3 9 Section 3 Scheduled Maintenance Procedures August 2007 CHECKLIST A PROCEDURES A 6 Inspect the Engine Air Filter Note Genie specifications require that this procedure be performed every 40 hours or weekly whichever comes first Maintaining the engine air filter in good condition is essential to good engine performance and service life Failure to perform this procedure can lead to poor engine performance and component damage 1 Kubota D905 models Pull up on the engine pivot plate lock pin located under the pump Swing the engine pivot plate out and away from the machine for access 2 Kubota D905 models Remove the wingnut securing the end cap to the air cleaner canister Remove the end cap All other models Disconnect the retaining clamps securing the end cap to the air cleaner canister Remove the end cap 3 Remove the air filter element 4 Clean the inside of the air filter canister and the canister gasket with a damp cloth 5 Inspect for and remove any blockage or debris from the intake air passages
22. 52 Attach a liftiing strap from an overhead crane to the lower secondary boom 53 Remove the pin retaining fasteners from the lower secondary boom to turntable pivot pin Use a soft metal drift to remove the pin 54 Remove the lower secondary boom from the machine AWARNING Crushing hazard The lower secondary boom could become unbalanced and fall when removed from the machine if not properly supported by the overhead crane Part No 128300 August 2007 Section 4 Repair Procedures REVA 5 2 Secondary Boom Lift Cylinder The secondary boom lift cylinder raises and lowers the secondary boom The secondary boom lift cylinder is equipped with counterbalance valves to prevent movement in the event of a hydraulic line failure How to Remove the Secondary Boom Lift Cylinder AWARNING 0 injury hazard This procedure requires specific repair skills lifting equipment and a suitable workshop Attempting this procedure without these skills and tools could result in death or serious injury and significant component damage Dealer service is strongly recommended Note When removing a hose assembly or fitting the O ring on the fitting and or hose end must be replaced and then torqued to specification during installation Refer to Section 2 Hydraulic Hose and Fitting Torque Specifications 1 Rotate the turntable to the side until the boom is centered between the steer and non steer tires 2 Raise the p
23. 6 Inspect the air filter element If needed blow from the inside out using low pressure dry compressed air or carefully tap out dust A TEREX Z 34 22 IC REV A 7 Securely install the filter element into the canister 8 Install the gasket and baffle if equipped and end cap onto the air cleaner canister Note Be sure the dust discharge valve is facing down when installed 9 Secure the end cap to the air cleaner cannister with the retaining clamps 10 Kubota D905 models Swing the engine pivot plate back to its original position and make sure the engine pivot plate lock pin locks into place Part No 128300 August 2007 Section 3 Scheduled Maintenance Procedures REVA CHECKLIST A PROCEDURES A 7 A 8 Perform Engine Maintenance Kubota Models Note Engine specifications require that this one time procedure be performed after the first 50 hours of operation Required maintenance procedures and additional engine information is available in the Kubota D905 Operator s Manual Kubota part number 16622 8916 5 OR the Kubota DF752 Operator s Manual Kubota part number EG601 8916 1 Kubota D905 Operator s Manual Perform Engine Maintenance Kubota Models Note Engine specifications require that this procedure be performed every 50 hours or weekly whichever comes first Required maintenance procedures and additional engine information is available in the Kubota D905 Operator s Manual
24. Indicates an imminently hazardous situation which if not avoided will result in death or serious injury Indicates a potentially hazardous AWARNING situation which if not avoided could result in death or serious injury Indicates a potentially hazardous ACAUTION situation which if not avoided may cause minor or moderate injury Indicates a potentially hazardous situation which if not avoided may result in property damage Indicates that a specific result is expected after performing a series of steps W Indicates that an incorrect result has occurred after performing a series of steps removed Wheels chocked All exernal AC power disconnected from the machine Part No 128300 Z 34 22 IC 4 1 Section 4 Repair Procedures August 2007 Platform Controls 1 1 Drive Joystick How to Adjust the Drive Joystick Note Perform this procedure with the engine off 1 Remove the fasteners from the platform control box lid 2 Open the control box lid and locate the drive joystick AWARNING Electrocution hazard Contact with electrically charged circuits could result in death or serious injury Remove all rings watches and other jewelry J EE B m
25. cep BLACK BROWN BR GND C7 3 BR GND C47 8 m c gt 9 C28TTA RD BK C1P 2 c gt o 5 C134PWR GRH 7 amp 5 5 C12FTS BL WH 12 5 C16DE OR RD 4 o gt 5 WH BK 5 c V CATRL C3P 4 C11SBD BL BK C3P 11 C10SBU BL C3P 10 C6MFV WH RD C3P 6 C38FL BL WH 12 i C39LP BL RD C2P 1 TS4 lt gt 1512 990 C35RPM BK RD 9 4 5 P25BAT C9 3 1 i C34SA 1 8 TS2 TS6 E C33STR C1P 7 1 TS7 6 7511 TS8 U C17PRL GR 5 RAL 20 D Qo C43JU GR C2P 5 2 1 TS14 5 C29MS RD WH 1 3 C44JD GR BK C2P 6 i C2PBD RD BK C3P 2 C1PBU RD C3P 1 C14PLU OR C4P 2 TS9 513 7 SO 24 C D p CA 457 5 C15PLD OR BK C4P 3 C8PBR BK WH C3P 8 7 7 C13DEL BL RD 1 4015 2 2 1 RD C31REV WH BK 5 m C32BRK WH RD C1P 6 OR RD i RD C30FWD WH 1 4 DP1 5 gt C36SCC 1 10 C37SCW 1 11 NG P24BAT WH 9 2 ms RD P2 a c 1
26. 4 Install the new filter and tighten it securely by hand Clean up any oil that may have spilled Part No 128300 Genie 2 34 22 IC CHECKLIST D PROCEDURES Medium pressure filter Burn hazard Beware of hot oil ACAUTION Contact with hot oil may cause severe burns Note The medium pressure filter is mounted in the engine compartment 5 Place a suitable container under the medium pressure filter 6 Remove the filter housing by using a wrench on the nut provided on the bottom of the housing 7 Remove the filter element from the housing 8 Inspect the housing seal and replace it if necessary 9 Install the new filter element into the housing and tighten securely 10 Clean up any oil that may have spilled during the installation procecure 11 Start the engine from the ground contols 12 Activate any boom function and inspect the filters and related components to be sure that there are no leaks 13 Use a permanent ink marker to write the date and number of hours from the hour meter on the filters Section 3 Scheduled Maintenance Procedures August 2007 CHECKLIST D PROCEDURES D 5 Check the Turntable Rotation Bearing Bolts Note Genie requires that this procedure be performed every 1000 hours or annually whichever comes first Maintaining proper torque on the turntable bearing bolts is essential to safe machine operation Improper bolt torque could result in an unsafe operating condi
27. Result The machine is not equipped with all required decals or one or more decals are illegible or in poor condition Remove the machine from service until the decals are replaced 4 Always return the manuals to the storage container after use Note Contact your authorized Genie distributor or Genie Industries if replacement manuals or decals are needed Section 3 Scheduled Maintenance Procedures August 2007 CHECKLIST A PROCEDURES A 2 Perform Pre operation Inspection Note Genie specifications require that this procedure be performed every 8 hours or daily whichever comes first Completing a pre operation inspection is essential to safe machine operation The pre operation inspection is a visual inspection performed by the operator prior to each work shift The inspection is designed to discover if anything is apparently wrong with a machine before the operator performs the function tests The pre operation inspection also serves to determine if routine maintenance procedures are required Complete information on how to perform this procedure is available in the appropriate Genie Z 34 22 IC Operator s Manual on your machine A TEREX Z 34 22 IC REV A A 3 Perform Function Tests Note Genie specifications require that this procedure be performed every 8 hours or daily whichever comes first Completing the function tests is essential to safe machine operation Function tests are desig
28. way BK Charge pressure circuit that gets hot oil out of low pressure side of drive pump and allows low pressure flow path for brake release and 2 speed motor shift 15 18 ft lbs 20 24 Nm Solenoid valve 2 position 3 way 2 speed motor Shift 20 ft lbs 27 1 Nm Check valve BE Drive motor anti cavitation 20 ft lbs 27 1 Nm 6 Orifice plug 0 039 inch 1 mm Equalizes pressure both sides of flow divider combiner valve BO 7 Flow divider combiner valve BO Controls flow to right side drive motors in forward and reverse 25 ft lbs 33 9 Nm 8 Orifice plug 0 039 inch 1 mm Equalizes pressure on both sides of flow divider combiner valve BO 9 Check valve BG Drive motor anti cavitation 20 ft lbs 27 1 Nm 10 Orifice plug 0 032 inch 0 8 mm BC Brake circuit 11 Orifice plug 0 079 inch 2 mm BH Equalizes pressure on both sides of flow divider combiner valve BI 12 Check valve BM Drive motor anti cavitation 20 ft lbs 27 1 Nm 13 Check valve BN Drive motor anti cavitation 20 ft lbs 27 1 Nm 14 Check valve BE Drive motor anti cavitation 2
29. 12 Primary Boom Components 44 Plastic Cable Track iom eet d eerie tende ete DR 4 14 4 2 Primary BOOM re 4 14 4 3 Primary Boom Lift Cylinder 4 18 4 4 Extension Cylinder 4 19 4 5 Platform Leveling Master 4 21 Secondary Boom Components 5 1 Secondary Boom eite 4 25 5 2 Secondary Boom Lift Cylinder 4 29 Kubota D 905 Engine 6 1 Timing 4 30 6 2 GIW PIUQS ERE 4 30 6 3 4 30 MBMIodd ccep 4 30 6 5 Coolant Temperature Oil Pressure Switches 4 31 Genie TEREX COMPANY Z 34 22 IC Part No 128300 August 2007 TABLE OF CONTENTS Section4 Rev Repair Procedures continued Kubota DF 752 Engine 751 Choke 5 4 32 7 2 Timing RANA 4 32 7 3 4 32 7 4 RPM Adj stmant uccisi ee tette ERN 4 32 Eddie ERST 4 32 7 6 Coolant Temperature and Oil Pressure Switches 4 33 A Perkins 403C 11 Engine 8 1 Timing Adj stmoent 4 34 8 2 4 34 8 3 Flex Plate eee eec
30. 2 4 pz d L M L1 L2 Ti I 6 BE TEST 1 M2A M2B M4A M4B 10 MICRON d pud 25 psi 7 e 3200 psi 777 2000 psi 7771 Q w PUM 1 1 0 5 gpm GENERATOR 1 Pd E EN 7 8 om H 3am F7 m i e ee ee e eid Tf 52 GENERATOR OPTION B oS L FUNCTION MANIFOLD A TEREX COMPANY Z 34 22 IC Part No 128300 STEER CYLINDER REVA ES344WM REV Ti 1 52 1 ES344WM TURNTABLE ROTATE 5 9 CU SECONDARY BOOM Li Quo s 3000 153 E Ea 1600 psi e amp H August 2007 Section 5 Schematics Hydraulic Schematic 4WD Models F E D C B A
31. 9 Perform Engine Maintenance Kubota 3 12 A 10 Grease the Turntable Rotation Bearing and Worm Drive Gear 3 12 A 11 Replace the Drive Hub 3 13 A 12 Perform Engine Maintenance Kubota 3 14 A 13 Drain the Fuel Filter Water Separator Diesel Models 3 14 Checklist B Procedures B 1 Check the Engine Choke Gasoline LPG Models 3 16 B 2 Check the Exhaust 3 17 B 3 Inspect the nec einen 3 17 B 4 Inspect the Electrical 3 19 B 5 Inspect the Tires Wheels and Lug Nut Torque 3 19 B 6 Confirm the Proper Brake Configuration 3 20 B 7 Check the Oil Level in the Drive 3 20 B 8 Perform Engine Maintenance Perkins 403 11 Models 3 21 B 9 Check and Adjust the Engine 3 21 B 10 Test the Ground Control Override 3 23 B 11 Test the Platform Self leveling 1 3 24 Genie viii TEREX COMPANY Z 34 22 IC Part No 128300 August 2007 TABLE OF CONTENTS Section3 Rev Scheduled Maintenance Procedures continued B 12 Test the Engine Idle
32. 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 The engine will not start until the temperature drops below the switch point An over temperature indicator light at the ground controls should turn on when the switch closes Component damage hazard Do not crank the engine with the over temperature light on The engine oil switch is a normally closed switch The switch contacts open at approximately 7 psi 0 48 bar If the oil pressure drops below the Switch point the contacts open and the engine will shut off to prevent damage A low oil pressure indicator light at the ground controls should turn on when the switch opens Component damage hazard Do not crank the engine with the low oil pressure light on 4 31 Section 4 Repair Procedures August 2007 Kubota DF752 Engine 7 1 Choke Adjustments The choke is solenoid operated and functions only in the gasoline mode This choke will not operate in LPG mode Note Choke adjustments are affected by climate Richer adjustment will be necessary in colder climates leaner adjustment in warmer climates 7 2 Timing Adjustment Note The ignition timing cannot be adjusted The timing adjustment screw is factory sealed with a tamper resistant cap installed by
33. enie A TEREX COMPANY Serial Number Range 2 34 22 from Z3406 4800 Part No 128300 Rev 1 January 2011 Introduction August 2007 Introduction Important Read understand and obey the safety rules and operating instructions in the appropriate Genie 2 34 22 IC Operator s Manual before attempting any maintenance or repair procedure This manual provides detailed scheduled maintenance information for the machine owner and user It also provides repair procedures for qualified service professionals Basic mechanical hydraulic and electrical skills are required to perform most procedures However several procedures require specialized skills tools lifting equipment and a suitable workshop In these instances we strongly recommend that maintenance and repair be performed at an authorized Genie dealer service center Compliance Machine Classification Group B Type 3 as defined by ISO 16368 Machine Design Life Unrestricted with proper opeation inspection and scheduled maintenance Technical Publications Genie Industries has endeavored to deliver the highest degree of accuracy possible However continuous improvement of our products is a Genie policy Therefore product specifications are subject to change without notice Readers are encouraged to notify Genie of errors and send in suggestions for improvement All communications will be carefully considered for future pri
34. 3 1 Counterbalance valve Genie TEREX COMPANY Brake 2 Variable orifice or shut off valve Flow divider combiner Shuttle valve 3 pos 3 way Z 34 22 IC Section 5 Schematics August 2007 5 4 7 34 221 Part No 128300 Section 5 Schematics August 2007 ees Electrical Schematic Gasoline LPG Models P24BAT WH REVA RD BATGND 22 RD C21IGN WH C1P 9 C35RPMBK RD C1B 9 012 C50 2 BR 1 TB52 RPMCUT OUT 1 T RELAY LOW RPM TS4 LO FSHI TS54 014 C35RPM BK RD HIGH RPM 013 TB35 RPM SOLENOID C49 8 R35RPM BK RD OPTION 1 d FUELRELAY BL RD R7 EH LPG LOCKOUT TB39 LPG SOLENOID s LP C2P 1 C39LPBURD 2 1 49 1 R39LP BURD BL RD R7 EH SI Yo 2 FUEL I SELECT C1P 12 C38FLBLWH C1B 12 GAS 49 10 R38FLBL WH BL WH R6 EH ANTI DIESEL VALVE 010 1 8 BLIWH R6 EH B ns FUEL PUMP yeas SELECT 1 8 FUEL RELAY 8 C34SA BK WH C1B 8 CHOKE RELAY BRN I o TB34
35. JIB BOOM t E J MANIFOLD 1 6 PLUG 5 VIEW 1 25 eie BRN JIB GND 7 PLUG noe las UE 3 25 8 BR GND 21 22 BK6 1 RD gt oH CABLE G 2 BR RD 3 4 Q Q 153 BK DRIVE ENABLE Wi WH LIMIT SWITCH A B SHOWN WITH BOOM ROTATED TILT SENSOR PAST EITHER NON STEER WHEEL f N f N C8 m 2 F 7 A A 4 RDS 13 5 PIN amp WIRES 5 SERVICE HORN 1 1 WH 5 21 22 5 L4 ote 1 CABLE 5 2 BR A amp E y H2 a p 5 m mz n 8 5 o BK Blo nz mz lt 5 Tm m 59 26 SECONDARY BOOM BE BE UP DOWN 4 5 26 Oz a als gt gt 5 gt 9 LIMIT SWITCH ojt 6518 9 2 t E 9 2 lt lt 20 zz 2 28 r5 Su m mo MANIFOLD HARNESS GRD BOX exce Ad
36. Kubota part number 16622 8916 5 OR the Kubota DF752 Operator s Manual Kubota part number EG601 8916 1 Kubota D905 Operator s Manual Genie part number 31743 Genie part number 31743 Kubota DF752 Operator s Manual Kubota DF752 Operator s Manual Genie part number 84250 Genie part number 84250 Genie Part No 128300 2 34 22 IC 3 11 Section 3 Scheduled Maintenance Procedures August 2007 CHECKLIST A PROCEDURES A 9 Perform Engine Maintenance Kubota Models Note Engine specifications require that this procedure be performed every 100 hours Required maintenance procedures and additional engine information is available in the Kubota D905 Operator s Manual Kubota part number 16622 8916 5 OR the Kubota DF752 Operator s Manual Kubota part number EG601 8916 1 Kubota D905 Operator s Manual Genie part number 31743 Kubota DF752 Operator s Manual Genie part number 84250 A TEREX Z 34 22 IC 10 Grease the Turntable Rotation Bearing and Worm Drive Gear Note Genie specifications require that this procedure be performed every 100 hours Yearly application of lubrication to the turntable bearing and worm drive gear is essential to good machine performance and service life Continued use of an improperly greased gear will result in component damage 1 Before serial number 5204 Raise the secondary boom and place a safety chock on the second
37. Result The engine should not change to high idle 8 Press down the foot switch Result The engine should change to high idle Part No 128300 Genie 2 34 22 IC CHECKLIST B PROCEDURES B 13 Test the Fuel Select Operation Gasoline LPG Models Note Genie requires that this procedure be performed every 250 hours or quarterly whichever comes first The ability to select and switch between gasoline and LPG fuels as needed is essential to safe machine operation A fuel selection can be made when the engine is running or not Switching malfunctions and or the failure of the engine to start and run properly in both fuel modes and through all idle speeds can indicate fuel system problems that could develop into a hazardous situation Note Perform this test after checking the gasoline and LPG fuel levels and warming the engine to normal operating temperature 1 Move the fuel select switch to gasoline and then move the engine idle control switch to foot switch activated high idle rabbit and foot switch symbol 2 Start the engine from the platform controls and allow it to run at low idle 3 Press down the foot switch to allow the engine to run at high idle Result The engine should start promptly and operate smoothly in low and high idle Section 3 Scheduled Maintenance Procedures August 2007 CHECKLIST B PROCEDURES Release the foot switch and stop the engine Move the fuel select switch
38. TS51 AUXILIARY TOGGLE SWITCH gt TS52 ENGINE START TOGGLE SWITCH RD C237 TS54 FUNCTION ENABLE ENGINE RPM TOGGLE SWITCH TS56 ENGINE GLOW PLUG TOGGLE SWITCH BR RD TS57 PLATFORM ROTATE TOGGLE SWITCH emm RD CR1 12GA TS58 JIB BOOM UP DOWN TOGGLE SWITCH 4 TS59 PLATFORM LEVEL TOGGLE SWITCH BK 7A TS60 SECONDARY BOOM UP DOWN TOGGLE SWITCH HM OR BK 15A TS63 TS59 WH RD 6A TS61 PRIMARY BOOM UP DOWN TOGGLE SWITCH E pm TS62 TURNTABLE ROTATE TOGGLE SWITCH 2 963 PRIMARY BOOM EXTEND RETRACT TOGGLE SWITCH CB1 CIRCUIT BREAKER ENGINE 15A J TI CIRCUIT BREAKER CONTROLS 104 GR C4B 5 TS58 TS61 1957 HOUR METER Q GR BK C4B 6 5 EH ENGINE HARNESS X Qos 0090 LAR MH MANIFOLD HARNESS 1556 7552 U CH CHASSIS HARNESS J J Z SP SWITCH PANEL TS60 CR CONTROL RELAY TS62 TS54 WH BK 5A ISM IGNITION START MODULE OD LAR H3 TRAVEL ALARM U H6 PLATFORM OVERLOAD ALARM CE OPTION 4 J 6 145 PLATFORM OVERLOAD LED OPTION WH 4A BL 10A BL BK 11A RD 1A RD BK 2A GR C2B 5 GR BK 44A GR BK H6 7 BK WH 34A BK 33A BK RD 35A ES34DV 5 20 Z 34 221C PartNo 128300 August 2007 Section 5 Schematics lt lt Ground Control Box Terminal Strip Wiring Diagram Diesel Models N M L K J H G F D
39. When adjusted correctly the platform overload system will deactivate normal boom operation at platform capacity Note Perform this procedure with the machine on a firm level surface 1 Turn the key switch to platform control Start the engine and level the platform 2 Determine the maximum platform capacity Refer to the machine serial plate 3 Remove all weight tools and accessories from the platform Note Failure to remove all weight tools and accessories from the platform will result in an inaccurate test Part No 128300 CHECKLIST C PROCEDURES Using a suitable lifting device place a test weight equal to that of the available capacity one of the locations shown Refer to Illustration 1 Result The platform overload indicator lights should be off at both the ground and platform controls and the alarm should not sound Result The platform overload indicator lights are on and the alarm is sounding Calibrate the platform overload system Refer to Repair Proceedure 2 3 How to Calibrate the Platform Overload System if equipped Carefully move the test weight to each remaining location Refer to Illustration 1 Result The platform overload indicator lights should be off at both the ground and platform controls and the alarm should not sound Result The platform overload indicator lights are on and the alarm is sounding Calibrate the platform overload system Refer to Repair Proceedure 2 3 How to
40. patch of a tire as a visual reference for use when crossing the start and finish lines 7 Bring the machine to top drive speed before reaching the start line Begin timing when your reference point on the machine crosses the start line 8 Continue at full speed and note the time when the machine reference point passes over the finish line Section 3 Scheduled Maintenance Procedures August 2007 CHECKLIST B PROCEDURES B 16 Test the Drive Speed Raised or Extended Position Note Genie requires that this procedure be performed every 250 hours or quarterly whichever comes first Proper drive function movement is essential to safe machine operation The drive function should respond quickly and smoothly to operator control Drive performance should also be free of hesitation jerking and unusual noise over the entire proportionally controlled speed range Note Select a test area that is firm level and free of obstructions 1 Create start and finish lines by marking two lines on the ground 40 feet 12 2 m apart 2 Start the engine from the platform controls 3 Move the engine idle select switch to foot switch activated high idle rabbit and foot switch symbol 4 Press down the foot switch and raise the primary boom above horizontal 5 Choose a point on the machine i e contact patch of a tire as a visual reference for use when crossing the start and finish lines 6 Bring the machine to top drive
41. when removed from the machine 7 Support and secure the hydraulic tank to a suitable lifting device Remove the hydraulic tank from the machine Crushing hazard The hydraulic AWARNING tank could become unbalanced and fall if not properly supported and secured to the lifting device when removed from the machine Genie REV 4 54 Z 34 22 IC Part No 128300 August 2007 Section 4 Repair Procedures Turntable Rotation Components 12 1 Rotation Hydraulic Motor The turntable rotation hydraulic motor is the only serviceable component of the turntable rotation assembly The worm gear may not be removed from the housing In order to remove the housing the entire turntable assembly has to be removed How to Remove the Turntable Rotation Motor Note Do not allow the turntable to rotate until the hydraulic motor is installed 1 Tag disconnect and plug the hydraulic hoses from the turntable rotation motor Cap the fittings on the motor AWARNING Bodily injury hazard Spraying hydraulic oil can penetrate and burn skin Loosen hydraulic connections very slowly to allow the oil pressure to dissipate gradually Do not allow oil to squirt or spray 2 Remove the turntable rotation motor mounting fasteners Remove the motor from the worm gear housing TEREX COMPANY Part No 128300 Z 34 22 IC Section 4 Repair Procedures August 2007 Axle Components 13 1 Hub and Bearings 2WD
42. whichever comes first Removing sediment from the fuel tank is essential to good engine performance and service life A dirty fuel tank may cause the fuel filter to clog prematurely resulting in poor engine performance and possible component damage Explosion and fire hazard Engine fuels are combustible Clean the fuel tank in an open well ventilated area away from heater sparks flames and lighted tobacco Always have an approved fire extinguisher within easy reach Note Immediately clean up any fuel that may have spilled during this procedure 1 Models with fuel shutoff valve Turn the manual fuel shutoff valve located next to the tank to the closed position Part No 128300 Genie 2 34 22 IC CHECKLIST C PROCEDURES 2 Using an approved hand operated pump drain the fuel tank into a suitable container Refer to Section 2 Specifications for tank capacity Explosion and fire hazard When transferring fuel connect a grounding wire between the machine and pump or container Note Be sure to only use a hand operated pump suitable for use with gasoline and or diesel fuel 3 Tag disconnect and plug the fuel supply and return hoses at the tank Clean up any fuel that may have spilled 4 Remove the tank retainer plate fasteners at the bulkhead Remove the tank from the machine Component damage hazard The fuel tank is plastic and may become damaged if allowed to fall 5 Rinse out the inside of the tan
43. 3 Nm 8 40 ft lbs 55 Nm 10 105 ft lbs 142 4 Nm 10 60 ft lbs 80 Nm 12 140 ft lbs 190 Nm 12 85 ft lbs 115 Nm 16 210 ft lbs 284 7 Nm 16 110 ft lbs 150 Nm 20 260 ft lbs 352 5 Nm 20 140 ft lbs 190 Nm 24 315 ft lbs 427 1 Nm 24 180 ft lbs 245 Nm Part No 128300 2 34 22 IC 2 9 Section 2 Specifications January 2011 SPECIFICATIONS REV SAE FASTENER TORQUE CHART This chart is to be used as a guide only unless noted elsewhere in this manual A574 High Strength Grade g Black Oxide Bolts LUBED DRY LUBED DRY LUBED Nm 0 65 Nm Nm Nm 9 100 113 10 140 130 120 160 140 LUBED DRY LUBED DRY LUBED 13 18 20 ribs 19 19 23 33 26 37 14 7 15 8 I 2 5 i 0 Q o 24 27 1 44 7 50 1 67 8 25 27 44 49 70 Nm 35 9 28 4 55 6 325 59 6 515 66 4 58 3 A 1054 68 149 162 142 203 176 250 189 284 244 325 271 515 133 569 474 827 591 37 50 21 18 5 773 0 54 857 ene 12 s 108 4 10 1 120 18 o 122 10 16 130 m 160 18 130 176 170 230 180 aa 10 20 21 20 366 280 379 220 298 300 406 310 420 19 320 430 583 450 50 610 350 474 40 637 50 68 60 908 759 o 650 640 867 680 92 910 1233 1044 12 718 70 962 750 1016 990 1342 159 E 1749 1477 s 312 60 908 89
44. 5042 34 93 579 5059 Genie Germany Phone 0800 180 9017 Phone 49 422 149 1818 Fax 49 422 149 1820 Genie North America Phone 425 881 1800 Toll Free USA and Canada 800 536 1800 Fax 425 883 3475 Genie Australia Pty Ltd Phone 61 7 3375 1660 Fax 61 7 3375 1002 Genie China Phone 86 21 53852570 Fax 86 21 53852569 Genie Malaysia Phone 65 98 480 775 Fax 65 67 533 544 Genie Japan Phone 81 3 3453 6082 Fax 81 3 3453 6083 Genie Korea Phone 82 25 587 267 Fax 82 25 583 910 Genie U K Phone 44 0 1476 584333 Fax 44 0 1476 584334 Genie Brasil Phone 55 11 41 665 755 Fax 55 11 41 665 754 Genie Mexico City Phone 52 55 5666 5242 Fax 52 55 5666 3241 Genie Holland Phone 31 183 581 102 Fax 31 183 581 566 California Proposition 65 Warning The exhaust from this product contains chemicals known to the State of California to cause cancer birth defects or other reproductive harm Service Manual 2 34122 IC from serial number 23406 4800 Part No 128300 Rev 1 A TERI
45. CONTROLS 10A ma o L R HM HOUR METER TS56 TS52 U U RBS EH ENGINE HARNESS MH MANIFOLD HARNESS TS60 862 CHASSIS HARNESS D WH BK 5A SP SWITCH PANEL L R CONTROL RELAY 4 6 15 IGNITION START MODULE AHAN H3 TRAVEL ALARM BL 10A 11 RD BK 2A GR C2B 5 GR BK 44A BL WH 38A BL RD 39A 7 BK WH 34A BK 33A BK RD 35A ES34GPW enie A TEREX COMPANY Z 34 221C 5 10 Part No 128300 August 2007 Section 5 Schematics nm REVA Ground Control Box Terminal Strip Wiring Diagram Gasoline LPG Models N M L K J D G B A 52 1 154 e ff SECONDARY BOOM UBIDOWN TER
46. Calibrate the Platform Overload System if equipped Illustration 1 Genie 2 34 22 IC Section 3 Scheduled Maintenance Procedures August 2007 CHECKLIST C PROCEDURES 6 Using a suitable lifting device place an additional 10 Ibs 4 5 kg of weight onto the platform Result The alarm should sound The platform overload indicator lights should be flashing at both the ground and platform controls Result The alarm does not sound and the platform overload indicator lights are not flashing Calibrate the platform overload System Refer to Repair Proceedure 2 3 How to Calibrate the Platform Overload System if equipped Note There may be a 2 second delay before the overload indicator lights flash and the alarm sounds 7 Carefully move the test weights to each remaining location on the platform Refer to Illustration 1 O Result The alarm should sound The platform overload indicator lights should be flashing at both the ground and platform controls Result The alarm does not sound and the platform overload indicator lights are not flashing Calibrate the platform overload system Refer to Repair Proceedure 2 3 How to Calibrate the Platform Overload System if equipped Note There may be a 2 second delay before the overload indicator lights flash and the alarm sounds A TEREX Z 34 22 IC REV A 8 Test all machine functions from the platform controls Result All
47. Engine Displacement 54 86 cu in 0 90 liters Number of cylinders 3 Bore and stroke 2 83 x 2 90 inches 72 73 6 mm Horsepower gross intermittent 26 3600 rpm 19 3kW Firing order 1 2 3 Compression ratio 23 1 Compression pressure 412 to 469 psi 28 4 to 32 3 bar Low idle 1300 rpm Frequency 260 hz High idle 3000 rpm Frequency 600 hz Governor centrifugal mechanical 0 0057 to 0 0072 in 0 145 to 0 185 mm Valve clearance cold Engine coolant Capacity 3 3 quarts 3 1 liters Lubrication system Oil pressure 36 to 64 psi 2 48 to 4 41 bar Oil capacity 5 4 quarts including filter 5 1 liters Oil viscosity requirements Units ship with 15W 40 Extreme operating temperatures may require the use of alternative engine oils For oil requirements refer to the Engine Operator Handbook on your machine A TEREX Z 34 22 IC Injection system Injection pump make Bocsh MD Injection timing 13 to 25 BTDC Injection pump pressure 1991 psi 137 bar Fuel requirement For fuel requirements refer to the engine Operator s Manual on your machine Battery Type 12V DC Group 34 78 Quantity 1 Ampere hour 75AH Cold cranking ampere 900A Reserve capacity 25A rate 125 minutes Alternator Output 30A 14V DC 1 4 to 3 8 inch 7 to 9 mm Fan belt deflection Continuous improvement of our products is a Genie policy Product sp
48. Models How to Remove the Hub and Bearings 1 Loosen the wheel lug nuts Do not remove them 2 Block the non steer wheels and place a lifting jack of ample capacity under the steer axle 3 Raise the machine 6 inches 15 cm and place blocks under the drive chassis for support Crushing hazard The machine ACAUTION may fall if not properly supported 4 Remove the lug nuts Remove the tire and wheel assembly 5 Remove the dust cap cotter pin and castle nut 6 Pullthe hub off the spindle The washer and outer bearing should fall loose from the hub 7 Place the hub on a flat surface and gently pry the bearing seal out of the hub Remove the rear bearing Genie Z 34 22 IC REVA How to Install the Hub and Bearings Note When replacing a wheel bearing both the inner and outer bearings including the pressed in races must be replaced 1 Be sure that both bearings are packed with clean fresh grease 2 Place the large inner bearing into the rear of the hub 3 Install a new bearing grease seal into the hub by pressing it evenly into the hub until it is flush Note Always replace the bearing grease seal when removing the hub 4 Slide the hub onto the yoke spindle Component damage Do not apply excessive force or damage to the lip of the seal may occur Fill the hub cavity with clean fresh grease Place the outer bearing into the hub Install the washer and castle nut Tighten the castle nut to 15
49. QIN RI um N 9 5 7 A N 5 m RIO 00 NIN o ol gt C 4 AYN PN coy Cy o MINIO o gt A 2 o 4 A A o A A Po A gt A 85 August 2007 Section 3 Scheduled Maintenance Procedures Scheduled Maintenance Procedures Observe and Obey Maintenance inspections shall be completed by a person trained and qualified on the maintenance of this machine M Scheduled maintenance inspections shall be completed daily quarterly semi annually annually and every 2 years as specified on the Maintenance Inspection Report AWARNING Failure to perform each procedure as presented and scheduled could result in death serious injury or substantial machine damage Immediately tag and remove from service damaged or malfunctioning machine Repair any machine damage or malfunction before operating the machine Use only Genie approved replacement parts Machines that have been out of service for a period longer than 3 months must complete the quarterly inspection Unless otherwise specified perform each procedure with the machine in the following configur
50. RD 1 TRAVEL ALARM n 5 1 26 BL BL 36 MH 1 10 C1B 10 a d teenies 1 1 11 C37SCW C1B 11 BL BK 37 MH 32 7 STEER RIGHT PPM udo a RES 8 C29MS RD WH C29MS RD WH 1 3 C51 il motor sTROKE g ak C12FTS BK C10 1 BK 7 LSI cs EXTEND RETRACT 1 2 LIMIT SWITCH C11 4 WH 6 TE 152 E CIS BKS aye PRIMARY BOOM 5 UP DOWN x m 052 1 8 2 SON g 154 C2P2 C40LS OR C2B 2 C52 2 WH 8 5 SEC NDARVBOOM 5 UP DOWN 3 WH RD C3P 6 WH RD C3B 6 a C6MFV WH RD 5 4 FLOW CONTROL A BRN 4 BK RD lt JIB BOOM UP gt JIB BOOM DOWN gt 47 8 GND BR uP C2P 5 C43JU GR C2B 5 9 4 C2P 6 C44JD C2B 6 PLATFORM LEVEL DOWN x ui 0 CUT OUT OPTION m 5 7 4 WH IA e C47 8 C43JU BK 2 9 2 RIGHT 9 PLATFORM 4 ROTATE RIGHT 7 1 lA 55 LEFT ROTATE LEFT 4 RE x C472 C18PRR BL li 5 29 mer 6 6 C18PRR GR BK C4B 6 4 5 C17PRL GR 5 UP SB PLATFORM 4 LEVEL UP td 4 PLATFORM 5 DOWN LEVEL DOWN a Lr m 5 1 4 2
51. all rings watches and other jewelry Hydraulic Schematics Bodily injury hazard Spraying AWARNING hydraulic oil can penetrate and burn skin Loosen hydraulic connections very slowly to allow the oil pressure to dissipate gradually Do not allow oil to squirt or spray General Repair Process Malfunction _ Identify Troubleshoot discovered symptoms problem still exists Perform repair Return to service solved Section 5 Schematics August 2007 Electrical Symbols Legend REVA m Ft 5 Circuit breaker Foot switch 4 Spark plug Circuit description d with wire color 1 x KS1 PLAT WTS1 Solenoid or Ground relay coil supression Key switch circuit Terminal Water temperature i wl vhs Switch normally open 1i5 HORN P4 Horn alarm M os Limit switch Horn button D Quick disconnect normally open terminal M T 152 Oil pressure switch T Pa normally closed eme w g Light Hoa closed held red Emergency T circuits connect Stop button at terminal normally closed 151 NO L45 DAT LED Limit switch T circuits normally open Gauge connect held closed EN NON hs uen
52. and should be stored in the container provided in the platform An illegible or missing manual will not provide safety and operational information necessary for a safe operating condition In addition maintaining all of the safety and instructional decals in good condition is mandatory for safe machine operation Decals alert operators and personnel to the many possible hazards associated with using this machine They also provide users with operation and maintenance information An illegible decal will fail to alert personnel of a procedure or hazard and could result in unsafe operating conditions 1 Check to make sure that the operator s and safety manuals are present and complete in the storage container on the platform 2 Examine the pages of each manual to be sure that they are legible and in good condition Result The operator s manual is appropriate for the machine and all manuals are legible and in good condition Result The operator s manual is not appropriate for the machine or all manuals are not in good condition or are illegible Remove the machine from service until the manual is replaced Part No 128300 TEREX COMPANY Z 34 22 IC 3 7 3 Open the operator s manual to the decals inspection section Carefully and thoroughly inspect all decals on the machine for legibility and damage Result The machine is equipped with all required decals and all decals are legible and in good condition
53. cylinder pivot pin Use a soft metal drift to remove the pin Genie Z 34 22 IC REVA 10 Carefully pull out and properly support the extension cylinder from the primary boom using a lifting strap from an overhead crane Crushing hazard The cylinder ACAUTION may become unbalanced and fall if not properly supported by the overhead crane when removed from the extension tube Note During removal the overhead crane strap will need to be carefully adjusted for proper balancing Note To make installation of the extension cylinder easier be sure that the cylinder rod is extended 3 to 4 feet 1 m Part No 128300 August 2007 Section 4 Repair Procedures REVA 4 5 Platform Leveling Master Cylinder The master cylinder acts as a pump for the slave cylinder It is part of the closed circuit hydraulic loop that keeps the platform level through the entire range of primary boom motion The master cylinder is located inside the upper mid pivot at the pivot end of the primary boom How to Remove the Platform Leveling Master Cylinder AWARNING Bodily injury hazard This procedure requires specific repair skills lifting equipment and a suitable workshop Attempting this procedure without these skills and tools could result in death or serious injury and significant component damage Dealer service is strongly recommended Note Before cylinder removal is considered bleed the cylinder to be sure that there is
54. every 400 hours Required maintenance procedures and additional engine information is available in the Kubota D905 Operator s Manual Kubota part number 16622 8916 5 Kubota D905 Operator s Manual Genie part number 31743 Part No 128300 Z 34 22 IC Genie hau CHECKLIST B PROCEDURES Section 3 Scheduled Maintenance Procedures August 2007 Checklist C Procedures C 1 Grease the Platform Overload Mechanism if equipped Note Genie specifications require that this procedure be performed every 500 hours or 6 months whichever comes first Perform this procedure more often if dusty conditions exist Application of lubrication to the platform overload mechanism is essential to safe machine operation Continued use of an improperly greased platform overload mechanism could result in the system not sensing an overloaded platform condition and will result in component damage 1 Locate the grease fittings on each pivot pin of the platform overload assembly 2 Thoroughly pump grease into each grease fitting using a multi purpose grease Grease Specification Chevron Ultra duty grease EP NLGI 2 lithium based or equivalent A TEREX Z 34 22 IC 2 Test the Platform Overload System if equipped Note Genie specifications require that this procedure be performed every 500 hours or six months whichever comes first Testing the platform overload system re
55. i P23BAT WH 7 2 WH ue 2 53135552 552555555 25252 lt 567555 55555225 3535555555262056 lt gt 55552555522 P26BAT 9 1 P22BAT 7 1 C9HRN BK RD C3P 9 C27AUX RD C1P 1 C18PRR GR BK C47 2 C17PRLGR C47 1 C44JD GR BK C47 4 C43JU GR C47 3 T N t 10 ES34GPW G TEREX COMPANY Z 34 221C No 128300 5 14 August 2007 Section 5 Schematics am Electrical Schematic Diesel Models REV 25 RD C9P 3 RD FS FS1 August 2007 Electrical Schematic Diesel Models Section 5 Schematics lt amp PLATFORM LOAD SENSE OPTION a 8 z 5 E lt lt 5 lt ao 9 f 5 1 9 8 8 8 i 1 Y RPM CUTOUT an RELA
56. no air in the closed loop See 2 1 How to Bleed the Slave Cylinder Note When removing a hose assembly or fitting the O ring on the fitting and or hose end must be replaced and then torqued to specification during installation Refer to Section 2 Hydraulic Hose and Fitting Torque Specifications 1 Remove the rear turntable cover Part No 128300 TEREX COMPANY Z 34 22 IC PRIMARY BOOM COMPONENTS 2 Raise the secondary boom until the master cylinder barrel end pivot pin is above the turntable counterweights 3 Raise the primary boom until the master cylinder rod end pivot pin is accessible 4 Attach a lifting strap from an overhead crane to the upper pivot for support Do not apply any lifting pressure 5 Secure the upper secondary boom to the pivot end of the primary boom with a strap Note Securing the upper secondary boom to the pivot will prevent the upper secondary boom from falling when the master cylinder barrel end pivot pin is removed from the cylinder 6 Tag disconnect and plug the master cylinder hydraulic hoses Cap the fittings on the cylinder AWARNING injury hazard Spraying ydraulic oil can penetrate and burn skin Loosen hydraulic connections very slowly to allow the oil pressure to dissipate gradually Do not allow oil to squirt or spray 7 Tiea strap around the lug on the rod end of the master cylinder and secure the strap to the primary boom Note The strap will be used to l
57. platform 2 Determine the maximum platform capacity Refer to the machine serial plate 3 Using a suitable lifting device place an appropriate test weight equal to that of the maximum platform capacity at the center of the platform floor Part No 128300 A TEREX Z 34 22 IC 4 9 PLATFORM COMPONENTS Determine the limit switch trigger point 4 Gently move the platform up and down by hand so it bounces approximately 1 to 2 inches 2 5 to 5 cm Allow the platform to settle Result The overload indicator light and the alarm is on Slowly tighten the load spring adjustment nut by turning it clockwise just until the overload indicator light and alarm turns off Note The platform will need to be moved up and down and allowed to settle between adjustments Note There may be an approximate 2 second delay before the overload indicator light turns on and the alarm sounds Result The overload indicator light and alarm is off Slowly loosen the load spring adjustment nut by turning it counterclockwise just until the overload indicator light and alarm turn on Note There may be an approximate 2 second delay before the overload indicator light turns on and the alarm sounds Note The platform will need to be moved up and down and allowed to settle between adjustments Section 4 Repair Procedures August 2007 PLATFORM COMPONENTS REV Confirm the setting 5 Turn the key switch to platform c
58. plug wire resistance 2 81 to 4 79 2 Spark plug wire resistance 3 4 to 5 8 3 Spark plug wire resistance 3 57 to 6 09 Spark plug type NGK BKR4E 11 Spark plug gap 0 039 to 0 043 inches alternative engine oils For oil requirements refer to the 1 to 1 1 mm Engine Operator Handbook on your machine Engine coolant Fuel pum sities Capacity 3 1 quarts Fuel pressure static 2 84 psi 2 9 liters 0 19 bar Alternator Fuel flow rate 0 125 0 47 ion Output 30A 14V DC Continuous improvement of our products is a Fan belt deflection 1 4 to 3 8 inch Genie policy Product specifications are 7 to 9 mm subject to change without notice Part No 128300 Z 34 22 IC 2 7 Section 2 Specifications January 2011 SPECIFICATIONS Perkins 403C 11 Engine Displacement 68 9 cu in 1 13 liters Number of cylinders 3 Bore and stroke 3 03 x 3 19 inches 77 x 81 mm Horsepower gross intermittent 26 1 3000 rpm 19 5 kW Firing order 1 2 3 Compression ratio 23 1 Compression pressure 425 psi 29 3 bar Pressure of the lowest cylinder must be within 50 psi 3 45 bar of the highest cylinder though at no time less than 360 psi 24 8 bar Low idle 1500 rpm Frequency 300 hz High idle 3000 rpm Frequency 600 hz Governor all speed mechanical Valve clearance cold 0 0078 in 0 2 mm Engine coolant capacity 3 28 quarts 3 1 liters Engine coolant should be clean soft water with 50 anti freez
59. pressure Install the relief valve cap AWARNING hazard Do not adjust the relief valve higher than specified 7 Repeatsteps 2 through 6 to confirm the relief valve pressure setting Genie Z 34 22 IC REVA How to Adjust the Secondary Boom Down Relief Valve 1 Connect a 0 to 3000 psi 0 to 206 bar pressure gauge to the test port on the function manifold 2 Startthe engine from the ground controls 3 Hold the function enable rpm select toggle switch to the high rpm position and activate and hold the secondary boom toggle switch in the down direction with the secondary boom fully lowered 4 Observe the pressure reading on the pressure gauge Refer to Section 2 Specifications 5 Turn the machine off Hold the relief valve and remove the cap item J 6 Adjust the internal hex socket Turn it clockwise to increase the pressure or counterclockwise to decrease the pressure Install the relief valve cap AWARNING Tip over hazard Do not adjust the relief valve higher than specified 7 Repeat steps 2 through 6 to confirm the relief valve pressure setting Part No 128300 August 2007 Section 4 Repair Procedures MANIFOLDS 10 3 Jib Boom Platform Rotate Manifold Components The jib boom platform rotate manifold is mounted to the jib boom Index Schematic No Description Item Function Torque 1 Solenoid valve 3 position 4 way CH Jib boo
60. primary boom REVA 23 Remove the hose clamp from the side of the primary boom 24 Remove the limit switch cam mounting fastener if equipped Note Note the position of the cam before removing it 25 Remove the pin retaining fasteners from the primary boom pivot pin 26 Use a soft metal drift to remove the primary boom pivot pin Carefully remove the boom from the machine and place it on a structure capable of supporting it AWARNING Crushing hazard If the overhead crane is not properly attached the boom could become unbalanced and fall when it is removed from the machine Note During removal the overhead crane strap will need to be carefully adjusted for proper balancing Genie TEREX COMPANY 2 34 22 IC Part No 128300 August 2007 Section 4 Repair Procedures REVA How to Disassemble the Primary Boom Note Complete disassembly of the boom is only necessary if the outer or inner boom tubes must be replaced The extension cylinder can be removed without completely disassembling the boom See 4 4 How to Remove the Extension Cylinder 1 Remove the boom See 4 2 How to Remove the Primary Boom 2 Place blocks under the extension cylinder for support 3 Remove the retaining fasteners from the extension cylinder barrel end pivot pin Use a soft metal drift to remove the pin 4 Label the location of all wear pads from the outer boom tube at the platform end Remove all wear pads in
61. speed before reaching the start line Begin timing when your reference point on the machine crosses the start line A TEREX Z 34 22 IC REV A 7 Continue at full speed and note the time when the machine reference point crosses the finish line 8 Lower the boom to the stowed position and extend the boom 1 foot 30 cm 9 Choose a point on the machine i e contact patch of a tire as a visual reference for use when crossing the start and finish lines 10 Bring the machine to top drive speed before reaching the start line Begin timing when your reference point on the machine crosses the start line 11 Continue at top speed and note the time when the machine reference point crosses the finish line Part No 128300 August 2007 Section 3 Scheduled Maintenance Procedures REVA B 17 Inspect the Fuel and Hydraulic Tank Cap Venting Systems Note Genie requires that this procedure be performed every 250 hours or quarterly whichever comes first Perform this procedure more often if dusty conditions exist Free breathing fuel and hydraulic tank caps are essential for good machine performance and service life A dirty or clogged tank cap may cause the machine to perform poorly and continued use may cause component damage Extremely dirty conditions may require that the caps be inspected more often Explosion and fire hazard Engine fuels are combustible Perform this procedure in an open well
62. the manufacturer If service or repair is needed contact your local Kubota dealer 7 3 Carburetor Adjustment Note The carburetor cannot be adjusted The carburetor mixture screws are factory sealed with tamper resistant caps installed by the manufacturer If service or repair is needed contact your local Kubota dealer 4 32 A TEREX COMPANY Z 34 22 IC REV A 7 4 RPM Adjustment Refer to maintenance procedure B 9 Check and Adjust the Engine RPM 7 5 Flex Plate The flex plate acts as a coupler between the engine and the pump It is bolted to the engine flywheel and has a splined center to drive the pump How to Remove the Flex Plate 1 Support the drive pump with a suitable lifting device 2 Remove all of the pump mounting plate to engine fasteners 3 Carefully pull the pump assembly away from the engine and secure it from moving 4 Remove the flex plate mounting fasteners Remove the flex plate from the flywheel Part No 128300 August 2007 Section 4 Repair Procedures REVA How to Install the Flex Plate 1 Install the flex plate onto the flywheel with the raised spline against the flywheel pump a b pump shaft pump coupler d flex plate e flywheel 2 Apply removable Loctite thread sealant to the flex plate mounting fasteners Torque the flex plate mounting fasteners to 36 ft lbs 49 Nm 3 Install the coupler onto the pump shaft with the set screw towards the
63. to LPG Restart the engine and allow it to run at low idle 7 Press down the foot switch to allow the engine to run at high idle Result The engine should start promptly and operate smoothly in low and high idle Note The engine may hesitate momentarily and then continue to run on the selected fuel if the fuel source is switched while the engine is running A TEREX Z 34 22 IC MPANY REVA B 14 Test the Drive Brakes Note Genie requires that this procedure be performed every 250 hours or quarterly whichever comes first Proper brake action is essential to safe machine operation The drive brake function should operate smoothly free of hesitation jerking and unusual noise Hydrostatic brakes and hydraulically released individual wheel brakes can appear to operate normally when not fully operational AWARNING Bodily injury hazard Be sure that the machine is not in free wheel or partial free wheel configuration See B 6 Confirm the Proper Brake Configuration Note Select a test area that is firm level and free of obstructions 1 Mark atest line on the ground for reference 2 Start the engine from the platform controls 3 Select high range drive machine on level surface symbol 4 Move the engine idle control switch to foot switch activated high idle rabbit and foot switch 5 Lower the boom into the stowed position Part No 128300 August 2007 Section 3 Scheduled Main
64. 0 1206 1080 1464 1440 1952 1220 1654 11 2074 2504 5 7 3620 2 312 160 2067 METRIC FASTENER TORQUE CHART This chart is to be used as a guide only unless noted elsewhere in this manual Size Class 4 6 Class 8 8 Class 10 9 03 Class 12 9 mm 5 6 gt AB 92 1 108 4 122 162 176 217 244 110 120 150 170 210 240 380 420 N alo o o E DRY 884 58 775 91 1031 132 15 116 132 155 17 6 DRY DRY 2 25 8i 110 147 600 458 622 612 830 536 727 715 970 20 570 562 762 583 791 778 1055 682 925 909 1233 2 10 Z 34 22 IC Part No 128300 1 ile BE 4 ile ile ER 4 A a m A O1 Al aj oj o En E o 5 e I N z clo A oo c 1 8 y lt ie 8 9 lt ie i r c UD i A 0 A NIA po BLO lt 1 o ajojo ajoo eo z hla Ol CO 555
65. 0 ft lbs 27 1 Nm 15 Orifice plug 0 079 inch 2 mm BJ Equalizes pressure on both sides of flow divider combiner valve BI 16 Relief valve 150 psi 10 3 bar BD Charge pressure circuit 20 ft lbs 27 1 Nm 17 Orifice plug 0 039 inch 1 mm BS Equalizes pressure on both sides of flow divider combiner valve BT 18 Flow divider combiner valve Controls flow to left side drive motors in forward and reverse 25 ft lbs 33 9 Nm 19 Orifice plug 0 039 inch 1 mm BR Equalizes pressure on both sides of flow divider combiner valve BT 20 Flow divider combiner valve Controls flow to flow divider combiner valves BO and BT uet ei ek 30 ft lbs 40 6 Nm 4 48 Z 34 22 IC Part No 128300 August 2007 Section 4 Repair Procedures REVA MANIFOLDS Genie Part No 128300 2 34 22 IC 4 49 Section 4 Repair Procedures August 2007 MANIFOLDS 10 7 Valve Adjustments Traction Manifold How to Adjust the Charge Pressure Relief Valve The charge pressure relief valve needs to be set for machine performance rather than a specific pressure value The relief valve is set correctly when the engine does not stall when placed under a heavy load 1 Chock both sides of all four wheels of the machine Note Be sure the machin
66. 00000 CONTROL RELAY 1 0 OPTION NUMBERS SPARE WIRE LIST CABLE 3 CR1 ENGINE START 1 PLATFORM LEVEL CUTOUT GR WH 3 CR2 ENGINE RUN 2 FLASHING BEACON RD WH 3 4 C3B CR3 RPM CUTOUT 3 DESCENT ALARM PAD CR4 HIGH RPM 4 AC GENERATOR 79998 CR5 HORN 5 DRIVE LIGHTS CR8 GLOW PLUG 000000 CR9 PLATFORM LEVEL CUTOUT BK CR1 86 8 1 START RELAY CR10 PLATFORM LEVEL CUTOUT OR BK C49 9 LO gt CR23 DRIVE LIGHTS BK 33D LCS a STaRTINEUT 22225 ES RD 27D HC 4 AUX ON BR CR4 85 5 GROUND IGNITION 5 RD CR8 30 LC 6 BATTERY START MODULE WH TB23D 7 KEY PWR DRIVE LIGHT OPTION 8 KEY BYPASS T RD C2B 11 GH BKCGRANBO 9 IGN FUELON WH C49 2 23 L 10 ENG FAULT BR OR RD C3B 3 L RD TB 21 OPTION CONTROL BOX Fio GROUND 10 6 GR BK ISM 9 BK RD 35D_ aay WH 21D 1464 12GA 4 2 BK ISM 1 BR ISM 5 0 alae 49 6 14GA BK RD C49 8 1464 PRO S 5 L m BKAWH 649 7 140 PLATFORM LEVEL CUTOUT CE VERSION ONLY mE MANIFOLD ENGINE HARNESS 5 L 466 OR TB14B 7 jews 1131415 6 7 12 OR BK TB15B C50 BK2D RD ISM 6 RD 11 1 eo BK RD C3B 9 ces m 5 _ TT ENGINE a1 C50 2 BR 52B BR 52C HARNESS C5 C2B 12 5 C7B 3
67. 1 8 3 Timing Adjustment Flex Plate Complete information to perform this procedure is available in the Perkins 403C 11 Workshop Manual Perkins part number TPD1458 Perkins 403C 11 Workshop Manual Genie part number 84817 8 2 RPM Adjustment Refer to maintenance procedure B 9 Check and Adjust the Engine RPM 4 34 A TEREX COMPANY Z 34 22 IC The flex plate acts as a coupler between the engine and the pump It is bolted to the engine flywheel and has a splined center to drive the pump How to Remove the Flex Plate 1 Support the drive pump with a suitable lifting device 2 Remove all of the pump mounting plate to engine fasteners 3 Carefully pull the pump assembly away from the engine and secure it from moving 4 Remove the flex plate mounting fasteners Remove the flex plate from the flywheel Part No 128300 August 2007 Section 4 Repair Procedures REVA How to Install the Flex Plate 1 Install the flex plate onto the flywheel with the raised spline against the flywheel pump b pump shaft pump coupler d flex plate e flywheel 2 Apply removable Loctite thread sealant to the flex plate mounting fasteners Torque the flex plate mounting fasteners to 36 ft Ibs 49 Nm 3 Install the coupler onto the pump shaft with the set screw towards the pump Leave a 1 2 inch 0 8 mm gap between the coupler and pump end plate 4 Apply removable Loctite thread sealant t
68. 16 n 9 49 6 R33STRBK 1 Pod 1 Be elles i STARTER MOTOR 2 E 9 E FUELSOLENOID T 8 3 gt 85 1 5 2 55 gt HN E Sun C1P 1 C27AUX RD 1 1 5 8 2 2 gt e 4 C49 1 C27AUXRD AUXILIARY POWER RELAY 7 C134PWR GR WH 4 7 5 AUXILIARY PUMP lo t AX 55 19 4 lt T 2 28 RD BK C1B 2 Ce8TTARD BK MH pp ES DEM d i 5 3 RD C134PWR MH BK BR 8 1 4 CIBSPLAOR RD 0284 FI i LEVEL SENSOR 1 1 g UR dus amp gt FLASHING BEACON 8 OPTION N 1 1 amp 2 amp E EROR EOM 11 4 EZ 9 C9HRN BK RD C3B 9 C9HRN BK RD 2 NZ gt RELAY C7P 2 P23BAT WH C7B 2 o 1 1 8 a m i 7 1 22 7 1 BK RD CR5487 MH l SERVICE HORN 5 3 9 19 gt LOADSENSE MODULE o 8 gt RD 3 4 4 amaa B E GLOW PLUGS 1 49 7 45 S QU amp 9 2 3 a 49 9 CAIRPMOR BK sma 2 P20BAT RD EH T acd o
69. 1B 8 34 BK WH SP C34SA GLOW PLUG PEE ee a ees SIT ALARM BK ISM 3 BK C1B 7 BK SP C33STR 181 PRIMARY BOOM e GRIBK SP C4B 6 PLAT ROTATE RIGHT WHI RD C54 __ WHIRD 6 32 WH RD SP C32BRK BRAKE RELEASE EXTEND RETRACT C17PRL SP C4B 5 PLAT ROTATE LEFT RD ISM 4 RD C1B 1 27 RD C49 1 RD SP C27AUX AUXILIARY PUMP OR RD 16 C4B 4 DRIVE ENABLE WH ISM 7 7 2 23 WH SP P23BAT KEYSWITCH POWER SURD E ENABLE GEE BK CR5 30 BK C23 4 22 BK SP P22BAT 12 TO PLATFORM E WH CR2 87 21 WH C49 5 WH SP C21IGN IGNITION POWER BIRD COHAN CRS 85 C3B 9 HORN WH 245 ISM 10 C492 OIL WATER SWITCH ORIBK 3 15 OR BK MH OR BK SP C15PLD PLAT LEVEL DOWN OR C4B2 14 OR MH OR SP CI4PLU PLAT LEVEL UP en ees og CABLE 2 BUWH 8 3 3 12 12 C10 1 CI2FTS FOOTSWITCH WHRD 1 31 11 BLIBK SP 11580 BOOM DOWN 3 BL C3B 10 10 BL MH BL SP C10SBU SEC BOOM UP BKWHC3B 8 BKWH MH BKWH SP C8PBR BOOM RETRACT BK C3B 7 7 BK SP C7PBE BOOM EXTEND s WH RD C3B 6 6 WH RD MH WH RD SP BOOM FUNCTION WHIBK C3B 5 5 WH BK MH WH BK SP CSTRR TURN ROTATE RIGHT WH C3B 4 WH MH WH SP C4TRL TURN ROTATE LEFT OPTIONS RD BKC3B2 2 RD BK SP C2PBD PRIMARY BOOM DOWN secte RD C3B 1 1 RD SP C1PBU PRIMARY BOOM UP D 0
70. 206 bar the pump is faulty and will need to be serviced or replaced Component damage hazard Hydraulic pressure in excess of 3000 psi 206 bar may result in severe component damage 6 Remove the pressure gauge and install the hydraulic hose 7 Gasoline LPG models Install the ignition coil wire to the center of the ignition coil Diesel models Release the manual fuel shutoff lever How to Remove the Function Pump Note When removing a hose assembly or fitting the O ring on the fitting and or hose end must be replaced and then torqued to specification during installation Refer to Section 2 Hydraulic Hose and Fitting Torque Specifications 1 Tag disconnect and plug the hydraulic hoses from the pump Bodily injury hazard Spraying AWARNING hydraulic oil can penetrate and burn skin Loosen hydraulic connections very slowly to allow the oil pressure to dissipate gradually Do not allow oil to squirt or spray 2 Remove the pump mounting fasteners Carefully remove the pump 4 37 Section 4 Repair Procedures August 2007 ey HYDRAULIC PUMPS REV 9 3 1 Remove the drain plug from the hydraulic tank and completely drain the tank into a container Drive Pump of suitable capacity Refer to Section 2 Specifications The drive pump is a bi directional variable i displacement piston pump The pump output is ACAUTION njury nazarc Beware controlled by a non feedback proportional h
71. 24 5 17 TEREX COMPANY Z 34 221C G No 128300 SWITCH SHOWN WITH BOOM ROTATED PAST EITHER NON STEER WHEEL 2 ALL LIMIT SWITCHES SHOWN WITH BOOM IN STOWED POSITION EXCEPT AS NOTED SWITCH SHOWN WITH BOOM EXTENDED August 2007 Section 5 Schematics p Electrical Schematic Diesel Models Section 5 Schematics August 2007 prec c R Ground Control Box Switch Panel Wiring Diagram Diesel Models Section 5 Schematics August 2007 M Ground Control Box Switch Panel Wiring Diagram REVA Diesel Models VOLTAGE OIL PRESSURE WATER TEMPERATURE 2 GAUGE GAUGE GAUGE WH 21A 1 WH RD C49 4 GAUGE 2 OPTION BR GND WH BK C49 3 BK 22A RD 134A WH RD 32A P1 RD TS51 LABEL DESCRIPTION LO 4 E P1 EMERGENCY STOP BUTTON p H8 27 3 Nc OF KS1 KEY SWITCH WH 23A
72. 24 Z 34 22 IC Part No 128300 August 2007 Section 4 Repair Procedures REVA 5 1 Secondary Boom How to Disassemble the Secondary Boom AWARNING injury hazard The procedures in this section require specific repair skills lifting equipment and a suitable workshop Attempting this procedure without these skills and tools could result in death or serious injury and significant component damage Dealer service is required Note When removing a hose assembly or fitting the O ring on the fitting and or hose end must be replaced and then torqued to specification during installation Refer to Section 2 Hydraulic Hose and Fitting Torque Specifications 1 Remove the rear turntable cover 2 Place a suitable lifting device under the platform for support Disconnect the battery 4 Remove the cable cover from the side of the jib boom 5 Remove the wire loom from the cables at the platform control box Part No 128300 SECONDARY BOOM COMPONENTS 6 Locate the cables from the primary boom cable track to the platform control box Number each cable and its entry location at the platform control box 7 Open the platform control box 8 Tag and disconnect each wire from the cables in the platform control box AWARNING Electrocution hazard Contact with electrically charged circuits could result in death or serious injury Remove all rings watches and other jewelry 9 Pull the cables out of the p
73. 24 cu in per revolution 4 Flow 3000rpm 3 11 4 L min January 2011 REV Function manifold System relief 3200 psi valve pressure 220 7 bar Primary boom down relief 1600 psi valve pressure 110 bar Secondary boom down relief 1600 psi valve pressure 110 bar Traction manifold Hot oil shuttle relief pressure 2WD models 170 psi 11 7 bar 4WD models 150 psi 10 3 bar Hydraulic filters Hydraulic tank return line filter Beta 10 gt 200 with 25 psi 1 7 bar bypass Medium pressure filter Beta 3 200 Auxiliary pump Medium pressure filter 50 psi Type Fixed displacement gear pump bypass pressure 3 45 bar Displacement 0 5 1 9 L min Auxiliary pump 3400 psi relief pressure 234 5 bar Front drive motors 4WD models Displacement per revolution 1 53 cu in 25 cc Rear drive motors all models Displacement per revolution 1 53 cu in 25 cc Continuous improvement of our products is a Genie policy Product specifications are subject to change without notice 2 4 Z 34 22 IC Part No 128300 2011 Section 2 Specifications Manifold Component Specifications Plug torque SAE No 2 36 in Ibs 4 Nm SAE No 4 10 ft Ibs 18 Nm SAE No 6 14 ft Ibs 19 Nm SAE No 8 38 ft lbs 51 Nm SAE No 10 41 ft lbs 55 Nm SAE No 12 56 ft lbs 76 Nm Valve Coil Resistance Note The following coil resistance sp
74. 250069 A O 3 1 x 3200 psi 3000 psi 2500 52 3 1 1 54 3 1 TEN P1 4 51 52 C1 c2 1 2 4 5 c7 e S M M 1 0 5 E F G H 1 3200 psi E eee EE 1 4 71 75 4 4 1600 1600 psi 42 0 or or 3000 psi 1500 psi 3 1 3 1 6 pr J1 J2 PRI PR2 Sic pp eee 4 4 L N P 5 T U MN Zi IL 7 INL 7 INL WA Wi TAL T IN ZI WIA X 1 gian PE un D ae lt a CH Hi pie RON A P2 0 028 inch ca oa T 3 gpm X 0 1 gpm 7 Ti T2 a T 4 4 4 4 4 4 4 0 035 inch T4 C Mr RTI WR e ucc T3 NOTES 0 052 inch orifice before serial number 5745 0 036 inch orifice after serial number 5744 ES342WL Genie TEREX COMPANY Z 34 22 IC Part No 128300 August 2007 Section 5 Schematics p t Hydraulic Schematic 2WD Models 32 Section 5 Schematics August 2007 e A Hydraulic Schematic 4WD Models Section 5 Schematics August 2007 n
75. 8 ft Ibs 214 Nm to seat the bearings Note Rotate the hub hand while torquing the castle nut to make sure the bearings seat properly 9 Loosen the castle nut one full turn and then torque to 35 ft lbs 47 Nm 10 Install a new cotter pin Bend the cotter pin to lock it in Note Always use a new cotter pin when installing a castle nut 11 Install the dust cap then the tire and wheel assembly Torque the wheel lug nuts to specification Refer to Section 2 Specifications Part No 128300 August 2007 Section 5 Schematics Observe and Obey Troubleshooting and repair procedures shall be completed by a person trained and qualified on the repair of this machine Immediately tag and remove from service damaged or malfunctioning machine Repair any machine damage or malfunction before operating the machine Before Troubleshooting Read understand and obey the safety rules and operating instructions printed in the appropriate Genie Z 34 22 IC Operator s Manual on your machine Be sure that all necessary tools and test equipment are available and ready for use Part No 128300 Genie TEREX 2 34 221 5 1 Schematics About This Section There are two groups of schematics in this section Electrical Schematics AWARNING Electrocution hazard Contact with electrically charged circuits could result in death or serious injury Remove
76. BOOM FUNCTION SPEED CONTROLLER TS1 AUXILIARY TOGGLE SWITCH TS2 ENGINE START TOGGLE SWITCH TS4 HIGH LOW RPM TOGGLE SWITCH TS6 GLOW PLUG TOGGLE SWITCH TS7 PLATFORM ROTATE TOGGLE SWITCH TS8 JIB BOOM UP DOWN TOGGLE SWITCH TS9 PLATFORM LEVEL TOGGLE SWITCH TS10 SECONDARY BOOM UP DOWN TOGGLE SWITCH JIB TS11 PRIMARY BOOM UP DOWN TOGGLE SWITCH TS12 TURNTABLE ROTATE TOGGLE SWITCH 7513 PRIMARY BOOM TOGGLE SWITCH C47 N TS14 DRIVE RANGE TOGGLE SWITCH OPTION OPTION 7815 DRIVE ENABLE TOGGLE SWITCH H1 TILT ALARM L1 DRIVE ENABLE LIGHT ES L4 TILT ALARM LED 148 PLATFORM OVERLOAD LED Y C2P GRAY BLACK GREEN BROWN BRIGND ET J BR GND 47 8 O 1 E oe 2 o 7 gt E C28TTA RD BK 2 o amp u C134PWR GR WH 7 z 3 o gt 9 C12FTS BL WH C3P 12 2 EB C16DE OR RD C4P 4 5 WH BK 5 C4TRL WH C3P 4 C11SBD BL BK C3P 11 C10SBU BL C3P 10 C6MFV WH RD C3P 6 i i TS4 7815 TS12 7510 7 C35RPM BK RD 1 9 E Ou i RAL oa D g P25BAT RD C9 3 i i BK WH 8 TS2 TS6 z C33STR BK C1P 7 i i TS7 C18PRR GR BK C4P 6 TS8 i U C17PRL GR 5 7090 C43JU GR C2P 5 1 TS14 C29MS RD WH C44JD GR BK C2P 6
77. C14PLU OR C4B 2 3 C15PLD OR BK C4B 3 EXTEND B BK PRIMARY BOOM 5 4 EXTEND 4 BK WH n 4 PRIMARY BOOM 89 g RETRACT 7 C7PBE 7 8 C8PBR C3B 8 UP E RD 4 PRIMARY BOOM uP gt 4 im RD BK Ui 5 PRIMARY BOOM zo DOWN g DOWN t E B i 121 zo UP 1 C1PBU RD C3B 1 2 C2PBD RD BK C3B 2 gt UP ER BL lA SECONDARY g E BOOM UP a 1 5 BUBK nt 4 SECONDARY 85 DOWN BOOM DOWN lt 8 B tw R Yos H RR 95 4 DESCENT ALARM ug uP 1 10 C3B 10 12 OPTION S CORNER IER UNI n n 11 C11SBD BLBK C3B 11 8 yo QT He VA y a WH 4 TURNTABLE ul LEFT 3 ROTATE LEFT 8 pg _RIGHT 5 C5TRR WH BK C3B 5 Li 4 C4TRLWH C3B 4 Gaal CS AL a RR RG A 1 RD 3 DLITE OR RD 3 OR RD 4 p 1 wt Yg BK 3 8 4 2095 DRIVE LIGHT rps 1 OPTION 8 lt 5 RD WT vay BK js 38 WH 8 5 AS 2 WH YN BK m AMA WORK LIGHT eee 5 2 E 2 a 8 5 WH
78. CR9 PLATFORM LEVEL CUTOUT 5 2 30 CR10 PLATFORM LEVEL CUTOUT 4 6 BATTERY MODULE CR23 DRIVE LIGHTS RD 7 KEY PWR 8 KEY BYPASS CO 9 IGN FUEL ON DRIVE LIGHT OPTION 10 ENG FAULT RD 2 11 OPTION 23 L BR ORD ca s RD ISM 6 RD 21 6 GR BK ISM 9 BK RD 35D CO ROUND ee WH 14GA WH 21D B HUBAP 40A RD SP 12GA 2 3 4 BK ISM 1 EM 49 6 1464 BK RD 49 8 14GA MANIFOLD mE BK RD MH BL WH C49 10 C49 11 648 7144 PLATFORM LEVEL CUTOUT VERSION ONLY 7 HARNESS MH a 6 L 7 8 OR TB14B H OR BK TB15B H RD 11 1 BK RD 9 BL WH 38D 10 9 BL RD 39D 4 D BR SP BR OPT 4 Er C50 2 BR 52B 52 8 HARNESS C2B 12 OPT 5 W OR BK MH OR MH OR 6 CONTROL BOX GROUND gt He ORIBK 648 3 15 OR BK CR10 OR BK 5P PLAT LEVEL DOWN E OR C4B 2 14 OR CR9 OR SP PLAT LEVEL UP ES34GPW enie A TEREX COMPANY Part No 128300 Z 34 221C 5 11 August 2007 Section 5 Schematics E Ground Control Box Terminal Strip Wiring Diagram Gasoline LPG Models Section 5 Schematics August 2007 _ Platform Control Wiring Diagram Gasoline LPG Models August 2007 Section 5 Schematics REVA Platform Control Box Wiring Di
79. How to Bleed the Slave Cylinder 1 Raise the jib boom to a horizontal position 2 Activate the platform level toggle switch up and down through two platform leveling cycles to remove any air that might be in the system Part No 128300 August 2007 Section 4 Repair Procedures REVA 2 2 Platform Rotator The platform rotator is a hydraulically activated helical gear assembly used to rotate the platform 160 degrees How to Remove the Platform Rotator Note When removing a hose assembly or fitting the O ring if equipped on the fitting and or the hose end must be replaced All connections must be torqued to specification during installation Refer to Section 2 Hydraulic Hose and Fitting Torque Specifications 1 Remove the platform 2 Tag disconnect and plug the hydraulic hoses from the platform rotator manifold Cap the fittings on the manifold AWARNING injury hazard Spraying ydraulic oil can penetrate and burn skin Loosen hydraulic connections very slowly to allow the oil pressure to dissipate gradually Do not allow oil to squirt or spray 3 Support the platform mounting weldment with a suitable lifting device Do not apply any lifting pressure 4 Remove the six mounting bolts from the platform mounting weldment Remove the center bolt and slide the platform mounting weldment off of the platform rotator Part No 128300 PLATFORM COMPONENTS 5 Support the platform rotator with a suit
80. LARM D40 RED 2 C28TTA RD BK C1B 2 C28TTA RD BK MH WH i 1 5 1 i E RD C134PWR MH RD 1 5 i BK BR LEVEL SENSOR FLASHING BEACON OPTION i 1 le SNL 7 HORN 9 BK RD C3B 9 C9HRN BK RD SERVICE HORN RELAY C7P 2 P23BAT WH C7B 2 TB23 CR5 02 7 1 P22BAT BK C7B 1 Electrical Schematic Gasoline LPG Models Section 5 Schematics BK RD CR5 87 MH SERVICE HORN RD BK 134 TB22 PLAT KS1 IND REGULATOR 49 9 _C41RPM sm 9080900 RD P20BAT RD EH s BAT 1 RES ALTERNATOR CB1 an 15 C21IGN WH EH Excl a 10 P20BAT RD C50 1 ES3GP1W PartNo 128300 A TEREX COMPANY Z 34 221C G Section 5 Schematics Electrical Schematic Gasoline LPG Models WH August 2007 REVA WH P24BAT
81. MINAL CIRCUIT DESCRIPTION OPTION 2 134 Ci34PWR KEYSWITCH POWER RD MH C4B 7 134 RD KSI Ci34PWR KEYSWITCH POWER 153 s BR C8 2 BR OPTION 1 52 GND GROUND DRIVE ENABLE BR OPT 2 3 52 BR GND STUD GND GROUND GRIWH C49 12 2 7 45 GRIWH TB35 Ph C45GEN GENERATOR OPTION 4 OPTION 3 C2B 6 44 GRIBK SP 44 0 JIB DOWN BURD CR6 30 BL RD 0284 _ 39 C39LP LP WIRES cincuit FROM DESC LS2 PRIMARY BOOM CR7 30 C1B 12 38 C38FL GAS BK F UP DOWN 9e BK RD CR3430 BK RD C1B 9 35 TB45 BK RD SP C35RPM HIGH RPM Wii 2 5521 ena 182154 2 cis 8 86 1 8 34 BK WH SP C34SA CHOKE GR ETT CORE TSUP BK ISM 3 BK C1B 7 BK SP C33STR START OR CAS E SEF LIMIT SPEED 181 PRIMARY BOOM WH RD 5 4 WH RDCIB 6 32 WH RD SP C32BRK BRAKE RELEASE SUB 75 RD ISM 4 RD C1B 1 27 RD C49 1 RD SP C27AUX AUXILIARY PUMP Sr AO STEER LEFT OPTION 7 2 23 WH SP P23BAT KEYSWITCH POWER WHEE CSIREV m DAVE REVERSE BK CR5 30 BKC7 1 22 BK SP 22 12V TO PLATFORM MEE WH CR2 87 21 WH C49 5 WH SP C21IGN IGNITION POWER AW 252 a HIGHLOWDHIVE ORIBK 3 15 OR BK MH OR BK SP C15PLD PLATFORM LEVEL DOWN pee BoM Na DET ALARM 4 2 14 OR MH OR SP C14PLU PLATFORM LEVEL U
82. ONDARY 5 4 BOOM UP 4 2 a SECONDARY 8 DOWN BOOM DOWN 2 7 85 4 uo uP 10 C10SBU C3B 10 OPTION 11 C11SBD BLBK C3B 11 RIGHT E WHBK TURNTABLE 4 EU ROTATE RIGHT t t WH lA 4 TURNTABLE LEFT i ROTATE LEFT Qu E EE g pg RIGHT C3P 5 C5TRR WH BK C3B 5 4 CATRL WH C3B 4 x a Rc SEES 1 RD C3P 3 gt gt ORAD 938 3 OR RD 4 1 1 3d WT _ 1 BI 205 CE DRIVE LIGHT ips 1 5 RD WT vay WH 5 Ls 4 A o z 1 WH 8D BK ASA WORK LIGHT OPTION i ER EI E ee P 8 2 5 5 2 a 8 5 TEREX COMPANY Z 34 221C G No 128300 SWITCH SHOWN WITH BOOM ROTATED PAST EITHER NON STEER WHEEL 1 ALL LIMIT SWITCHES SHOWN WITH BOOM IN STOWED POSITION EXCEPT AS NOTED SWITCH SHOWN WITH BOOM EXTENDED August 2007 Section 5 Schematics p Electrical Schematic Gasoline LPG Models Section 5 Schematics August 2007 prec c Ground Control Box Switch Panel Wiring Diagram Gasoline LPG Models Section 5 Schematics August 2007
83. P COEUR SE PLATEGEM ROTATE RIGHT 8 3 C3B 12 12 C10 1 CI2FTS FOOTSWITCH CAES PLATFORM ROTATE LEFT J OPTION 3 BL BK 11 BUBK MH BUBK SP C11SBD SECONDARY BOOM DOWN 3 OR RD 16 C81 4 DRIVE ENABLE BL C3B 10 10 BL MH BL SP C10SBU SECONDARY BOOM UP TA TE SIVE ENABLE LIGHT C3B 8 8 BKWH SP C8PBR PRIMARY BOOM RETRACT BUND ns HORN BK C3B 7 7 BK SP C7PBE PRIMARY BOOM EXTEND e RN E ee WH RD C3B 6 6 WH RD MH WH RD SP BOOM FUNCTION FLOW CONTROL mE 52 C3B 5 5 WH BK MH WH BK SP C5TRR TURNTABLE ROTATE RIGHT MS eon 0498 ARIES PUE EUR WH C3B 4 WH MH WH SP CATRL TURNTABLE ROTATE LEFT OPTION 3 3 2 2 RD BK MH RD BK SP C2PBD PRIMARY BOOM DOWN RD C3B 1 1 RD MH RD SP PRIMARY BOOM UP D B A 2 SEE OPTIONAL WIRING CABLE 3 4 000000 Mn CONTROL RELAY 1 0 OPTION NUMBERS SPARE WIRE LIST CR1 ENGINE START 1 PLATFORM LEVEL CUTOUT GR WH 3 S BK CR1 86 CR2 ENGINE RUN 2 FLASHING BEACON RD WH 8 see tee CO 1 START RELAY CR3 RPM CUTOUT 3 DESCENT ALARM C2B C49 9 LC 2 TACHOMETER CR4 HIGH RPM 4 AC GENERATOR CR5 HORN 5 DRIVE LIGHTS CABLE 1 3 START INPUT CR6 FUEL PUMP RD 27D CR7 LPG SOLENOID O 4 AUX ON CR8 CHOKE BR CR4 85 LO 5 GROUND SH TION
84. RNING Crushing hazard The secondary boom lift cylinder could become unbalanced and fall when removed from the machine if not properly supported by the overhead crane Section 4 Repair Procedures August 2007 Kubota D 905 Engine 6 1 Timing Adjustment Complete information to perform this procedure is available in the Kubota D 905 Workshop Manual Kubota part number 97897 02432 Kubota D905 Workshop Manual Genie part number 31742 6 2 Glow Plugs How to Check the Glow Plugs 1 Connect the leads from an ohmmeter between the far left glow plug and ground Result The resistance should be approximately 10 2 If the ohm reading is different than 10 remove the wire and connector plate from the three individual glow plugs Then one glow plug at a time measure the resistance between the glow plug and ground Result The resistance should be approximately 1 8Q for each individual glow plug 3 Install the connector plate and wires to all three glow plugs 4 Turn the key switch to ground control and pull out the red Emergency Stop button to the on position 5 Connect the red positive lead from a volt meter to the number three glow plug Connect the black negative lead to ground 6 Hold the glow plug switch in the on position Result The volt meter should read 12V DC or more Genie Z 34 22 IC REVA 6 3 RPM Adjustment Refer to maintenance procedure B 9 Check and Adj
85. Relay contact Ch Connection amh HM terminal Tilt sensor 6 Rotary OEM m Hour Meter flow control 82 AUX Dy eeu ee COQUE n T PUMP Toggle switch SPDT Circuits crossing pwr connection L PND A m REV qe cm 24 064 DRIVE STEER i T 8 DP1 E Se 1 Ll DAMES RE Toggle switch DPDT F18 10 12V Fuse Battery Drive control Genie TEREX COMPANY 5 2 Z 34 22 IC Part No 128300 August 2007 Section 5 Schematics REVA G1 Pressure gauge test port 10 MICRON 25 psi Filter Fixed displacement pump 9 Bi directional motor Bi directional variable displacement pump 5 2 bi directional motor engine or motor Double acting cylinder Pm 0 035 Orifice with size c Check valve 7 Relief valve 4 Priority flow regulator valve Differential sensing valve Part No 128300 Hydraulic Symbols Legend Ke Solenoid operated proportional valve Solenoid operated 2 pos 3 way directional valve I xh Solenoid operated 3 pos 4 way closed center directional valve PS 3200 psi
86. Y 5 a 5 5 9 ENGINE SPEED 35 BK RD ls 4 RPMCOIL e 2 xd 5 5 1 1 60598 R35RPM BK RD lE E e MC EU ee QM MC GS i ag C2P 7 CA5GEN GR WH C2B 7 C4942 C4SGEN GR WH ACGENERATOR EI a 1 AC GENERATOR 5 eye ane AG 1 1 iji 1 1 1 1 tlt a CIP B 45 CIB 8 i BKWH 1181 T Ye GLOWPLUG RELAY O GLOW 5 1 1 PLUGS WH BRN EE g t lt VOLT METER en 8 GAUGE rf GLOW 1 pg PLUGS M WH C494 C26TSR WH RD 2 WATER TEMPERATURE Aii EER 1 GAUGE 85 WH 49 3 C25PSR GiPRESSURE C1P 7 C33STR BK C1B 7 n 1 GAUGE B 5 1 T ENGINE START WATER TEMPERATURE NN 8 552555982 gt SWITCH 9 E 1 4 WH EH 1 START 9 o C92 245 PRESSURE 1 BK SWITCH p 1 BRN 8 4 8 1 WH HOUR LD gi M p fo 8 Le 4 2 E 5
87. able lifting device Do not apply any lifting pressure 6 Remove the pin retaining fasteners from the jib boom and leveling links to platform rotator pivot pins Do not remove the pins 7 Use a soft metal drift to remove the leveling link pivot pin Lower the leveling links to the ground 8 Support the jib boom and jib boom lift cylinder with an overhead crane 9 Use a soft metal drift to drive both pins out and remove the platform rotator from the machine Crushing hazard The jib boom AWARNING and jib boom lift cylinder could fall when when the platform rotator is removed if not properly supported by the overhead crane Z 34 22 IC 4 7 Section 4 Repair Procedures August 2007 PLATFORM COMPONENTS REVA How to Bleed the Platform 5 Hold the platform rotate toggle switch in the left direction for approximately 5 seconds then Rotator release it 1 Connect a clear hose to the top bleed screw 6 Fully rotate the platform to the left and continue Place the other end of the hose in a container holding the platform rotate toggle switch until air to collect any discharge stops coming out of the bleed screw Immediately release the platform rotate toggle switch and close the bleed screw 7 Rotate the platform to the right until it is centered screw Open the bottom bleed screw but do a 8 Connect the clear hose to the bottom bleed not remove it 9 Rotate the platform to the right and co
88. acked welds 3 Check each lug nut for proper torque Refer to Section 2 Specifications 4 Check the pressure in each air filled tire Refer to Section 2 Specifications Section 3 Scheduled Maintenance Procedures August 2007 CHECKLIST B PROCEDURES B 6 Confirm the Proper Brake Configuration Note Genie requires that this procedure be performed every 250 hours or quarterly whichever comes first Proper brake configuration is essential to safe operation and good machine performance Hydraulically released spring applied individual wheel brakes can appear to operate normally when they are actually not fully operational 1 Check each torque hub disconnect cap to be sure it is in the engaged position brake disengaged position p arf RM brake engaged position A TEREX Z 34 22 IC 7 Check the Oil Level in the Drive Hubs Note Genie requires that this procedure be performed every 250 hours or quarterly whichever comes first Failure to maintain proper drive hub oil levels may cause the machine to perform poorly and continued use may cause component damage 1 Drive the machine to rotate the hub until the plugs are located one on top and the other at 90 degrees plugs 2 Remove the plug located at 90 degrees and check the oil level Result The oil level should be even with the bottom of the plug hole If necessary remove the top
89. act 0 004 from the reading of each cell for every 10 12 C below 80 F 26 72 C Result All battery cells display a specific gravity of 1 277 or greater The battery is fully charged Proceed to step 10 Result The difference in specific gravity readings between cells is greater than 0 1 OR the specific gravity of one or more cells is less than 1 217 Replace the battery Check the battery acid level If needed replenish with distilled water to 1 8 inch 3 mm below the bottom of the battery fill tube Do not overfill Install the vent caps and neutralize any electrolyte that may have spilled A TEREX COMPANY 3 18 Z 34 22 IC Part No 128300 August 2007 Section 3 Scheduled Maintenance Procedures REVA B 4 Inspect the Electrical Wiring Note Genie requires that this procedure be performed every 250 hours or quarterly whichever comes first Maintaining electrical wiring in good condition is essential to safe operation and good machine performance Failure to find and replace burnt chafed corroded or pinched wires could result in unsafe operating conditions and may cause component damage AWARNING Electrocution hazard Contact with hot or live circuits may cause death or serious injury Remove all rings watches and other jewelry 1 Inspect the following areas for burnt chafed corroded and loose wires Engine compartment electrical panel Engine wiring harness Inside of the g
90. agram Gasoline LPG Models SPARE WIRES LABEL DESCRIPTION RD WH 3 P2 EMERGENCY STOP BUTTON BURD 1 P3 HORN BUTTON BLWH 1 DP1 __ DRIVE CONTROLLER BOOM FUNCTION SPEED CONTROLLER TS1 AUXILIARY TOGGLE SWITCH TS2 ENGINE START TOGGLE SWITCH TS3 FUEL SELECT TOGGLE SWITCH TS4 HIGH LOW RPM TOGGLE SWITCH TS6 CHOKE TOGGLE SWITCH TS7 PLATFORM ROTATE TOGGLE SWITCH TS8 JIB BOOM UP DOWN TOGGLE SWITCH TS9 PLATFORM LEVEL TOGGLE SWITCH JIB TS10 SECONDARY BOOM UP DOWN TOGGLE SWITCH 7511 PRIMARY BOOM UP DOWN TOGGLE SWITCH 1512 TURNTABLE ROTATE TOGGLE SWITCH C47 R TS13 EXTEND RETRACT TOGGLE SWITCH OPTION OPTION 1914 DRIVE RANGE TOGGLE SWITCH 1515 DRIVE ENABLE TOGGLE SWITCH Al TILT ALARM FS L1 DRIVE ENABLE LIGHT 14 TILT ALARM LED C9
91. aintenance Symbols Legend The following symbols have been used in this manual to help communicate the intent of the instructions When one or more of the symbols appear at the beginning of a maintenance procedure it conveys the meaning below Indicates that tools will be required to perform this procedure Indicates that new parts will be required to perform this procedure Indicates that a cold engine will be required to perform this procedure Indicates that a warm engine will be required to perform this procedure Indicates that dealer service will be required to perform this procedure A TEREX 3 2 Z 34 22 IC Pre delivery Preparation Report The pre delivery preparation report contains checklists for each type of scheduled inspection Make copies of the Pre delivery Preparation report to use for each inspection Store completed forms as required Maintenance Schedule There are five types of maintenance inspections that must be performed according to a schedule daily quarterly semi annually annual and two year The Scheduled Maintenance Procedures Section and the Maintenance Inspection Report have been divided into five subsections A B C D and E Use the following chart to determine which group s of procedures are required to perform a scheduled inspection Inspection Checklist Daily or every 8 hours A Quarterly or every 250 hours A B Semi annually or every 500 h
92. aintenance procedures and additional engine information is available in the Kubota D905 Operator s Manual Kubota part number 16622 8916 5 OR the Kubota DF752 Operator s Manual Kubota part number EG601 8916 1 OR the Perkins 403C 11 User s Handbook Perkins part number 100816460 Kubota D905 Operator s Manual to lock it in Genie part number 31743 Note Always use a new cotter pin when installing Kubota DF752 Operator s Manual a castle nut Genie part number 84250 23 Install th i 3 Install the dust cap then the tire and wheel Perkins 403 11 User s Handbook assembly Torque the wheel lug nuts to si Genie number 97360 specification Refer to Section 2 Specifications Genie Part No 128300 Z 34 22 IC 3 47 Section 3 Scheduled Maintenance Procedures August 2007 CHECKLIST E PROCEDURES E 4 Perform Engine Maintenance Perkins 403C 11 Models Note Engine specifications require that this procedure be performed every 3000 hours Required maintenance procedures and additional engine information is available in the Perkins 403C 11 User s Handbook Perkins part number 100816460 Perkins 403C 11 User s Handbook Genie part number 97360 REVA TEREX COMPANY 3 48 Z 34 22 IC Part No 128300 August 2007 Section 4 Repair Procedures Observe and Obey Repair procedures shall be completed by a person trained and qualified on the repair of this mac
93. alled into Aluminum SAE Dash size Torque 4 11 ft lbs 14 9 Nm 6 23 ft lbs 31 2 Nm 8 40 ft Ibs 54 2 Nm 10 69 ft lbs 93 6 Nm 12 93 ft lbs 126 1 Nm 16 139 ft Ibs 188 5 Nm 20 172 ft lbs 233 2 Nm 24 208 ft lbs 282 Nm SAE O ring Boss Port SPECIFICATIONS Seal Lok fittings 1 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 Note The O rings used in the Parker Seal Lok fittings and hose ends are custom size O rings They are not standard SAE size O rings They are available in the O ring field service kit Genie part number 49612 2 Lubricate the O ring before installation 3 Be sure that the face seal O ring is seated and retained properly 4 Position the tube and nut squarely on the face seal end of the fitting and tighten the nut finger tight 5 Tighten the nut or fitting to the appropriate torque per given size as shown in the table 6 Operate all machine functions and inspect the hoses and fittings and related components to confirm that there are no leaks Seal Lok Fittings tube fitting installed into Steel hose end SAE Dash size Torque SAE Dash size Torque 4 16 ft lbs 21 7 Nm 4 18 ft lbs 25 Nm 6 35 ft lbs 47 5 Nm 6 30 ft lbs 40 Nm 8 60 ft lbs 81
94. arings including the pressed in races must be replaced 10 Remove the castle nut 11 Pull the hub off of the spindle The washer and outer bearing should fall loose from the hub 12 Place the hub on a flat surface and gently pry the bearing seal out of the hub Remove the rear bearing 13 Pack both bearings with clean fresh grease 14 Place the large inner bearing into the rear of the hub 15 Install a new bearing grease seal into the hub by pressing it evenly into the hub until it is flush Note Always replace the bearing grease seal when removing the hub Part No 128300 August 2007 Section 3 Scheduled Maintenance Procedures REVA 16 Slide the hub onto the yoke spindle Component damage hazard Do not apply excessive force or damage to the lip of the seal may occur 17 Fill the hub cavity with clean fresh grease 18 Place the outer bearing into the hub 19 Install the washer and castle nut 20 Tighten the castle nut to 158 ft lbs 214 Nm to seat the bearings Note Rotate the hub by hand while torquing the castle nut to make sure the bearings seat properly 21 Loosen the castle nut one full turn and then torque to 35 ft lbs 47 Nm 22 Install a new cotter pin Bend the cotter pin CHECKLIST E PROCEDURES E 3 Perform Engine Maintenance Note Engine specifications requires that this procedure be performed every 2000 hours or every two years whichever comes first Required m
95. ary boom lift cylinder Carefully lower the boom onto the lift cylinder safety chock Crushing hazard Keep hands AWARNING away from the cylinder and all moving parts when lowering the secondary boom Note The lift cylinder safety chock is available through Genie Service Parts part number 36555 2 Before serial number 5204 Locate the grease fitting on the inside of the bearing in the middle of the turntable After serial number 5203 Locate the grease fitting in front of the function manifold below the ground control box 3 Pump grease into the turntable rotation bearing Rotate the turntable in increments of 4 to 5 inches 10 to 13 cm at a time and repeat this step until the entire bearing has been greased Part No 128300 August 2007 Section 3 Scheduled Maintenance Procedures REVA 4 Before serial number 5204 Remove the safety chock Lower the boom to the stowed position 5 Locate the grease fitting on the worm drive housing a grease fitting 6 Pump grease into the gear until you see it coming out of the side of the gear housing 7 Grease each tooth on the outside of the turntable rotation bearing Grease Specification Chevron Ultra duty grease EP NLGI 2 lithium based or equivalent Part No 128300 Genie 2 34 22 IC CHECKLIST A PROCEDURES A 11 Replace the Drive Hub Oil Note Manufacturer drive hub specifications require that this one time procedure be perfo
96. ation Machine parked on a firm level surface Boom in the stowed position Turntable rotated with the boom between the non steer wheels Key switch in the off position with the key removed Wheels chocked All external AC power supply disconnected from the machine Part No 128300 A TEREX COMPANY Z 34 22 IC 3 1 About This Section This section contains detailed procedures for each scheduled maintenance inspection Each procedure includes a description safety warnings and step by step instructions Symbols Legend A Safety alert symbol used to alert personnel to potential personal injury hazards Obey all safety messages that follow this symbol to avoid possible injury or death Indicates an imminently hazardous Situation which if not avoided will result in death or serious injury AWARNING Indicates a potentially hazardous situation which if not avoided could result in death or serious injury Indicates a potentially hazardous A CAUTION situation which if not avoided may cause minor or moderate injury Indicates a potentially hazardous situation which if not avoided may result in property damage O Indicates that a specific result is expected after performing a series of steps W Indicates that an incorrect result has occurred after performing a series of steps Section 3 Scheduled Maintenance Procedures August 2007 SCHEDULED MAINTENANCE PROCEDURES M
97. ator Diesel Models Note Genie specifications require that this procedure be performed every 200 hours or monthly whichever comes first Proper maintenance of the fuel filter water separator is essential for good engine performance Failure to perform this procedure can lead to poor engine performance and component damage Explosion and fire hazard Engine fuels are combustible Perform this procedure in an open well ventilated area away from heaters sparks flames and lighted tobacco Always have an approved fire extinguisher within easy reach Note Perform this procedure with the engine off 1 Locate the fuel filter water separator and loosen the vent plug located on the fuel filter water separator head 2 Loosen the drain plug located at the bottom of the bowl Allow the water to drain into a suitable container until fuel starts to come out Immediately tighten the drain plug Part No 128300 August 2007 Section 3 Scheduled Maintenance Procedures REVA head bolt b ventplug separator head d filter bowl e drain plug 3 Tighten the vent plug and clean up any spills or wet surfaces Note If the fuel bowl is completely drained you must prime or bleed the fuel filter water separator before starting the engine See step 5 4 Startthe engine from the ground controls and check the fuel filter water separator for leaks Part No 128300 Geni
98. balanced and fall if not properly supported when removed from the machine 7 Support and secure the hydraulic tank to a suitable lifting device Remove the hydraulic tank from the machine 8 Remove the suction strainers and clean them using a mild solvent 9 Rinse out the inside of the tank using a mild solvent 10 Install the suction strainers using a pipe thread sealant on the threads 11 Install the drain plug into the tank using a pipe thread sealant on the threads 12 Install the hydraulic tank on to the machine Install the hydraulic tank hold down straps and tighten the retaining fasteners 13 Fill the tank with hydraulic oil until the fluid until the fluid is within the top 2 inches 5 1 cm of the sight gauge Do not overfill 14 Clean up any oil that may have spilled Properly discard of oil 15 Start the engine and check for leaks Section 3 Scheduled Maintenance Procedures August 2007 CHECKLIST E PROCEDURES E 2 Grease the Steer Axle Wheel Bearings 2WD Models Note Genie requires that this procedure be performed every 2000 hours or every two years whichever comes first Maintaining the steer axle wheel bearings is essential for safe machine operation and service life Operating the machine with loose or worn wheel bearings may cause an unsafe operating condition and continued use may result in component damage Extremely wet or dirty conditions or regular steam cleaning and pressure
99. booms to full height Visually inspect the the dial indicator to be sure the needle returns to the 0 position 9 Remove the dial indicator and rotate the turntable 90 10 Repeat steps 4 through 9 until the rotation bearing has been checked in at least four equally spaced areas 90 apart 11 Lower the primary and secondary booms to the stowed position and turn the machine off 12 Remove the dial indicator from the machine A TEREX Z 34 22 IC 0 7 Perform Engine Maintenance Note Engine specifications requires that this procedure be performed every 1000 hours or annually whichever comes first Required maintenance procedures and additional engine information is available in the Kubota D905 Operator s Manual Kubota part number 16622 8916 5 OR the Kubota DF752 Operator s Manual Kubota part number EG601 8916 1 OR the Perkins 403C 11 User s Handbook Perkins part number 100816460 Kubota D905 Operator s Manual Genie part number 31743 Kubota DF752 Operator s Manual Genie part number 84250 Perkins 403C 11 User s Handbook Genie part number 97360 Part No 128300 August 2007 Section 3 Scheduled Maintenance Procedures Checklist E Procedures REVA E 1 Test or Replace the Hydraulic Oil Note Genie requires that this procedure be performed every 2000 hours or two years whichever comes first Replacement or testing of the hydraulic oil is essent
100. cedures August 2007 MANIFOLDS REVA E 999 Os Cm v Os 100 Or cin NO lt J A 9 NGN N 9 666636006 gt lt na u Q S gt A G YB 9 S I SEIN N 4 BEX 2 9 DOE AS 2 9 6 LT 2 34 22 1 128300 Section 4 Repair Procedures August 2007 MANIFOLDS Function Manifold Components continued The function manifold is mounted to the turntable under the ground control box Index Schematic No Description Item Function 16 Solenoid valve 2 position 3 way Pits Secondary boom up 17 Solenoid valve 2 position 3 way Turntable rotate left 18 Solenoid valve 2 position way Platform level up 19 Solenoid valve 2 position 3 way Tasas Primary boom extend 20 Solenoid valve 2 position way S uses Primary boom down 21 Solenoid valve 2 position 3 way Secondary boom down 22 Solenoid valve 2 position 3 way Turntable rotate right 23 Orifice 0 052 inch 1 32 mm Xu Turntable rotate circuit 24 Solenoid valve 2 position way Platform level down 25 Orifice 0 052 inch 1 32 mm Turntable rotate circuit G
101. cification plus or minus 30 replace the coil MANIFOLDS Valve Coil Resistance Specification Note The following coil resistance specifications are at an ambient temperature of 68 F 20 C As valve coil resistance is sensitive to changes in air temperature the coil resistance will typically increase or decrease by 4 for each 18 F 8 C that your air temperature increases or decreases from 68 F 20 Valve coil specifications 2 position 3 way solenoid valve 10V DC 60 schematic items L Q R T AA AB BA and BB 3 position 4 way solenoid valve 10V DC 60 schematic item Cl Proportional solenoid valve 12V DC 50 schematic item 0 Genie Part No 128300 TEREX COMPANY Z 34 22 IC 4 51 Section 4 Repair Procedures August 2007 MANIFOLDS How to Test a Coil Diode Genie incorporates spike suppressing diodes in all of its valve coils 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 Faulty diodes can fail to protect the electrical system resulting in a tripped circuit breaker or component damage AWARNING Electrocution hazard Contact with electrically charged circuits could result in death or serious injury Remove all rings watches and other jewelry 1 the coil for re
102. cluding shims from the platform end of the boom Note Pay careful attention to the location and amount of shims used with each wear pad 5 Carefully rotate the barrel end of the extension cylinder until the pin mounting bore is ina vertical position 6 Attach a lifting strap from an overhead crane to the extension tube at the platform end Part No 128300 TEREX COMPANY Z 34 22 IC PRIMARY BOOM COMPONENTS 7 Support and slide the extension tube out of the outer primary boom tube Place the extension boom tube on blocks for support Crushing hazard The boom tubes AWARNING could become unbalanced and fall if not properly supported by the overhead crane Note During removal the overhead crane strap will need to be carefully adjusted for proper balancing 8 Remove the external snap rings from the extension cylinder rod end pivot pins at the platform end of the extension tube Use a soft metal drift to remove the pins 9 Support and slide the extension cylinder out of the base end of the extension tube Place the extension cylinder on blocks for support Note During removal the overhead crane strap will need to be carefully adjusted for proper balancing 10 Remove and label the wear pads from the extension cylinder Note Pay careful attention to the location of each wear pad Section 4 Repair Procedures August 2007 PRIMARY BOOM COMPONENTS 4 3 Primary Boom Lift Cylinder The lift cylind
103. connections very slowly to allow the oil pressure to dissipate gradually Do not allow oil to squirt or spray 19 Using the overhead crane lower the boom assembly to the fully stowed position 20 Pull all the cables and hoses through the upper pivot Component damage hazard Cables and hoses can be damaged if they are kinked or pinched Genie Z 34 22 IC REVA 21 Position a lifting strap from the overhead crane approximately 2 feet 60 cm from the platform end of the primary boom Measure from the platform end of the primary boom tube 22 Remove the pin retaining fasteners from the upper pivot to upper secondary compression arm pivot pins Place a rod through the compression arm pivot pin and twist to remove the pins 23 Swing the compression arms down and out of the way Secure them from moving 24 Remove the pin retaining fasteners from the upper pivot to the upper secondary boom pivot pin Use a soft metal drift to remove the pin 25 Carefully remove the entire primary boom assembly from the machine primary boom assembly jib boom assembly platform master cylinder primary lift cylinder and upper pivot AWARNING Crushing hazard The primary boom assembly could become unbalanced and fall when removed from the machine if not properly supported by the overhead crane Do not remove the assembly from the machine until it is properly balanced Note During removal the overhead crane strap will need to b
104. could get into machine components and cause damage other lifting or supporting device is fully capable of supporting and stabilizing the weight to be lifted Use only chains or straps that are in good condition and of ample capacity Be sure any forklift overhead crane or Be sure ds fasteners intended for one time use i e cotter pins and self locking nuts are not reused These components may fail if they are used a second time Be sure to properly dispose of old oil or 27 other fluids Use an approved container aw Please be environmentally safe Sure that your workshop or work area is properly ventilated and well lit Part No 128300 August 2007 Table of Contents Introduction IMportantlNfOrMation SRS li SetialiNumber Informatiohi uuo cte etr etit nme Serial Number iii Section 1 Safety Rules General Safety Rules dci eine Section2 Rev Specifications B Machine Specifications 00000000 nennen nennen 2 1 Performance Specifications 2 2 Hydraulic Oil Specifications eee 2 3 Hydraulic Component 2 4 Manifold Component Speci
105. death or serious injury and component damage 1 Grease the turntable bearing See A 10 Grease the Turntable Bearing and Rotate Gear 2 Torque the turntable bearing bolts to specification See D 5 Check the Turntable Rotation Bearing Bolts 3 Raise the primary and secondary booms to full height using the ground controls Do not extend the primary boom Part No 128300 Genie 2 34 22 IC CHECKLIST D PROCEDURES 4 Place a dial indicator between the drive chassis and the turntable at a point that is directly under or in line with the boom and no more than 1 inch 2 5 cm from the bearing Note To obtain an accurate measurement place the dial indicator no more than 1 inch 2 5 cm from the turntable rotation bearing turntable dial indicator drive chassis turntable rotation bearing 5 Adjust the dial indicator to 0 6 Lower the secondary boom to the stowed position and lower the primary boom to a horizontal position Fully extend the primary boom 7 Note the reading on the dial indicator Result The measurement is less than 0 055 inch 1 4 mm The bearing is good Result The measurement is more than 0 055 inch 1 4 mm The bearing is worn and needs to be replaced Section 3 Scheduled Maintenance Procedures August 2007 CHECKLIST D PROCEDURES 8 Fully retract the primary boom Raise the primary and secondary
106. dle select B 13 Fuel select Gasoline LPG models B 14 Drive brakes A 10 Grease rotation bearing Perform after 150 hours A 11 Drive hub oil Perform every 200 hours A 12 Engine maintenance Kubota models A 13 Fuel filter water separator Diesel models B 15 Drive speed stowed B 16 Drive speed raised or extended B 17 Fuel and hydraulic tank cap venting B 18 Hydraulic oil analysis B 19 Alarm package if equipped Perform every 400 hours Comments Part No 128300 B 20 Replace fuel filter separator Diesel models B 21 Engine maintenance Kubota D905 models A TEREX COMPANY Z 34 22 IC Section 3 Scheduled Maintenance Procedures MAINTENANCE INSPECTION REPORT Model Serial number Date Hour meter Machine owner Inspected by print Inspector signature Inspector title Inspector company Instructions Make copies of this page to use for each inspection Select the appropriate checklist s for the type of inspection to be performed Daily or 8 hour Inspection A Quarterly or 250 hour Inspection Semi annually 500 hour Inspection A B C Annual or 1000 hours Inspection A B C D 2 Year or 2000 hour Inspection A B C D E Place a check in the appropriate box after each inspection procedure is completed Use the step by step procedures in this section to learn how to perform these inspect
107. e 2 34 22 IC CHECKLIST A PROCEDURES Bleed the fuel system Note Before bleeding the system fill the fuel tank 5 Loosen the vent plug screw located on the filter head 6 Operate the hand primer until fuel free of air flows from the vent plug screw Tighten the vent plug screw on the filter head 7 Loosen the vent screw located on top of the fuel injection pump 8 Operate the hand primer until fuel free of air flows from the vent plug screw Tighten the vent plug screw on the injection pump 9 Clean up any fuel that may have spilled 10 Attempt to start the engine using the starter motor for a maximum of 15 seconds resting the starter for 30 seconds before trying again 11 Inspect the fuel filter water separator for leaks Explosion and fire hazard If a fuel leak is discovered keep any additional personnel from entering the area and do not operate the machine Repair the leak immediately Note Information to perform this procedure is also available in the Kubota D905 Operator s Manual Kubota part number 16622 8916 5 OR the Perkins 403C 11 User s Handbook Perkins part number 100816460 Kubota D905 Operator s Manual Genie part number 31743 Perkins 403C 11 User s Handbook Genie part number 97360 Section 3 Scheduled Maintenance Procedures August 2007 Checklist B Procedures B 1 Check the Engine Choke Gasoline LPG Models Note Genie requires that this procedure be perform
108. e cannot move in either direction 2 the engine from the platform controls Slowly move the drive joystick to full stroke in either direction Result The engine rpm lowers considerably as if the engine is under a heavy load but does not stall The charge pressure relief valve is set correctly Proceed to step 8 Wi Result The engine rpm does not lower considerably The charge pressure relief valve is set too low Proceed to step 3 to adjust the charge pressure relief valve Result The engine stalls The charge pressure relief valve is set too high Proceed to step 3 to adjust the charge pressure relief valve REV A Turn the engine off Connect a 0 to 600 psi 0 to 40 bar pressure gauge to the test port located on the traction manifold Start the engine from the platform controls Slowly move the drive joystick to full stroke in either direction and observe the pressure reading on the pressure gauge Result When the charge pressure relief valve is set correctly the pressure reading on the gauge should be between 135 to 180 psi 9 to 12 bar Turn the engine off Hold the relief valve and remove the cap item B or BD Adjust the internal hex socket Turn it clockwise to increase the pressure or counterclockwise to decrease the pressure Install the relief valve cap Repeat this procedure beginning with step 2 Remove the wheel chocks Turn the engine off and remove the pressure gauge G
109. e carefully adjusted for proper balancing 26 Place the entire assembly onto a structure capable of supporting it Part No 128300 August 2007 Section 4 Repair Procedures REVA 27 Remove the pin retaining fasteners from the upper secondary compression arm pivot pins Do not remove the pins 28 Position a lifting strap from an overhead crane at the center of the control box side upper compression arm 29 Place a rod through the compression arm pivot pin and twist to remove the pin Remove the compression arm from the machine AWARNING Crushing hazard The upper compression arm could become unbalanced and fall when removed from the machine if not properly supported by the overhead crane 30 Repeat step 29 for the engine side upper compression arm 31 Remove the plastic plug in the bulkhead to access the secondary boom lift cylinder rod end pivot pin 32 Remove the pin retaining fasteners from the rod end of the secondary boom lift cylinder Use a soft metal drift to remove the pin Secure the cylinder from moving 33 Remove the pin retaining fasteners from the lower pivot pin of the compression link Use a soft metal drift to remove the pin 34 Attach a lifting strap from an overhead crane to the upper secondary boom Part No 128300 TEREX COMPANY Z 34 22 IC SECONDARY BOOM COMPONENTS 35 Remove the pin retaining fasteners from the mid pivot to upper secondary boom pivot pin Use a soft me
110. e concentration ethylene glycol to BS 6580 1992 or ASTMD 3306 89 or AS 2108 1977 Lubrication system Oil pressure hot 2000 rpm 40 to 60 psi 2 76 to 4 14 bar Oil capacity including filter 4 3 quarts 4 07 liters Oil viscosity requirements Units ship with 15W 40 Extreme operating temperatures may require the use of alternative engine oils For oil requirements refer to the Engine Operator Handbook on your machine A TEREX Z 34 22 IC Injection system REV Injection pump make Bosch Injection timing 23 BTDC 3000 rpm Injection pump pressure Fuel requirement 2133 psi 150 bar diesel number 2 D Battery Type 12V DC Group 34 78 Quantity 1 Ampere hour 75AH Cold cranking ampere 900A Reserve capacity 25 rate 125 minutes Alternator Output 40A 12V DC Fan belt deflection 3 16 inch 5 Continuous improvement of our products is a Genie policy Product specifications are subject to change without notice Part No 128300 2011 Section 2 Specifications REV B Hydraulic Hose and Fitting Torque Specifications Your machine is equipped with Parker Seal Lok fittings and hose ends Genie specifications require that fittings and hose ends be torqued to specification when they are removed and installed or when new hoses or fittings are installed SAE O ring Boss Port tube fitting inst
111. ecifications are subject to change without notice Part No 128300 2011 Kubota DF 752 Engine Displacement 45 21 cu in 0 74 liters Number of cylinders 3 2 68 x 2 68 inches 68 x 68 mm Bore amp stroke Horsepower gross intermittent 24 8 3600 rpm 18 5 kW 3600 rpm Firing order 1 2 3 Low idle 1600 rpm 320 hz High idle 3000 rpm 600 hz Governor centrifugal ball mechanical Compression ratio 9 2 1 Compression pressure 128 to 185 psi 8 8 to 12 7 bar 0 0057 to 0 0072 inches 0 145 to 0 085 mm Valve clearances cold Lubrication system Oil pressure 28 to 64 psi operating temp 3850 rpm 1 9 to 4 4 bar Oil capacity 3 4 quarts including filter 3 25 liters Oil viscosity requirements Units ship with 15W 40 Extreme operating temperatures may require the use of Section 2 Specifications Starter motor SPECIFICATIONS Brush length new 0 669 in 17mm Brush length wear limit 0 453 in 11 5 Brush spring tension 50 to 91 ounces 13 7 to 25 5 Newtons Battery Type 12V DC Group 34 78 Quantity 1 Ampere hour 75AH Cold cranking ampere 900A Reserve capacity 25A rate 125 minutes Ignition System Ignition spark advance 18 BTDC Ignition coil primary 1 3 to 1 60 resistance 75 F 24 C Ignition coil secondary resistance 10 7 to 14 5 kQ 75 F 24 C 1 Spark
112. ecifications are at an ambient temperature of 68 F 20 C As valve coil resistance is sensitive to changes in air temperature the coil resistance will typically increase or decrease by 4 for each 18 F 20 C that your air temperature increases or decreases from 68 F 20 C Valve coil specifications 2 position 3 way solenoid valve 10V DC 60 schematic items L M N O P Q R S T U AA AB BA and BB 3 position 4 way solenoid valve 10V DC 60 schematic item Proportional solenoid 12V DC 50 schematic D Part No 128300 A TEREX Z 34 22 IC PANY SPECIFICATIONS Machine Torque Specifications Platform rotator 3 4 10 center bolt GR 8 dry 380 ft lbs 515 3 4 10 center bolt GR 8 lubricated 280 ft lbs 379 Nm 3 8 16 bolts GR 8 dry 44 ft lbs 60 Nm 3 8 16 bolts GR 8 lubricated 33 ft lbs 45 Nm Turntable rotate assembly Rotate bearing mounting bolts lubricated 180 ft lbs 244 Nm Rotate bearing motor 93 ft lbs mounting bolts lubricated 126 Nm Drive motor and hubs Drive hub mounting bolts lubricated 180 ft lbs 244 Nm Drive motor mounting bolts lubricated 3 8 16 GR5 23 ft lbs 31 Nm 7 16 14 GR 5 37 ft lbs 50 Nm Continuous improvement of our products is a Genie policy Product specifications are subject to change without notice Section 2 Specifications January 2011 SPECIFICATIONS Kubota D 905
113. ed Emergency Stop button to the on position 3 Start the engine from the ground controls and operate each boom function through a partial cycle at the ground controls Result All boom functions should operate Section 3 Scheduled Maintenance Procedures August 2007 CHECKLIST B PROCEDURES B 11 Test the Platform Self leveling Note Genie requires that this procedure be performed every 250 hours or quarterly whichever comes first Automatic platform self leveling throughout the full cycle of boom raising and lowering is essential for safe machine operation The platform is maintained at level by the platform leveling slave cylinder which is controlled by the master cylinder located at the base of the primary boom A platform self leveling failure creates an unsafe working condition 1 Turn the key switch to ground control and pull out the red Emergency Stop button to the on position Lower the boom to the stowed position 3 Adjust the platform to a level position using the platform leveling switch 4 Raise and lower the primary boom through a full cycle Result The platform should remain level at all times to within 5 degrees A TEREX Z 34 22 IC 12 Test the Engine Idle Select Note Genie requires that this procedure be performed every 250 hours or quarterly whichever comes first A properly operating engine idle select switch is essential to good e
114. ed every 250 hours or quarterly whichever comes first A properly functioning choke is essential to good engine performance An improperly functioning choke will result in difficulty with engine starting Note The manual choke is solenoid operated and is only operational in the gasoline mode This choke will not operate in propane mode 1 Check the choke linkage connections choke solenoid linkage lock nuts Turn the key switch to ground control and then pull out the ground control red Emergency Stop button to the on position While operating the choke switch inspect the choke solenoid Result The choke solenoid should be fully retracted when the choke switch is activated Turn the key switch to platform control Pull out the platform control red Emergency Stop button to the on position and then operate the choke switch and listen for choke solenoid operation TEREX COMPANY 3 16 Z 34 22 IC Part No 128300 August 2007 Section 3 Scheduled Maintenance Procedures REVA CHECKLIST B PROCEDURES B 2 B 3 Check the Exhaust System Note Genie requires that this procedure be performed every 250 hours or quarterly whichever comes first Maintaining the exhaust system is essential to good engine performance and service life Running the engine with a damaged or leaking exhaust system can cause component damage and unsafe operating conditions AWARNING Bod
115. el that may have spilled Remove the fuel tank retaining plate fasteners at the bulkhead Remove the fuel tank from the machine using an appropriate lifting device Note Clean the fuel tank and inspect for cracks and damage before installing A TEREX COMPANY Part No 128300 Z 34 22 IC Section 4 Repair Procedures August 2007 FUEL AND HYDRAULIC TANKS 11 2 Hydraulic Tank The primary functions of the hydraulic tank are to cool clean and deaereate the hydraulic fluid during operation It utilizes internal suction strainers for the pump supply suction lines and has an external return line filter How to Remove the Hydraulic Tank 1 Place a suitable container under the hydraulic tank Refer to Section 2 Specifications 2 Remove the drain plug from the hydraulic tank and completely drain the tank into a container of suitable capacity Refer to Section 2 Specifications Bodily injury hazard Beware of ACAUTION hot oil Contact with hot oil may cause severe burns 3 Tag disconnect and plug the hoses from the return filter Cap the fittings on the return filter 4 Tag disconnect and plug the suction hoses from the bottom of the tank Cap the fittings 5 Remove the fasteners from the hydraulic tank hold down straps Remove the straps 6 Remove the turntable cover using a suitable lifting device Crushing hazard The turntable AWARNING cover could become unbalanced and fall if not properly supported
116. ell crank at the extension boom Use a soft metal drift to remove the pin 6 Use a soft metal drift to remove the slave cylinder rod end pivot pin 7 Remove the jib boom bell crank from the extension boom Crushing hazard The jib boom AWARNING bell crank could become unbalanced and fall when the pins are removed if not properly supported and secured to the lifting device Genie Z 34 22 IC REVA 3 3 Jib Boom Lift Cylinder How to Remove the Jib Boom Lift Cylinder Note Perform this procedure with the boom in the stowed position Note When removing a hose assembly or fitting the O ring on the fitting and or hose end must be replaced and then torqued to specification during installation Refer to Section 2 Hydraulic Hose and Fitting Torque Specifications 1 Raise the jib boom slightly and place blocks under the platform mounting weldment Lower the jib boom until the platform is resting on the blocks Part No 128300 August 2007 Section 4 Repair Procedures lt lt lt _ JIB BOOM COMPONENTS 2 Tag disconnect and plug the jib boom lift cylinder hydraulic hoses Cap the fittings on the jib boom lift cylinder AWARNING injury hazard Spraying ydraulic oil can penetrate and burn skin Loosen hydraulic connections very slowly to allow the oil pressure to dissipate gradually Do not allow oil to squirt or spray 3 Remove the pi
117. els Disconnect the ignition coil wire from the center of the ignition coil Diesel models Hold the manual fuel shutoff lever clockwise to the closed position 3 Crank the engine with the starter motor for 15 seconds wait 15 seconds then crank the engine an additional 15 seconds or until the pressure reaches 320 psi 22 bar Genie 4 38 Z 34 22 IC Part No 128300 August 2007 Section 4 Repair Procedures mmmm UEM REVA This page intentionally left blank TEREX COMPANY Part No 128300 Z 34 22 IC 4 39 Section 4 Repair Procedures August 2007 Manifolds REVA 10 1 Function Manifold Components The function manifold is mounted to the turntable under the ground control box Index Schematic No Description Item Function Torque 1 Counterbalance valve 3000 psi 207 Platform level 25 30 ft Ibs 34 41 Nm 2 Counterbalance valve 3000 psi 207 Platform level down 25 30 ft lbs 34 41 Nm 3 Counterbalance valve 1500 psi 103 Hsu Turntable rotate 25 30 ft lbs 34 41 Nm 4 Counterbalance valve 1500 psi 103 inis Turntable rotate right
118. enie REV Torque 8 10 ft lbs 11 14 Nm 8 10 ft lbs 11 14 Nm 8 10 ft lbs 11 14 Nm 8 10 ft lbs 11 14 Nm 8 10 ft lbs 11 14 Nm 8 10 ft lbs 11 14 Nm 8 10 ft lbs 11 14 Nm 8 10 ft Ibs 11 14 Nm TEREX COMPANY 4 42 Z 34 22 IC Part No 128300 August 2007 Section 4 Repair Procedures REVA MANIFOLDS O 19 uw f A gt gt lt 6 P up m SS 9 Cops Qe B S 9 SWI WG OO SK 2 T m 60 5 3 f MC 83 Genie Part No 128300 2 34 22 IC 4 43 Section 4 Repair Procedures August 2007 MANIFOLDS 10 2 Valve Adjustments Function Manifold How to Adjust the Primary Boom Down Relief Valve 1 Connect a 0 3000 psi 0 to 206 bar pressure gauge to the test port on the function manifold 2 Start the engine from the ground controls 3 Hold the function enable rpm select toggle Switch to the high rpm position and activate and hold the primary boom toggle switch in the down direction with the primary boom fully lowered 4 Observe the pressure reading on the pressure gauge Refer to Section 2 Specifications 5 Turn the machine off Hold the relief valve and remove the cap item K 6 Adjust the internal hex socket Turn it clockwise to increase the pressure or counterclockwise to decrease the
119. enie 4 50 Z 34 22 IC Part No 128300 August 2007 Section 4 Repair Procedures REVA 10 8 Valve Coils How to Test a Coil A properly functioning coil provides an electromotive force which operates the solenoid valve Critical to normal operation is continuity within the coil Zero resistance indicates the coil has failed Since coil resistance is sensitive to temperature resistance values outside specification can produce erratic operation When coil resistance decreases below specification amperage increases As resistance rises above specification voltage increases While valves may operate when coil resistance is outside specification maintaining coils within specification will help ensure proper valve function over a wide range of operating temperatures AWARNING Electrocution hazard Contact with electrically charged circuits could result in death or serious injury Remove all rings watches and other jewelry 1 and disconnect the wiring from the coil to be tested 2 coil resistance Coils with 2 terminals Connect the leads from the ohmmeter to the valve coil terminals Coils with 1 terminal Connect the positive lead from the ohmmeter to the valve coil terminal then connect the negative lead from the ohmmeter to the internal ring of the valve coil Result The resistance should be within specification plus or minus 30 Result If the resistance is not within spe
120. er raises and lowers the primary boom The lift cylinder is equipped with counterbalance valves to prevent movement in the event of a hydraulic line failure How to Remove the Primary Boom Lift Cylinder AWARNING injury hazard This procedure requires specific repair skills lifting equipment and a suitable workshop Attempting this procedure without these skills and tools could result in death or serious injury and significant component damage Dealer service is strongly recommended Note When removing a hose assembly or fitting the O ring on the fitting and or hose end must be replaced and then torqued to specification during installation Refer to Section 2 Hydraulic Hose and Fitting Torque Specifications 1 Raise the primary boom enough to access the primary boom lift cylinder rod end pivot pin 2 Raise the secondary boom enough to access the primary boom lift cylinder barrel end pivot pin 3 Attach a lifting strap from an overhead crane to the primary boom for support Do not apply any lifting pressure Genie Z 34 22 IC REVA 4 Place a block of wood across the upper secondary boom to support the cylinder when the rod end pivot pin is removed 5 Attach a lifting strap from a second overhead crane or other similar lifting device to the primary boom lift cylinder Remove the rear turntable cover 7 Place a 4x4 inch 10 x 10 cm block between the lower compression arms and the cross member of the up
121. esel fuel filter is essential to good engine performance and service life A dirty or clogged filter may cause the engine to perform poorly and continued use may cause component damage Extremely dirty conditions may require that the filter be replaced more often Explosion and fire hazard Engine fuels are combustible Replace the fuel filter in an open well ventilated area away from heater sparks flames and lighted tobacco Always have an approved fire extinguisher within easy reach Note Perform this procedure with the engine off 1 Locate the fuel filter water separator and loosen the vent plug located on the fuel filter water separator head Section 3 Scheduled Maintenance Procedures August 2007 CHECKLIST B PROCEDURES a head bolt b vent plug separator head d filter bowl e drain plug 2 Place a container under the filter bowl Loosen the drain plug located at the bottom of the bowl Completely drain the fuel 3 Loosen the head bolt then rotate the filter bowl counterclockwise and remove it 4 Remove the filter element from the bowl 5 Apply athin layer of oil to the bowl gasket and then install the new filter element onto the bowl 6 Tighten the drain plug and fill the bowl and filter assembly with clean diesel fuel 7 Install the filter and bowl assembly onto the filter head Torque the head bolt to 65 in Ibs 7 Nm 8 Tighten the vent plug 9 C
122. fications 2 5 Machine Torque 2 5 Kubota D 905 Engine Specifications 0 2444 0 100000000 2 6 Kubota DF 752 Engine Specifications 2 7 Perkins 403 11 Engine 2 8 Hydraulic Hose and Fitting Torque Specifications 2 9 SAE and Metric Fastener Torque Charts 2 10 Part No 128300 Z 34 22 IC Vil August 2007 TABLE OF CONTENTS Section 3 Rev Scheduled Maintenance Procedures p 3 1 Pre Delivery ooo iter cocer enciende cua Eu ede eR 3 3 Maintenance Inspection Report en 3 5 Checklist A Procedures A 1 Inspect the Manuals and Decals 3 7 2 Perform Pre operation 3 8 A 3 Perform Function Tests 3 8 4 Perform Engine 3 9 A 5 Perform 30 Day Da e 3 9 6 Inspect the Engine Air 0 3 10 A 7 Perform Engine Maintenance Kubota 3 11 A 8 Perform Engine Maintenance Kubota 3 11
123. gularly is essential to safe machine operation Continued use of an improperly operating platform overload system could result in the system not sensing an overloaded platform condition Machine stablity could be compromised resulting in the machine tipping over The platform overload system is designed to detect an overloaded platform and prevent machine operation anytime the machine is turned on When activated the system halts all normal boom operation giving visual and audible warning to the operator Models equipped with the platform overload option are provided with additional machine components an adjustable spring loaded platform support subassembly a limit switch an electronic module which receives the overload signal and interrupts power and an audio visual warning indication to alert the operator of the overload Part No 128300 August 2007 Section 3 Scheduled Maintenance Procedures REVA The platform support subassembly utilizes two load support arms that are opposed in a full parallelogram link This isolates platform loads into a shear or vertical state which translates into a compressive load A spring in the parallelogram link supports this purely compressive load regardless of where the load is placed in the platform As weight is added to the platform the spring will compress until when the platform is overloaded the lower arm contacts a limit switch and thereby activating the overload signal
124. he machine AWARNING she hazard The secondary oom lift cylinder could become unbalanced and fall when removed from the machine if not properly supported by the overhead crane Note Access the pins using the access holes located in the bulkheads one on each side 45 Attach a lifting strap from an overhead crane to the mid pivot for support Do not lift it 46 Remove the pin retaining fasteners from the mid pivot to lower compression arm pivot pins Place a rod through the compression arm pivot pins and twist to remove the pins 47 Remove the pin retaining fasteners from the mid pivot to lower secondary boom pivot pins Use a soft metal drift to remove the pin Genie Z 34 22 IC REVA 48 Remove the mid pivot from the machine AWARNING Crushing hazard The mid pivot could become unbalanced and fall when removed from the machine if not properly supported by the overhead crane 49 Attach a lifting strap from an overhead crane to the control box side lower compression arm 50 Remove the pin retaining fasteners from the lower compression arm to turntable pivot pins Place a rod through the compression arm pivot pin and twist to remove the pin Remove the compression arm from the machine AWARNING Crushing hazard The lower compression arm could become unbalanced and fall when removed from the machine if not properly supported by the overhead crane 51 Repeat step 50 for the engine side lower compression arm
125. he O ring on the fitting and or hose end must be replaced and then torqued to specification during installation Refer to Section 2 Hydraulic Hose and Fitting Torque Specifications Note Perform this procedure with the boom in the stowed position 1 Remove the platform 2 Remove the platform rotator See 2 2 How to Remove the Platform Rotator 3 Remove the jib boom See 3 1 How to Remove the Jib Boom 4 Remove the jib boom bell crank See 3 2 How to Remove the Jib Boom Bell Crank 5 Support the slave cylinder Part No 128300 A TEREX COMPANY Z 34 22 IC PRIMARY BOOM COMPONENTS 6 Tag and disconnect the hydraulic hoses to the slave cylinder and connect them together using a connector Plug the slave cylinder hoses from the cable track AWARNING Bodily injury hazard Spraying hydraulic oil can penetrate and burn skin Loosen hydraulic connections very slowly to allow the oil pressure to dissipate gradually Do not allow oil to squirt or spray Remove the external snap ring from the slave cylinder barrel end pivot pin 8 Use a soft metal drift to remove the slave cylinder barrel end pin 9 Remove the slave cylinder from the primary boom 10 Support the cable track with an overhead crane or similar lifting device 11 Remove the cable track mounting fasteners then remove the cable track from the boom and lay it off to the side Component damage hazard The boom cable track can be damaged if it is
126. heel Configuration 2222 3 39 D 3 Replace Drive Hub 3 40 0 4 Replace the Hydraulic Filters 3 41 D 5 Check the Turntable Rotation Bearing Bolts 3 42 D 6 Inspect for Turntable Bearing Wear 3 43 D 7 Perform Engine Maintenance 3 44 A Checklist E Procedures E 1 Testor Replace the Hydraulic 3 45 E 2 Grease the Steer Axle Wheel Bearings 2WD Models 3 46 E 3 Perform Engine Maintenant 3 47 E 4 Perform Engine Maintenance Perkins 4030 11 Models 3 48 Part No 128300 Z 34 22 IC ix August 2007 TABLE OF CONTENTS Section4 Rev Repair Procedures 522 EIE EET 4 1 A Platform Controls ti Rosie We EE 4 2 1 2 Boom Function Speed 4 5 Platform Components 2 1 Platform Leveling Slave Cylinder 4 6 2 2 Platform nnne nnns 4 7 2 3 Platform Overload System if equipped 4 9 Jib Boom Components SW BOOM c 4 11 3 2 Jib Boom Bell Crank nennen nnns 4 12 3 3 Jib Boom Lift Cylinder enne nnne 4
127. high idle adjustment nut Genie TEREX COMPANY 2 34 22 IC Part No 128300 August 2007 Section 3 Scheduled Maintenance Procedures REVA Perkins 403C 11 solenoid yoke locknut yoke low idle lock nut low idle adjustment screw 3 Move the engine idle control switch to high idle rabbit symbol from the ground controls Result High idle should be 3000 rpm If high idle rpm is correct disregard adjustment step 4 4 Loosen the lock nut on the solenoid then turn the solenoid boot counterclockwise to increase the rpm or clockwise to decrease the rpm Tighten the lock nut and recheck the rpm Part No 128300 Genie 2 34 22 IC CHECKLIST B PROCEDURES B 10 Test the Ground Control Override Note Genie requires that this procedure be performed every 250 hours or quarterly whichever comes first A properly functioning ground control override is essential to safe machine operation The ground control override function is intended to allow ground personnel to operate the machine from the ground controls whether or not the red Emergency Stop button on the platform controls is in the on or off position This function is particularly useful if the operator at the platform controls cannot return the boom to the stowed position 1 Push in the platform red Emergency Stop button to the off position 2 Turn the key switch to ground control and pull out the r
128. hine Immediately tag and remove from service damaged or malfunctioning machine Repair any machine damage or malfunction before operating the machine Before Repairs Start Read understand and obey the safety rules and operating instructions in the appropriate Genie Z 34 22 IC Operator s Manual on your machine Be sure that all necessary tools and parts are available and ready for use Use only Genie approved replacement parts Read each procedure completely and adhere to the instructions Attempting shortcuts may produce hazardous conditions Unless otherwise specified perform each repair procedure with the machine in the following configuration Machine parked on a firm level surface Boom in the stowed position Turntable rotated with the boom between the non steer wheels Key switch in the off position with the key Repair Procedures About This Section Most of the procedures in this section should only be performed by a 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 To re assemble perform the disassembly steps in reverse order Symbols Legend Safety alert symbol used to alert personnel to potential personal injury hazards Obey all safety messages that follow this symbol to avoid possible injury or death
129. hose assembly or fitting the O ring on the fitting and or hose end must be replaced and then torqued to specification during installation Refer to Section 2 Hydraulic Hose and Fitting Torque Specifications 1 Raise the primary boom to a horizontal position Then extend the boom approximately 3 to 4 feet 1 m until the extension cylinder rod end pivot pins are accessible 2 Remove the external snap rings from the extension cylinder rod end pivot pins Use a soft metal drift to remove the pins Section 4 Repair Procedures August 2007 PRIMARY BOOM COMPONENTS Remove the rear turntable cover Raise the secondary boom until the master cylinder rod end pivot pin is accessible 5 Remove the drive speed limit switch from the pivot end of the primary boom Do not disconnect the wiring 6 Remove the pin retaining fasteners from the master cylinder rod end pivot pin Use a soft metal drift to remove the pin 7 Manually retract the master cylinder and push it toward the platform end of the boom to obtain enough clearance for the extension cylinder removal 8 Tag disconnect and plug the extension cylinder hydraulic hoses Cap the fittings on the cylinder AWARNING Bodily injury hazard Spraying hydraulic oil can penetrate and burn skin Loosen hydraulic connections very slowly to allow the oil pressure to dissipate gradually Do not allow oil to squirt or spray 9 Remove the pin retaining fasteners from the extension
130. hould be and flashing 2 Move the primary boom switch to the down position hold for a moment and then release it Move the secondary boom switch to the down position hold for a moment and then release it Result The descent alarm should sound when each switch is held down 3 Turn the key switch to platform control Part No 128300 August 2007 Section 3 Scheduled Maintenance Procedures REVA 4 Atthe platform controls pull out the red Emergency Stop button to the on position Result The flashing beacon should be on and flashing 5 Press down the foot switch Move the primary boom switch to the down position hold for a moment and then release it Move the secondary boom switch to the down position hold for a moment and then release it Result The descent alarm should sound when each control switch is held down 6 Press down the foot switch Move the drive control handle off center hold for a moment and then release it Move the drive control handle off center in the opposite direction hold for a moment and then release it Result The travel alarm should sound when the drive control handle is moved off center in either direction Part No 128300 Genie 2 34 22 IC CHECKLIST B PROCEDURES B 20 Replace the Diesel Fuel Filter Water Separator Element Diesel Models Note Engine specifications require that this procedure be performed every 400 hours Replacing the di
131. ial for good machine performance and service life Dirty oil and suction strainers may cause the machine to perform poorly and continued use may cause component damage Extremely dirty conditions may require oil changes to be performed more often Note The machine uses Dexron equivalent hydraulic oil Before replacing the hydraulic oil the oil may be tested by an oil distributor for specific levels of contamination to verify that changing the oil is necessary If the hydraulic oil is not replaced at the two year inspection test the oil quarterly Replace the oil when it fails the test Note Perform this procedure with the boom in the stowed position 1 Place a suitable container under the hydraulic tank Refer to Section 2 Specifications 2 Remove the drain plug from the hydraulic tank and completely drain the tank into a container of suitable capacity Refer to Section 2 Specifications Bodily injury hazard Beware of ACAUTION hot oil Contact with hot oil may cause severe burns Part No 128300 Genie 2 34 22 IC 3 Tag disconnect and plug the hoses from the return filter Cap the fittings on the return filter 4 Tag disconnect and plug the suction hoses from the bottom of the tank Cap the fittings 5 Remove the fasteners from the hydraulic tank hold down straps Remove the straps 6 Remove the turntable cover using a suitable lifting device Crushing hazard The turntable AWARNING cover could become un
132. iffer by a minimum of 2096 the coil and or its internal diode are faulty and the coil should be replaced Part No 128300 August 2007 Section 4 Repair Procedures REVA 11 1 7 Fuel Tank How to Remove the Fuel Tank B 1 Raise the secondary boom so the upper pivot is 9 approximately 12 feet 4 m off the ground 2 Gasoline LPG models Turn the LPG shutoff valve to the closed position on the LPG tank 3 Gasoline LPG models Remove the LPG hose from the tank and then remove the tank from the machine 4 Gasoline LPG models Remove the mounting fasteners from the LPG bottle bracket then remove the bracket from the machine 5 Turn the manual fuel shutoff valve if equipped to the closed position on the fuel tank 6 Using an approved hand operated pump drain the fuel tank into a suitable container Refer to Section 2 Specifications Explosion and fire hazard Engine fuels are combustible Remove the fuel tank in an open well ventilated area away from heaters sparks flames and lighted tobacco Always have an approved fire extinguisher within easy reach Explosion and fire hazard When transferring fuel connect a grounding wire between the machine and pump or container Note Be sure to only use a hand operated pump suitable for use with gasoline and diesel fuel Fuel and Hydraulic Tanks Tag disconnect and plug the fuel hoses from the fuel tank Cap the fittings on the fuel tank Clean up any fu
133. ily injury hazard Do not inspect while the engine is running Remove the key to secure from operation Bodily injury hazard Beware of ACAUTION hot engine components Contact with hot engine components may cause severe burns 1 Pull up on the pull pin on the engine pivot plate located under the pump Swing the engine pivot plate away from the machine to access the exhaust system 2 sure that all nuts and bolts are tight Inspect all welds for cracks 4 Inspect for exhaust leaks i e carbon buildup around seams and joints Part No 128300 Genie 2 34 22 IC Inspect the Battery Note Genie requires that this procedure be performed every 250 hours or quarterly whichever comes first Proper battery condition is essential to good machine performance and operational safety Improper fluid levels or damaged cables and connections can result in component damage and hazardous conditions AWARNING Electrocution hazard Contact with hot or live circuits could result in death or serious injury Remove all rings watches and other jewelry AWARNING P dily injury hazard Batteries contain acid Avoid spilling or contacting battery acid Neutralize battery acid spills with baking soda and water 1 Puton protective clothing and eye wear 2 Be sure that the battery cable connections are free of corrosion Note Adding terminal protectors and a corrosion preventative sealant will help eliminate corrosion
134. inder is equipped with counterbalance valves to prevent movement in the event of a hydraulic line failure How to Remove the Platform Leveling Slave Cylinder Note When removing a hose assembly or fitting the O ring if equipped on the fitting and or the hose end must be replaced All connections must be torqued to specification during installation Refer to Section 2 Hydraulic Hose and Fitting Torque Specifications Note Before cylinder removal is considered bleed the slave cylinder to be sure there is no air in the closed loop 1 Extend the boom until the slave cylinder barrel end pivot pin is accessible 2 Raise the boom slightly and place blocks under the platform for support Lower the boom until the platform is resting on the blocks 3 Remove the pin retainer fastener from the rod end pivot pin 4 Remove the external snap ring from the barrel end pivot pin Genie 4 6 Z 34 22 IC REVA 5 Use a soft metal drift to remove rod end pivot pin 6 Use a soft metal drift to remove the barrel end pivot pin 7 Carefully pull the cylinder out of the boom 8 Tag and disconnect the hydraulic hoses from the slave cylinder and connect them together with a connector Cap the fittings on the cylinder AWARNING injury hazard Spraying ydraulic oil can penetrate and burn skin Loosen hydraulic connections very slowly to allow the oil pressure to dissipate gradually Do not allow oil to squirt or spray
135. ion A Quarterly or 250 hour Inspection Semi annually 500 hour Inspection A B C Annual or 1000 hours Inspection A B C D 2 Year or 2000 hour Inspection A B C D E Place a check in the appropriate box after each inspection procedure is completed Use the step by step procedures in this section to learn how to perform these inspections If any inspection receives an tag and remove the machine from service repair and re inspect it After repair place a check in the R box Legend Y yes acceptable no remove from service repaired Checklist Rev Y NR Checklist Rev YNR A 1 Manuals and decals 2 Pre operation inspection B 1 Engine choke Gasoline LPG models B 2 Exhaust system A 3 Function tests B 3 Battery 4 Engine maintenance Perform after 40 hours A 5 30 Day Service Perform every 40 hours A 6 Engine air filter Perform after 50 hours A 7 Engine maintenance Kubota models Perform every 50 hours A 8 Engine maintenance Kubota models Perform every 100 hours A 9 Engine maintenance Kubota models B 4 Electrical wiring B 5 Tires wheels and lug nut torque B 6 Brake configuration B 7 Drive hub oil level B 8 Engine maintenance Perkins models B 9 Engine RPM B 10 Ground control override B 11 Platform self leveling B 12 Engine i
136. ion 2 Specifications January 2011 SPECIFICATIONS Performance Specifications Drive speeds maximum REV Boom function speeds maximum from platform controls with rated load in platform Jib boom up 24 to 30 seconds stowed high range mph Jib boom down 15 to 21 seconds 5 1 km h 40 ft 8 5 sec Primary boom up 15 to 21 seconds 12 2 m 8 5 sec Primary boom down 13 to 19 seconds Boom raised or extended 0 6 mph eae Primary boom extend 24 to 30 seconds 40 1 40 sec Primary boom retract 14 to 20 seconds 12 2 m 40 sec Secondary boom up 15 to 21 seconds Braking distance maximum 3 to 4 ft on paved surface 0 9 to 1 2m Secondary boom down 11 to 17 seconds Gradeability See Operator s Manual Turntable rotate 355 62 to 68 seconds Platform rotate 160 4 to 7 seconds Continuous improvement of our products is a Genie policy Product specifications are subject to change without notice 2 2 Z 34 22 IC Part No 128300 2011 Section 2 Specifications REV B Hydraulic Oil Specifications Hydraulic Oil Specifications Hydraulic oil type Chevron Rykon MV equivalent Viscosity grade Multi viscosity Viscosity index 200 Cleanliness level minimum 15 13 Water content maximum 200 ppm Chevron Rykon MV oil is fully compatible and mixable with Shell Donax TG Dexron oils Genie specifications require hydraulic oils which are designed to give maximum pro
137. ions If any inspection receives an tag and remove the machine from service repair and re inspect it After repair place a check in the R box Legend yes acceptable no remove from service R repaired Checklist C Rev C 1 Grease platform overload if equipped C 2 Test platform overload if equipped C 3 Clean fuel tank Diesel models C 4 Engine maintenance Diesel models Perform every 800 hours C 5 Engine maintenance Kubota D905 models Checklist D Rev A Y N R D 1 Boom wear pads D 2 Free wheel configuration D 3 Drive hub oil D 4 Replace hydraulic filters D 5 Turntable rotation bolts D 6 Turntable bearing wear D 7 Engine maintenance Checklist E Rev A E 1 Replace hydraulic oil E 2 Grease wheel bearings 2WD models E 3 Engine maintenance Perform every 3000 hours E 4 Engine maintenance Perkins models Comments August 2007 A TEREX COMPANY Z 34 22 IC Part No 128300 August 2007 Section 3 Scheduled Maintenance Procedures Checklist A Procedures REVA A 1 Inspect the Manuals and Decals Note Genie specifications require that this procedure be performed daily or every 8 hours whichever comes first Maintaining the operator s and safety manuals in good condition is essential to safe machine operation Manuals are included with each machine
138. k using a mild solvent 6 Install the tank onto the machine Install the tank retainer plate fasteners at the bulkhead 7 Install the fuel supply and return hoses to the tank Tighten the clamps 8 Models with fuel shutoff valve Turn the manual fuel shutoff valve located next to the tank to the open position Section 3 Scheduled Maintenance Procedures August 2007 CHECKLIST C PROCEDURES C 4 Perform Engine Maintenance Diesel Models Note Engine specifications require that this procedure be performed every 500 hours Required maintenance procedures and additional engine information is available in the Kubota D905 Operator s Manual Kubota part number 16622 8916 5 OR the Perkins 403C 11 User s Handbook Perkins part number 100816460 Kubota D905 Operator s Manual REVA C 5 Perform Engine Maintenance Kubota D905 Models Note Engine specifications require that this procedure be performed every 800 hours Required maintenance procedures and additional engine information is available in the Kubota D905 Operator s Manual Kubota part number 16622 8916 5 Kubota D905 Operator s Manual Genie part number 31743 Genie part number 31743 Perkins 403C 11 User s Handbook Genie part number 97360 Genie 3 38 Z 34 22 IC Part No 128300 August 2007 Section 3 Scheduled Maintenance Procedures Checklist Procedures D 1 D 2 Check the Primary Boom Check the Free wheel Wea
139. latform control box 10 Pull all of the electrical cables out of the plastic cable track Do not pull out the hydraulic hoses 11 Remove the hose clamps from the bottom side of the primary boom 12 Tag disconnect and plug the hydraulic hoses at the union located on the bottom side of the primary boom Cap the fittings on the union AWARNING Bodily injury hazard Spraying hydraulic oil can penetrate and burn skin Loosen hydraulic connections very slowly to allow the oil pressure to dissipate gradually Do not allow oil to squirt or spray 13 Remove the hose clamp from the side of the primary boom at the pivot end TEREX COMPANY Z 34 22 IC Section 4 Repair Procedures August 2007 SECONDARY BOOM COMPONENTS 14 Remove the primary boom extend drive speed limit switch mounted on the side of the primary boom at the pivot end Do not disconnect the wiring 15 Attach a lifting strap from an overhead crane to the pivot end of the primary boom 16 Using the overhead crane carefully lift the secondary and primary boom assembly until the master cylinder and primary boom lift cylinder hydraulic hoses are accessible 17 Remove the cable covers from the top of the upper secondary boom 18 Tag disconnect and plug the primary boom lift cylinder and master cylinder hydraulic hoses Cap the fittings on the cylinders AWARNING Bodily injury hazard Spraying hydraulic oil can penetrate and burn skin Loosen hydraulic
140. lean up any diesel fuel that may have spilled during the installation procedure REVA Bleed the fuel system Note Before bleeding the system fill the fuel tank 10 Loosen the vent plug screw located on the filter head 11 Operate the hand primer until fuel free of air flows from the vent plug screw Tighten the vent plug screw on the filter head 12 Loosen the vent screw located on top of the fuel injection pump 13 Operate the hand primer until fuel free of air flows from the vent plug screw Tighten the vent plug screw on the injection pump 14 Clean up any fuel that may have spilled 15 Attempt to start the engine using the starter motor for a maximum of 15 seconds resting the starter for 30 seconds before trying again 16 Inspect the fuel filter water separator for leaks Jy Explosion and fire hazard If a fuel eo leak is discovered keep any additional personnel from entering the area and do not operate the machine Repair the leak immediately Note Information to perform this procedure is also available in the Kubota D905 Operator s Manual Kubota part number 16622 8916 5 Kubota D905 Operator s Manual Genie part number 31743 Genie TEREX COMPANY 2 34 22 IC Part No 128300 August 2007 Section 3 Scheduled Maintenance Procedures REVA B 21 Perform Engine Maintenance Kubota D905 Models Note Engine specifications require that this procedure be performed
141. ll speed and note the time when the machine reference point passes over the finish line Refer to Section 2 Specifications Result The raised drive speed does not meet specification Adjust the Lo RANGE potentiometer on the drive joystick clockwise to increase the speed or counterclockwise to decrease the raised drive speed Continue to perform steps 24 through 26 until the raised drive speed meets specification 27 Lower the primary boom to the stowed position Turn the engine off 28 Close the platform control box lid and install the fasteners Part No 128300 August 2007 Section 4 Repair Procedures REVA 1 2 Boom Function Speed Controller Boom Function Speed Controller Adjustments AWARNING Electrocution hazard Contact with electrically charged circuits could result in death or serious injury Remove all rings watches and other jewelry Note Do not adjust the controllers unless the static battery supply voltage is above 12V DC 1 Turn the key switch to platform control and pull out the red Emergency Stop button to the on position at both the ground and platform controls 2 Open the platform control box lid and locate the boom function speed controller PLATFORM CONTROLS 4 Connect the red lead from a volt meter to the wire connector of the white red wire next to the diode Connect the black lead to ground 5 Turn the boom function speed controlle
142. m up down 8 10 ft lbs 11 14 Nm 2 Solenoid valve 3 position 4 way CI Platform rotate left right 8 10 ft lbs 11 14 Nm Flow regulator valve 0 3 1 14 L MIN CG Platform rotate circuit 8 10 ft lbs 11 14 Nm 4 Orifice plug 0 028 inch 0 71 mm located in P port CF Platform rotate and jib boom circuit 4 ES 9 5 9 O Y 27 Genie Part No 128300 2 34 22 IC 4 45 Section 4 Repair Procedures August 2007 amp amp amp _ MANIFOLDS REV 10 4 Brake 2 speed Manifold Components 2WD Models The brake 2 speed manifold is located under the drive chassis cover at the non steer end Index No N 2 Schematic Description Item Function Torque 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 Solenoid valve 2 position 3 way AA Brake ii eto epe 25 30 ft lbs 34 41 Nm Orifice Plug 0 025 inch 0 64 mm AD Tank return circuit Genie Z 34 22 IC Part No 128300 August 2007 Section 4 Repair Procedures
143. n just until a current reading appears on the mulitmeter display 8 Hold the drive joystick in position and adjust the THRESHOLD potentiometer until the multimeter displays approximately 600 mA Set the high range 9 Press down the foot switch Move and hold the drive joystick full stroke in either direction 10 Hold the drive joystick in position and adjust the HI RANGE potentiometer until the multimeter displays slightly higher than 1100 mA Part No 128300 A TEREX COMPANY Z 34 22 IC 4 3 PLATFORM CONTROLS Set the low range 11 Start the engine from the platform controls and raise the primary boom approximately 3 feet 1 m Turn the engine off 12 Press down the foot switch Move and hold the drive joystick full stroke in either direction 13 Hold the drive joystick in position and adjust the LO RANGE potentiometer until the multimeter displays approximately 700 mA 14 Push in the red Emergency Stop button to the off position at the platform controls 15 Disconnect the multimeter 16 Connect the wire that was disconnected in step 3 to terminal A of the drive joystick Set the stowed drive speed Note Select a test area that is firm level and free of obstructions 17 Pull out the red Emergency Stop button out to the on position at both the ground and platform controls 18 Create start and finish lines by marking two lines on the ground 40 feet 12 2 m apart 19 Start the engine from the pla
144. n retaining fasteners from the jib boom lift cylinder rod end pivot pin Do not remove the pin 4 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 5 Attach a lifting strap from an overhead crane to the rod end of the jib boom lift cylinder 6 Remove the pin retaining fasteners from the jib boom lift cylinder barrel end pivot pin Use a soft metal drift to remove the barrel end pivot pin Crushing hazard The jib boom AWARNING and or platform could fall when the pin is removed if not properly supported 7 Usea soft metal drift to remove the jib boom lift cylinder rod end pivot pin Remove the jib boom lift cylinder from the machine AWARNING Crushing hazard The jib boom lift cylinder could fall when the pins are removed if not properly supported by the overhead crane TEREX COMPANY Part No 128300 Z 34 22 IC 4 13 Section 4 Repair Procedures August 2007 Primary Boom Components 4 1 Plastic Cable Track The primary boom cable track guides the cables and hoses running up the boom It can be repaired link by link without removing the cables and hoses that run through it Removing the entire primary boom cable track is only necessary when performing major repairs that involve removing the primary boom How to Repair the Plastic Cable Track C
145. nd or hose end must be replaced and then torqued to specification during installation Refer to Section 2 Hydraulic Hose and Fitting Torque Specifications 1 Remove the platform 2 Remove the platform mounting weldment and the platform rotator See 2 2 How to Remove the Platform Rotator 3 Tag disconnect and plug the jib boom lift cylinder hydraulic hoses Cap the fittings on the jib boom lift cylinder Bodily injury hazard Spraying AWARNING hydraulic oil can penetrate and burn skin Loosen hydraulic connections very slowly to allow the oil pressure to dissipate gradually Do not allow oil to squirt or spray 4 Remove the cable cover from the side of the jib boom Part No 128300 TEREX COMPANY Z 34 22 IC Jib Boom Components 5 Tag disconnect and plug the hydraulic hoses from ports T and P of the jib boom manifold Cap the fittings on the manifold Bodily injury hazard Spraying AWARNING hydraulic oil can penetrate and burn skin Loosen hydraulic connections very slowly to allow the oil pressure to dissipate gradually Do not allow oil to squirt or spray 6 Tagand disconnect the electrical wiring from the jib boom manifold 7 Attach a lifting strap from an overhead crane to the jib boom 8 Remove the pin retaining fasteners from the jib boom pivot pin at the jib boom bellcrank 9 Use a soft metal drift to remove the jib boom pivot pin Remove the jib boom from the jib boom bellcrank Cru
146. ned to discover any malfunctions before the machine is put into service A malfunctioning machine must never be used If malfunctions are discovered the machine must be tagged and removed from service Complete information on how to perform this procedure is available in the appropriate Genie Z 34 22 IC Operator s Manual on your machine Part No 128300 August 2007 Section 3 Scheduled Maintenance Procedures REVA A 4 Perform Engine Maintenance Note Engine specifications require that this procedure be performed every 8 hours or daily whichever comes first Required maintenance procedures and additional engine information is available in the Kubota D905 Operator s Manual Kubota part number 16622 8916 5 OR the Kubota DF752 Operator s Manual Kubota part number EG601 8916 1 OR the Perkins 403C 11 User s Handbook Perkins part number 100816460 Kubota D905 Operator s Manual CHECKLIST A PROCEDURES A 5 Perform 30 Day Service The 30 day maintenance procedure is a one time sequence of procedures to be performed after the first 30 days or 40 hours of usage After this interval refer to the maintenance checklists for continued scheduled maintenance 1 Perform the following maintenance procedures Kubota models B 5 Inspect the Tires Wheels and Lug Nut Torque C 5 Perform Engine Maintenance Kubota D905 Models D 4 Replace the Hydraulic Filters Genie part number 31743
147. ngine performance and safe machine operation There are three settings Low idle turtle symbol allows the operator to control individual boom functions and to drive the machine at a reduced speed High idle rabbit symbol allows the operator to control multiple boom and or drive functions simultaneously This setting maintains a consistent high idle Foot switch activated high idle rabbit and foot switch symbols should be used for normal machine operation This selection activates high idle only when the foot switch is pressed down 1 Pull out the red Emergency Stop button to the on position at both the ground and platform controls 2 Startthe engine from the ground controls Then move the engine idle control switch to high idle rabbit symbol and hold in the ow position Result The engine should change to high idle Release the engine idle control switch Result The engine should return to low idle Turn the key switch to platform controls a At the platform controls move the engine idle control switch to high idle rabbit symbol Result The engine should change to high idle Part No 128300 August 2007 Section 3 Scheduled Maintenance Procedures REVA 6 Move the engine idle control switch to low idle turtle symbol Result The engine should change to low idle 7 Move the engine idle control switch to foot switch activated high idle rabbit and foot switch symbol
148. ntings of this and other manuals Contact Us http Awww genieindustries com e mail techsup genieind com li Z 34 22 IC Serial Number Information Genie Industries offers the following Service Manual for this models Title Part No 2 34 22 IC Service Manual First Edition from serial number 101 to 1186 43037 Z 34 22 IC Service Manual Second Edition from serial number 1187 to 3241 119987 Z 34 22 IC Service Manual Third Edition from serial number 3242 to 4799 128267 Copyright O 1997 by Genie Industries 128300 Rev August 2007 Fourth Edition First Printing Genie and Z are registered trademarks of Genie Industries in the USA and many other countries Printed on recycled paper Printed in U S A Part No 128300 August 2007 INTRODUCTION Serial Number Legend Genie Model 7 34 22 Serial number 2342207 12345 Model year 2007 Manufacture date 02 01 07 Electrical schematic number ESXXXX Machine unladen weight Rated work load including occupants XX kg Maximum number of platfrm occupants XX Maximum allowable side force Maximum allowable inclination of the chassis 0 deg 23422 07 12345 Maximum wind speed XX m s Maximum platform height XX m Maximum platform reach XXm Sequence number Gradeability N A Country of ma
149. ntinue holding the platform rotate switch until air stops coming out of the bleed screw Crushing hazard Keep hands ACAUTION clear of the platform pivot a clear hose weldment during rotation b top bleed valve c bottom bleed valve 10 Close the bleed screw and remove the hose d container 11 Turn the key switch to the off position and clean 2 Open the top bleed screw but do not remove it up any hydraulic oil that may have spilled 3 the key switch to ground control and pull 12 Turn the key switch to ground control and pull out the red Emergency Stop button to the on out the red Emergency Stop button to the on position position 4 Hold the platform rotate toggle switch in the 13 Rotate the platform full left and right and inspect right direction for approximately 5 seconds the bleed screws for leaks then release it Repeat three times Crushing hazard Keep hands ACAUTION clear of the platform pivot weldment during rotation Genie 4 8 Z 34 22 IC Part No 128300 August 2007 Section 4 Repair Procedures REVA 2 3 Platform Overload System How to Calibrate the Platform Overload System if equipped Calibration of the platform overload system is essential to safe machine operation Continued use of an improperly calibrated platform overload system could result in the system failing to sense an overloaded platform The stability of the machine is compromised and it could tip over 1 Level the
150. nufacture USA Model year This machine complies with ANSI A92 5 CAN B 354 4 Serial number Genie Industries stamped on chassis 18340 NE 76th Street Serial label Redmond WA 98052 located under cover USA PN 77055 Genie TEREX COMPANY Part No 128300 Z 34 22 IC iii August 2007 T This page intentionally left blank iv Z 34 22 IC Part No 128300 August 2007 Section 1 Safety Rules Safety Rules Danger Failure to obey the instructions and safety rules in this manual and the appropriate Genie 2 34 22 IC Operator s Manual will result in death or serious injury Many of the hazards identified in the operator s manual are also safety hazards when maintenance and repair procedures are performed Do Not Perform Maintenance Unless You are trained and qualified to perform maintenance on this machine You read understand and obey manufacturer s instructions and safety rules employer s safety rules and worksite regulations applicable governmental regulations M You have the appropriate tools lifting equipment and a suitable workshop Part No 128300 Z 34 22 IC Section 1 Safety Rules August 2007 SAFETY RULES Personal Safety Any person working on or around a machine must be aware of all known safety hazards Personal safety and the continued safe operation of the machine should be you
151. o the coupler set screw Torque the set screw to 65 70 ft lbs 88 95 Nm Component damage hazard Do not force the drive pump during installation or the flex plate teeth may become damaged Part No 128300 PERKINS 403C 11 ENGINE 8 4 Coolant Temperature and Oil Pressure Switches The engine coolant temperature switch is a normally open switch The switch contacts close at approximately 221 F 105 C If the coolant temperature rises above the switch point the Switch contacts close and the engine will shut off to prevent damage The engine will not start until the temperature drops below the switch point Component damage hazard Do not crank the engine with the over temperature light on The engine oil pressure switch is a normally open Switch The switch contacts close at approximately 4 27 psi 0 3 bar If the oil pressure drops below the switch point the contacts close and the engine will shut off to prevent damage Component damage hazard Do not crank the engine with the low oil pressure light on Z 34 22 IC 4 35 Section 4 Repair Procedures August 2007 Hydraulic Pumps 9 1 Auxiliary Pump How to Test the Auxiliary Pump Note When removing a hose assembly or fitting the O ring on the fitting and or hose end must be replaced and then torqued to specification during installation Refer to Section 2 Hydraulic Hose and Fitting Torque Specifications 1 disconnect and plug the high p
152. omponent damage hazard The primary boom cable track can be damaged if it is twisted a link separation point b lowerclip 1 Use slotted screwdriver to pry down on the lower clip 2 Repeat step 1 for each link 3 To remove a single link open the lower clip and then use a screw driver to pry the link to the side Genie Z 34 22 IC REVA 4 2 Primary Boom How to Shim the Primary Boom Note Measure each wear pad Replace the pad if itis less than 0 41 inch 1 cm thick If the pad is more than 0 41 inch 1 cm thick perform the following procedure 1 Extend the boom until the wear pads are accessible 2 Loosen the wear pad mounting fasteners 3 Install the new shims under the wear pad to obtain zero clearance and zero drag 4 Tighten the mounting fasteners 5 Extend and retract the boom through an entire cycle Check for tight spots that could cause scraping or binding Note Always maintain squareness between the outer and inner boom tubes Part No 128300 August 2007 Section 4 Repair Procedures REVA How to Remove the Primary Boom AWARNING 2 clly injury hazard This procedure requires specific repair skills lifting equipment and a suitable workshop Attempting this procedure without these skills and tools could result in death or serious injury and significant component damage Dealer Service is strongly recommended Note When removing a hose assembly or fitting t
153. on the battery terminals and cables 3 Be sure that the battery retainer and cable connections are tight 4 Fully charge the battery Allow the battery to rest 24 hours before continuing this procedure to allow the battery cells to equalize Section 3 Scheduled Maintenance Procedures August 2007 CHECKLIST B PROCEDURES 5 Remove the battery vent caps and check the 9 specific gravity of each battery cell with a hydrometer Note the results 6 Check the ambient air temperature and adjust the specific gravity reading for each as follows Add 0 004 to the reading of each cell for every 10 F 12 C above 80 26 7 C e Subtract 0 004 from the reading of each cell for every 10 F 12 below 80 26 7 C Result All battery cells display an adjusted w specific gravity of 1 277 or higher The battery is fully charged Proceed to step 10 Result or more battery cells display specific gravity of 1 217 or below Proceed to 10 step 7 7 Perform an equalizing charge OR fully charge the battery and allow the battery to rest at least 6 hours 11 8 Remove the battery vent caps and check the specific gravity of each battery cell with a hydrometer Note the results REV A Check the ambient air temperature and adjust the specific gravity reading for each cell as follows Add 0 004 to the reading of each cell for every 10 F 12 C above 80 F 26 7 Subtr
154. ontrol 6 Lift the test weight off the platform floor using a suitable lifting device 7 Place the test weight back onto the center of the platform floor using a suitable lifting device Result The alarm should be off The platform overload indicator light should be off at both the ground and platform controls Note There may be an approximate 2 second delay before the overload indicator light and alarm turn off 8 Add an additional 10 Ib 4 5 kg test weight to the original test weight to overload the platform Result The alarm should sound The platform overload indicator light should be flashing at both the ground and platform controls Note There may be an approximate 2 second delay before the overload indicator light turns on and the alarm sounds 9 Test all machine functions from the platform controls Result All platform control functions should not operate 10 Turn the key switch to ground control 11 Test all machine functions from the ground controls Result All ground control functions should not operate Note If the platform overload system is not operating properly repeat steps 1 through 4 Genie 4 10 Z 34 22 IC Part No 128300 August 2007 Section 4 Repair Procedures REVA 3 1 Jib Boom How to Remove the Jib Boom Note Perform this procedure with the boom in the stowed position Note When removing a hose assembly or fitting the O ring on the fitting a
155. ot oil Contact with hot oil may electrical displacement controller located cause severe burns on the pump The only adjustment that can be 2 Disconnect the electrical connectors from the made to the pump is the neutral or null adjustment coils of the NFPE controller NFPE located on Any internal service to the pump should only be the drive pump performed at an authorized Sauer Danfoss service center 3 Tag disconnect and plug the hydraulic hoses from the pump How to Remove the Drive Pump AWARNING Bodily injury hazard Spraying Component damage hazard The hydraulic oil can penetrate and work area and surfaces where this burn skin Loosen hydraulic procedure will be performed must connections very slowly to allow be clean and free of debris that the oil pressure to dissipate could get into the hydraulic system gradually Do not allow oil to squirt that could result in severe or spray component damage Dealer 4 Support the pump with a suitable lifting device service is recommended 5 Remove the drive pump mounting bolts Note When removing a hose assembly or fitting Carefully remove the pump the O ring on the fitting and or hose end must be replaced and then torqued to specification during How to Prime the Pump installation Refer to Section 2 Hydraulic Hose and Fitting Torque Specifications 1 Connect a 0 to 6000 psi 0 to 414 bar pressure gauge to the test port on the drive pump 2 Gasoline LPG mod
156. ot pin is removed 15 Remove the pin retaining fasteners from the lift cylinder barrel end pivot pin Do not remove the pivot pin 16 Use the overhead crane to raise the primary boom 1 inch 2 5 cm This will relieve pressure on the barrel end pivot pin 17 Place a rod through the barrel end pivot pin and twist to remove the pin Crushing hazard The primary ACAUTION boom lift cylinder may fall when the barrel end pivot pin is removed if not properly supported by the overhead crane 18 Attach a lifting strap from an overhead crane or similar lifting device to the rod end of the primary boom lift cylinder Carefully loosen the straps and allow the barrel end of the primary boom lift cylinder to slowly swing down 19 Carefully remove the cylinder from the machine Part No 128300 A TEREX COMPANY Z 34 22 IC PRIMARY BOOM COMPONENTS 4 4 Extension Cylinder The extension cylinder extends and retracts the primary boom extension tube The extension cylinder is equipped with counterbalance valves to prevent movement in the event of a hydraulic line failure How to Remove the Extension Cylinder AWARNING injury hazard This procedure requires specific repair skills lifting equipment and a suitable workshop Attempting this procedure without these skills and tools could result in death or serious injury and significant component damage Dealer service is strongly recommended Note When removing a
157. ours A B C Annually or every 1000 hours A B C D Two years or every 2000 hours A B C D E Maintenance Inspection Report The maintenance inspection report contains checklists for each type of scheduled inspection Make copies of the Maintenance Inspection Report to use for each inspection Store completed forms for three years Part No 128300 Pre Delivery Preparation Fundamentals It is the responsibility of the dealer to perform the Pre delivery Preparation The Pre delivery Preparation is performed prior to each delivery The inspection is designed to discover if anything is apparently wrong with a machine before it is put into service A damaged or modified machine must never be used If damage or any variation from factory delivered condition is discovered the machine must be tagged and removed from service Repairs to the machine may only be made by a qualified service technician according to the manufacturer s specifications Scheduled maintenance inspections shall be performed by qualified service technicians according to the manufacturer s specifications and the requirements listed in the responsibilities manual Genie Industries USA 18340 NE 76th Street PO Box 97030 Redmond WA 98073 9730 425 881 1800 Genie UK The Maltings Wharf Road Grantham Lincolnshire NG31 6BH England 44 1476 584333 Copyright 2002 by Genie Industries Genie is a
158. ove the pump Part No 128300 August 2007 Section 4 Repair Procedures REVA 9 2 Function Pump How to Test the Function Pump Note When removing a hose assembly or fitting the O ring on the fitting and or hose end must be replaced and then torqued to specification during installation Refer to Section 2 Hydraulic Hose and Fitting Torque Specifications 1 Tag disconnect and plug the high pressure hydraulic hose from the function pump Bodily injury hazard Spraying AWARNING hydraulic oil can penetrate and burn skin Loosen hydraulic connections very slowly to allow the oil pressure to dissipate gradually Do not allow oil to squirt or spray 2 Connect a 0 to 5000 psi 0 to 350 bar pressure gauge to the high pressure port on the pump 3 Gasoline LPG models Disconnect the ignition coil wire from the center of the ignition coil Diesel models Hold the manual fuel shutoff lever clockwise to the closed position 4 Turn the key switch to ground control and pull the Emergency Stop button to the on position at both the ground and platform controls Part No 128300 TEREX COMPANY Z 34 22 IC HYDRAULIC PUMPS 5 Observe the pressure gauge while cranking the engine Immediately stop if the pressure reaches or exceeds 3000 psi 206 bar Result The pressure gauge reads 3000 psi 206 bar immediately stop cranking the engine The pump is good Result The pressure fails to reach 3000 psi
159. ower the cylinder out of the upper pivot 8 Remove the pin retaining fasteners from the master cylinder rod end pivot pin Use a soft metal drift to remove the pin Section 4 Repair Procedures August 2007 m PRIMARY BOOM COMPONENTS REVA 9 Remove the pin retaining fasteners from the master cylinder barrel end pivot pin 10 Use a soft metal drift to remove the pin from the cylinder Do not remove the pin from the upper mid pivot Push the pin to one side only far enough to remove the cylinder Crushing hazard The upper ACAUTION secondary boom and the upper pivot may fall if the pivot pin is completely removed Note The pin should remain in one side of the upper secondary boom and upper mid pivot 11 Use the strap around the rod end lug to lower the cylinder out of the machine Genie 4 22 Z 34 22 IC Part No 128300 August 2007 Section 4 Repair Procedures This page intentionally left blank TEREX COMPANY Part No 128300 Z 34 22 IC 4 23 Section 4 Repair Procedures August 2007 Secondary Boom Components REV A 9 upper pivot upper compression arm mid pivot compression link lower secondary boom lower compression arm turntable pivot upper secondary boom ro Q0 0M Genie 4
160. per secondary boom Carefully lower the secondary boom onto the block AWARNING Crushing hazard Keep hands away from the block and all moving parts when lowering the secondary boom 8 Remove the pin retaining fasteners from the primary boom lift cylinder rod end pivot pin Use a soft metal drift to remove the pin Crushing hazard The primary AWARNING boom could fall when the primary boom lift cylinder rod end pivot pin is removed if not properly supported by the overhead crane 9 Lower the rod end of the cylinder onto the blocks that were placed on the upper secondary boom 10 Remove the pin retaining fasteners from the upper compression arm pivot pin same side of machine as the primary boom lift cylinder barrel end pivot pin retaining fasteners Part No 128300 August 2007 Section 4 Repair Procedures REVA 11 Place a rod through the compression arm pivot pin and twist to remove the pin 12 Swing the compression arm up out of the way and secure it from moving 13 Tag disconnect and plug the primary boom lift cylinder hydraulic hoses Cap the fittings on the cylinder Bodily injury hazard Spraying AWARNING hydraulic oil can penetrate and burn skin Loosen hydraulic connections very slowly to allow the oil pressure to dissipate gradually Do not allow oil to squirt or spray 14 Support the primary boom lift cylinder with straps or ropes to restrict it from swinging freely when the barrel end piv
161. platform control functions should not operate 9 Turn the key switch to ground control 10 Test all machine functions from the ground controls Result All ground control functions should not operate 11 Using auxiliary power test all machine functions from the ground controls Result All ground control functions should operate 12 Using a suitable lifting device lift the additional test weight from the platform Result The platform overload indicator lights should turn off at both the ground and platform controls and the alarm should not sound Note There may be an 2 second delay before the overload indicator lights and alarm turn off 13 Start the engine and test all machine functions from the ground controls Result All ground control functions should operate normally 14 Turn the key switch to platform control 15 Test all machine functions from the platform controls Result All platform control functions should operate Note If the platform overload system is not operating properly Refer to Repair Procedure 2 3 How to Calibrate the Platform Overload System if equipped 16 Using a suitable lifting device remove the remaining test weights from the platform Part No 128300 August 2007 Section 3 Scheduled Maintenance Procedures REVA C 3 Clean the Fuel Tank Diesel Models Note Genie requires that this procedure be performed every 500 hours or six months
162. plug and add oil until the oil level is even with the bottom of the side plug hole 4 Apply pipe thread sealant to the plugs then install the plugs into the hub 5 Check the torque of the drive hub mounting bolts Refer to Section 2 Specifications 6 Repeat this procedure for each drive hub Part No 128300 August 2007 Section 3 Scheduled Maintenance Procedures REV A CHECKLIST B PROCEDURES B 8 B 9 Perform Engine Maintenance Check and Adjust the Perkins 403C 11 Models Engine RPM Note Engine specifications require that this procedure be performed every 250 hours or six months whichever comes first Required maintenance procedures and additional engine information is available in the Perkins 403C 11 User s Handbook Perkins part number 100816460 Perkins 403C 11 User s Handbook Genie part number 97360 Part No 128300 Genie 2 34 22 IC Note Genie requires that this procedure be performed every 250 hours or quarterly whichever comes first Maintaining the engine rpm at the proper setting for both low and high idle is essential to good engine performance and service life The machine will not operate properly if the rpm is incorrect and continued use may cause component damage Gasoline LPG Models Note Perform this procedure in gasoline mode with the engine at normal operating temperature 1 Connect an rpm gauge to the engine then start the engine from the ground controls Res
163. pump Leave a 1 2 inch 0 8 mm gap between the coupler and pump end plate 4 Apply removable Loctite thread sealant to the coupler set screw Torque the set screw to 65 70 ft lbs 88 95 Nm Component damage hazard Do not force the drive pump during installation or the flex plate teeth may become damaged Part No 128300 A TEREX COMPANY Z 34 22 IC KUBOTA DF752 ENGINE 7 6 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 The engine will not start until the temperature drops below the switch point An over temperature indicator light at the ground controls should turn on when the switch closes Component damage hazard Do not crank the engine with the over temperature light on The engine oil switch is a normally closed switch The switch contacts open at approximately 7 psi 0 48 bar If the oil pressure drops below the Switch point the contacts open and the engine will shut off to prevent damage A low oil pressure indicator light at the ground controls should turn on when the switch opens Component damage hazard Do not crank the engine with the low oil pressure light on Section 4 Repair Procedures August 2007 Perkins 403C 11 Engine 8
164. r C21IGN WH EH EXCT ate 84 u P20BAT RD C501 4 4 ES34D1V Part No 128300 A TEREX COMPANY Z 34 221C G 5 16 Section 5 Schematics Electrical Schematic Diesel Models August 2007 REVA WH c7P 3 GNDBAT BR C7B 3 GROUND 12 C12FTS BUWH C3B 12 CI2FTS BLWH gt lt lt lt T29 C4P 1 C13DEL BURD C4B 1 BURD 4 WH 5 amp 2 BR 5 2 21 DRIVE ENABLE 4 4 C16DE OR RD C4B 4 OR RD C81 RD 5 5 PMA SWITGH I os lt 41 CI2FTS BK 2 1 4 C30FWD WH 1 4 5 2 CSFWD vM 4e FWDDRIVE 7 0 C31REV WH BK C C31REV WH BK gt d 5 985 953 z 2 Ola 1 6 C32BRK WH RD 1 amp C54 C32BRK WH RD Ibi BRAKE RELEASE 5 5 E m soos gt e WH
165. r Pads Configuration Note Genie requires that this procedure be performed every 1000 hours or annually whichever comes first Maintaining the primary boom wear pads in good condition is essential to safe machine operation Wear pads are placed on boom tube surfaces to provide a low friction replaceable wear pad between moving parts Improperly shimmed wear pads or continued use of worn out wear pads may result in component damage and unsafe operating conditions 1 Turn the key switch to ground control and pull out the red Emergency Stop button to the on position 2 Extend the primary boom approximately 10 inches 25 cm 3 Measure each wear pad Replace the wear pad if itis less than 0 41 inch 1 cm thick If the wear pad is more than 0 41 inch 1 cm thick shim as necessary to obtain zero clearance and zero drag 4 Extend and retract the primary boom through the entire range of motion to check for tight spots that could cause binding or scraping Note Always maintain squareness between the primary boom outer and inner tubes Part No 128300 Genie 2 34 22 IC Note Genie requires that this procedure be performed every 1000 hours or annually whichever comes first Proper use of the free wheel configuration is essential to safe machine operation The free wheel configuration is used primarily for towing A machine configured to free wheel without operator knowledge may cause death or serious injury and proper
166. r to the CREEP position 6 Setthe threshold Press down the foot switch Move the primary boom toggle switch in the up direction until the voltage reading appears Adjust the voltage to 5 5 to 6V DC Turn the threshold trimpot adjustment screw clockwise to increase the voltage or counterclockwise to decrease the voltage 7 Turn the boom function speed controller to the 9 position 8 Setthe max out Press down the foot switch Move the primary boom toggle switch in the up direction Adjust the voltage to 8 5 to 9V DC Turn the max out trimpot adjustment screw clockwise to increase the voltage or counterclockwise to decrease the voltage Boom function speed On controller specifications Threshold 5 to 6V DC Max out 8 5 to 9V DC a black wire b diode c white red wire d function speed controller e max out adjustable trimpot f threshold adjustable trimpot 3 Locate the diode between the black wire from the boom function speed controller and the white red wire Genie TEREX COMPANY Part No 128300 Z 34 22 IC 4 5 Section 4 Repair Procedures August 2007 Platform Components 2 1 Platform Leveling Slave Cylinder The slave cylinder and the rotator pivot are the two primary supports for the platform The slave cylinder keeps the platform level through the entire range of primary boom motion It operates in a closed circuit hydraulic loop with the master cylinder The slave cyl
167. r top priority Read each procedure thoroughly This manual and the decals on the machine use signal words to identify the following Safety alert symbol used to alert personnel to potential personal injury hazards Obey all safety messages that follow this symbol to avoid possible injury or death A A DANGER Indicates an imminently hazardous situation which if not avoided will result in death or serious injury Indicates a potentially hazardous AWARNING situation which if not avoided could result in death or serious injury Indicates a potentially hazardous ACAUTION situation which if not avoided may cause minor or moderate injury Indicates a potentially hazardous situation which if not avoided may result in property damage Be sure to wear protective eye wear and other protective clothing if the situation warrants it Be aware of potential crushing hazards such as moving parts free swinging unsecured components when lifting or placing loads Always wear approved steel toed shoes TEREX vi Z 34 22 IC Workplace Safety Be sure to keep sparks flames and lighted tobacco away from flammable combustible materials like battery gases and engine fuels Always have an approved fire extinguisher within easy reach Be sure that all tools and working areas are properly maintained and ready for use Keep work surfaces clean and free of debris that
168. registered trademark of Genie Industries Rev B Instructions Use the operator s manual on your machine The Pre delivery Preparation consists of completing the Pre operation Inspection the Maintenance items and the Function Tests Use this form to record the results Place a check in the appropriate box after each part is completed Follow the instructions in the operator s manual If any inspection receives an N remove the machine from service repair and re inspect it After repair place a check in the R box Legend Y yes completed no unable to complete R repaired Pre Delivery Preparation Y N R Pre operation inspection completed Maintenance items completed Function tests completed Model Serial number Date Machine owner Inspected by print Inspector signature Inspector title Inspector company Section 3 Scheduled Maintenance Procedures August 2007 This page intentionally left blank TEREX COMPANY 3 4 Z 34 22 IC Part No 128300 August 2007 Section 3 Scheduled Maintenance Procedures Maintenance Inspection Report Model Serial number Date Hour meter Machine owner Inspected by print Inspector signature Inspector title Inspector company Instructions Make copies of this page to use for each inspection Select the appropriate checklist s for the type of inspection to be performed Daily or 8 hour Inspect
169. requires that this procedure be performed every 250 hours or quarterly whichever comes first Replacement or testing of the hydraulic oil is essential for good machine performance and service life Dirty oil and a clogged suction strainer may cause the machine to perform poorly and continued use may cause component damage Extremely dirty conditions may require oil changes to be performed more often Note Before replacing the hydraulic oil the oil may be tested by an oil distributor for specific levels of contamination to verify that changing the oil is necessary If the hydraulic oil is not replaced at the two year inspection test the oil quarterly Replace the oil when it fails the test See E 1 Test or Replace the Hydraulic Oil A TEREX Z 34 22 IC Note Genie requires that this procedure be performed every 250 hours or quarterly whichever comes first The alarm package includes Travel alarm Descent alarm standard equipment after serial number 6195 Flashing beacon Alarms and a beacon are installed to alert operators and ground personnel of machine proximity and motion The alarm package is installed on the ground controls side turntable cover Note The alarms and beacon will operate with the engine running or not running 1 Atthe ground controls pull out the red Emergency Stop button to the on position and turn the key switch to ground control Result The flashing beacon s
170. ressure hydraulic hose from the auxiliary pump Bodily injury hazard Spraying AWARNING hydraulic oil can penetrate and burn skin Loosen hydraulic connections very slowly to allow the oil pressure to dissipate gradually Do not allow oil to squirt or spray 2 Connect a 0 to 5000 psi 0 to 350 bar pressure gauge to the high pressure port on the pump 3 Turn the key switch to ground control and pull out the red Emergency Stop button to the on position at both the ground and platform controls 4 Activate any function using auxiliary power Result The pressure gauge reads 2800 psi 193 bar immediately stop The pump is good Result The pressure fails to reach 2800 psi 193 bar the pump is faulty and will need to be serviced or replaced 5 Remove the pressure gauge and install the hydraulic hose Genie Z 34 22 IC REVA How to Remove the Auxiliary Pump Note When removing a hose assembly or fitting the O ring on the fitting and or hose end must be replaced and then torqued to specification during installation Refer to Section 2 Hydraulic Hose and Fitting Torque Specifications 1 Tag disconnect and plug the hydraulic hoses from the pump AWARNING nud injury hazard Spraying ydraulic oil can penetrate and burn skin Loosen hydraulic connections very slowly to allow the oil pressure to dissipate gradually Do not allow oil to squirt or spray 2 Remove the pump mounting fasteners Carefully rem
171. rimary boom to full height Do not extend it Turn the machine off 3 Attach a lifting strap from an overhead crane to the lug on the rod end of the secondary boom lift cylinder Part No 128300 TEREX COMPANY Z 34 22 IC SECONDARY BOOM COMPONENTS 4 Open the engine side turntable cover Pull up on the engine tray lock pin and swing the engine tray out and away from the machine Secure the engine tray from moving 5 Remove the pin retaining fasteners from the secondary boom lift cylinder barrel end pivot pins 6 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 7 Remove the pin retaining fasteners from the secondary boom lift cylinder rod end pivot pin Use a soft metal drift to remove the pin 8 Carefully lower the cylinder down through the secondary boom just enough to access the hydraulic hoses Component damage hazard Hoses can be damaged if they are kinked or pinched 9 Tag disconnect and plug the hydraulic hoses from the secondary boom lift cylinder Cap the fittings on the cylinder AWARNING al injury hazard Spraying ydraulic oil can penetrate and burn skin Loosen hydraulic connections very slowly to allow the oil pressure to dissipate gradually Do not allow oil to squirt or spray 10 Carefully remove the cylinder by raising it through the top of the secondary boom using the overhead crane AWA
172. rmed after the first 150 hours Replacing the torque hub oil is essential for good machine performance and service life Failure to replace the torque hub oil at yearly intervals may cause the machine to perform poorly and continued use may cause component damage 1 Select the drive torque hub to be serviced Drive the machine to rotate the hub until the plugs are located one on top and the other at 90 degrees plugs 2 Remove both plugs and drain the oil 3 Drive the machine until one plug is at the top and the other is at 90 degrees 4 Fill the hub with oil from the top hole until the oil level is even with the bottom of the side hole Refer to Section 2 Specifications 5 Install the plugs into the drive hub 6 Repeat this procedure for each torque hub Section 3 Scheduled Maintenance Procedures August 2007 CHECKLIST A PROCEDURES A 12 Perform Engine Maintenance Kubota Models Note Engine specifications require that this procedure be performed every 200 hours Required maintenance procedures and additional engine information is available in the Kubota D905 Operator s Manual Kubota part number 16622 8916 5 OR the Kubota DF752 Operator s Manual Kubota part number EG601 8916 1 Kubota D905 Operator s Manual Genie part number 31743 Kubota DF752 Operator s Manual Genie part number 84250 A TEREX Z 34 22 IC MPANY REVA A 13 Drain the Fuel Filter Water Separ
173. round control box Turntable manifold wiring 2 Start the engine from the ground controls 3 Raise the secondary boom until the mid pivot is 10 feet 3 m off the ground 4 Inspect the turntable center area for burnt chafed and pinched cables 5 Lower the boom to the stowed position and turn the engine off 6 Inspect the following areas for burnt chafed corroded pinched and loose wires Cable track on the primary jib and secondary booms Jib boom to platform cable harness Inside of the platform control box Part No 128300 Genie 2 34 22 IC CHECKLIST B PROCEDURES B 5 Inspect the Tires Wheels and Lug Nut Torque Note Genie requires that this procedure be performed every 250 hours or quarterly whichever comes first Maintaining the tires and wheels including proper wheel fastener torque is essential to safe operation and good performance Tire and or wheel failure could result machine tip over Component damage may also result if problems are not discovered and repaired in a timely fashion AWARNING injury hazard An over inflated tire can explode and could cause death or serious injury AWARNING Tip over hazard Do not use temporary flat tire repair products Note The tires on some machines are foam filled and do not need air added to them 1 Check all tire treads and sidewalls for cuts cracks punctures and unusual wear 2 Check each wheel for damage bends and cr
174. s Machine Specifications Specifications Fluid capacities Tires and wheels Rough terrain Industrial Fuel tank capacity 9 3 gallons 35 2 liters Tire size 10 16 5 NHS 9 14 5 LT Hydraulic tank capacity 18 gallons Tire ply rating Tread 6 68 1 liters Sidewall 6 5 Hydraulic system capacity 22 gallons Tire weight new foam filled minimum 175 lbs including tank 83 3 liters Rough terrai 79 ei 3 Drive hubs 17 fl oz Overall tire diameter 30 5 in 28 in 0 5 liter 77 5 37 7 Drive hub type EP 80 90W gear oil Wheel diameter 16 5 in 14 5 in API service classification GL5 42 cm 45 cm Wheel width 10 in 7 in For operational specifications refer to the 25 4 cm 18cm Operator s Manual Wheel lugs 4WD 9 5 8 18 Wheel lugs 2WD Front 8 5 18 8 5 8 18 Rear 9 5 8 18 9 Q 5 8 18 Tire pressure 45 psi 100 psi 3 1 bar 6 89 bar Lug nut torque 125 ft lbs 125 ft lbs lubricated 170 Nm 170 Nm Tires and wheels Hi flotation option Tire size 31 15 5 15 Overall tire diameter 31 in 78 7 cm Wheel diameter 15 38 1 Wheel width 13 in 33 cm Tire pressure 44 psi 3 bar Wheel lugs 4WD 9 5 8 18 Lug nut torque 125 ft lbs lubricated 170 Nm Continuous improvement of our products is a Genie policy Product specifications are subject to change without notice Genie Part No 128300 TEREX COMPANY Z 34 22 IC 2 1 Sect
175. shing hazard The jib boom AWARNING could fall when the pin is removed if not properly supported by the overhead crane 10 Remove the pin retaining fasteners from the jib boom lift cylinder rod end pivot pin Do not remove the pin 11 Remove both of the jib boom leveling links from the bellcrank 12 Attach a lifting strap from an overhead crane to the rod end of the jib boom lift cylinder 13 Use a soft metal drift to remove the jib boom lift cylinder rod end pivot pin Remove the jib boom lift cylinder from the jib boom bellcrank Crushing hazard The jib boom AWARNING lift cylinder could fall when the pin is removed if not properly supported by the overhead crane Section 4 Repair Procedures August 2007 JIB BOOM COMPONENTS 3 2 Jib Boom Bell Crank How to Remove the Jib Boom Bell Crank Note Perform this procedure with the boom in the stowed position Note When removing a hose assembly or fitting the O ring on the fitting and or hose end must be replaced and then torqued to specification during installation Refer to Section 2 Hydraulic Hose and Fitting Torque Specifications 1 Remove the platform 2 Remove the Jib Boom See 3 1 How to Remove the Jib Boom 3 Support and secure the jib boom bell crank to an appropriate lifting device 4 Remove the pin retaining fasteners from the slave cylinder rod end pivot pin Do not remove the pin 5 Remove the pin retaining fasteners from the jib boom b
176. sistance See How to Test a Coil 2 Connect 100 resistor to the negative terminal of a known good 9V DC battery Connect the other end of the resistor to a terminal on the coil Note The battery should read 9V DC or more when measured across the terminals Resistor 10Q Genie part number 27287 COIL T a a9 100 5 5 EA ADAC ig AMNES ey ji H 1 n 1 multimeter 9V DC battery 100 resistor coil Note Dotted lines in illustration indicate reversed connection as specified in step 6 4 52 Genie Z 34 22 IC REVA 3 Seta multimeter to read DC current Note The multimeter when set to read DC current should be capable of reading up to 800 mA 4 Connect the negative lead to the other terminal on the coil Note If testing a single terminal coil connect the negative lead to the internal metallic ring at either end of the coil 5 Momentarily connect the positive lead from the multimeter to the positive terminal on the 9 DC battery Note and record the amperage reading 6 Atthe battery or coil terminals reverse the connections Note and record the current reading Result Both current readings are greater than 0 mA and are different by a minimum of 20 The coil is good Result If one or both of the current readings 0 mA or if the two current readings do not d
177. tal drift to remove the pin 36 Remove the upper secondary boom with compression link from the machine AWARNING Crushing hazard The upper secondary boom with compression link could become unbalanced and fall when removed from the machine if not properly supported by the overhead crane 37 Remove the drive speed limit switch mounted on the inside of the lower mid pivot Do not disconnect the wiring 38 Remove the cable covers from the top of the lower secondary boom Pull all the cables and hoses towards the counterweight end of the turntable 39 Gasoline LPG models Remove the LPG hose from the tank and then remove the LPG tank 40 Remove the battery hold down and battery 41 Remove the pin retaining fasteners from the secondary boom lift cylinder barrel end pivot pins Section 4 Repair Procedures August 2007 SECONDARY BOOM COMPONENTS 42 Attach a lifting strap from an overhead crane to the lug on the rod end of the secondary boom lift cylinder 43 Tag disconnect and plug the hydraulic hoses from the secondary boom lift cylinder Cap the fittings on the cylinder AWARNING ia injury hazard Spraying ydraulic oil can penetrate and burn skin Loosen hydraulic connections very slowly to allow the oil pressure to dissipate gradually Do not allow oil to squirt or spray 44 Use a slide hammer to remove the secondary boom lift cylinder barrel end pivot pins Remove the secondary boom lift cylinder from t
178. tection to hydraulic systems have the ability to perform over a wide temperature range and the viscosity index should exceed 140 They should provide excellent antiwear oxidation corrosion inhibition seal conditioning and foam and aeration suppression properties Optional fluids Biodegradable Petro Canada Environ MV46 Statoil Hydra Way Bio Pa 32 BP Biohyd SE S Fire resistant UCON Hydrolube HP 5046 Quintolubric 822 Mineral based Shell Tellus T32 Shell Tellus T46 Chevron Aviation A Continued use of Chevron Aviation A hydraulic fluid when ambient temperatures are consistently above 32 F 0 C may result in component damage Note Use Chevron Aviation A hydraulic fluid when ambient temperatures are consistently below O F 18 C Note Use Shell Tellus T46 hydraulic oil when oil temperatures consistently exceed 205 F 96 C Note Genie specifications require additional equipment and special installation instructions for the approved optional fluids Consult the Genie Industries Service Department before use SPECIFICATIONS TEREX COMPANY Part No 128300 Z 34 22 IC Section 2 Specifications SPECIFICATIONS Hydraulic Component Specifications Drive pump Type bi directional variable displacement piston pump Displacement 1 71 cuin per revolution 28 cc Flow rate 3000rpm 22 84 L min Function pump Type Fixed displacement gear pump Displacement 0
179. tenance Procedures REVA 6 Choose a point on the machine i e contact patch of a tire as a visual reference for use when crossing the test line 7 Bring the machine to top drive speed before reaching the test line Release the drive joystick when your reference point on the machine crosses the test line 8 Measure the distance between the test line and your machine reference point Note The brakes must be able to hold the machine on any slope it is able to climb Part No 128300 Genie 2 34 22 IC CHECKLIST B PROCEDURES B 15 Test the Drive Speed Stowed Position Note Genie requires that this procedure be performed every 250 hours or quarterly whichever comes first Proper drive function movement is essential to safe machine operation The drive function should respond quickly and smoothly to operator control Drive performance should also be free of hesitation jerking and unusual noise over the entire proportionally controlled speed range Note Select a test area that is firm level and free of obstructions 1 Create start and finish lines by marking two lines on the ground 40 feet 12 2 m apart 2 Start the engine from the platform controls 3 Select high range drive machine on level surface symbol 4 Move the engine idle control switch to foot switch activated high idle rabbit and foot switch 5 Lower the boom into the stowed position 6 Choose a point on the machine i e contact
180. tform controls and move the engine idle select switch to foot Switch activated high idle rabbit and foot switch symbol 20 Choose point on the machine i e contact patch of a tire as a visual reference for use when crossing the start and finish lines Section 4 Repair Procedures August 2007 PLATFORM CONTROLS 21 Bring the machine to top drive speed before reaching the start line Begin timing when your reference point on the machine crosses the start line 22 Continue at full speed and note the time when the machine reference point passes over the finish line Refer to Section 2 Specifications Result The stowed drive speed does not meet specification Adjust the Hi RANGE potentiometer on the drive joystick clockwise to increase the speed or counterclockwise to decrease the stowed drive speed Continue to perform steps 20 through 22 until the stowed drive speed meets specification Set the raised drive speed Note Select a test area that is firm level and free of obstructions 23 Press down the foot switch and raise the primary boom approximately 3 feet 1 m 24 Choose a point on the machine i e contact patch of a tire as a visual reference for use when crossing the start and finish lines 25 Bring the machine to top drive speed before reaching the start line Begin timing when your reference point on the machine crosses the start line Genie 4 4 Z 34 22 IC REV 26 Continue at fu
181. tion and component damage 1 Raise the secondary boom and place a safety chock on the secondary boom lift cylinder Carefully lower the boom onto the lift cylinder safety chock Turn the machine off Crushing hazard Keep hands AWARNING away from the cylinder and all moving parts when lowering the secondary boom Note The lift cylinder safety chock is available through Genie Service Parts Genie part number 36555 A TEREX Z 34 22 IC REV A 2 Check to ensure that each turntable bearing bolt is torqued in specified order to 180 ft lbs 244 Nm Bolt torque sequence Remove the safety chock Lower the boom to the stowed position 4 Access the turntable bearing bolts through the access hole on the side of the chassis 5 Check to ensure that each bearing mounting bolt under the drive chassis is torqued in specified order to 180 ft lbs 244 Nm 9 1 o 30 04 140 15 5 2 2 10 Bolt torque sequence Part No 128300 August 2007 Section 3 Scheduled Maintenance Procedures REVA D 6 Inspect for Turntable Bearing Wear Note Genie requires that this procedure be performed every 1000 hours or annually whichever comes first Periodic inspection of turntable bearing wear is essential to safe machine operation good machine performance and service life Continued use of a worn turntable bearing could create an unsafe operating condition resulting in
182. twisted 12 Remove the turntable end cover 13 Remove the pin retaining fasteners from the master cylinder rod end pivot pin Use a soft metal drift to remove the pin Pull the cylinder back and secure it from moving 14 Remove the drive speed limit switch mounted on the side of the boom at the pivot end Do not disconnect the wiring Section 4 Repair Procedures August 2007 PRIMARY BOOM COMPONENTS 15 Tag disconnect and plug the extension cylinder hydraulic hoses Cap the fittings on the cylinder AWARNING Bodily injury hazard Spraying hydraulic oil can penetrate and burn skin Loosen hydraulic connections very slowly to allow the oil pressure to dissipate gradually Do not allow oil to squirt or spray 16 Attach an overhead 5 ton 5 000 kg crane to the center point of the boom 17 Attach a similar lifting device to the primary boom lift cylinder 18 Using the overhead crane raise the primary boom to a horizontal position 19 Place support blocks across the secondary boom to support the boom lift cylinder 20 Remove the pin retaining fasteners from the primary boom lift cylinder rod end pin Use a soft metal drift to remove the pin Crushing hazard The boom lift ACAUTION cylinder will fall unless it is properly supported 21 Lower the rod end of the primary boom lift cylinder onto support blocks Protect the cylinder rod from damage 22 Remove the hose clamp brackets from the underside of the
183. ty damage Collision hazard Select a work AWARNING site that is firm and level 1 Chock the steer wheels to prevent the machine from rolling 2 Center a lifting jack of ample capacity 15000 Ibs 7000 kg under the drive chassis between the non steering wheels 3 Lift the wheels off the ground and then place jack stands under the drive chassis for support 4 Disengage the torque hubs by turning over the torque hub disconnect caps on each non steering wheel hub E disengaged position arf due arg brake engaged position Section 3 Scheduled Maintenance Procedures August 2007 CHECKLIST D PROCEDURES 5 Manually rotate each non steering wheel Result Each non steering wheel should rotate with minimum effort 6 Re engage the torque hubs by turning over the hub disconnect caps Carefully remove the jack stands lower the machine and remove the jack AWARNING Collision hazard Failure to re engage the torque hubs may cause death or serious injury and property damage REVA D 3 Replace the Drive Hub Oil Note Genie requires that this procedure be performed every 1000 hours or annually whichever comes first Replacing the torque hub oil is essential for good machine performance and service life Failure to replace the torque hub oil at yearly intervals may cause the machine to perform poorly and continued use may cause component damage 1 Select the drive torque hub to be ser
184. ult Low idle should be 1600 rpm Skip to step 3 if the low idle rpm is correct Section 3 Scheduled Maintenance Procedures August 2007 CHECKLIST B PROCEDURES 2 Turn the low idle adjustment screw on the carburetor clockwise to increase rpm or counterclockwise to decrease rpm Gasoline LPG idle adjustments a high idle adjustment nut and lock nut b solenoid boot high idle solenoid 3 Move the engine idle control switch to high idle rabbit symbol from the ground controls Result High idle should be 3000 rpm If high idle rpm is correct disregard adjustment steps 4 through 6 4 Loosen the spring lock nut 5 Turn the high idle adjustment nut and spring lock nut clockwise to increase the rpm or counterclockwise to decrease the rpm 6 Tighten the spring lock nut Then recheck the rpm REVA Diesel models 1 Connect an rpm gauge to the engine and then start the engine from the ground controls Kubota D905 models Result Low idle should 1300 rpm Perkins 403C 11 models Result Low idle should be 1500 rpm Skip to step 3 if the low idle rpm is correct 2 Loosen the lock nut then turn the low idle adjustment screw clockwise to increase the rpm or counterclockwise to decrease the rpm Tighten the lock nut and recheck the rpm Kubota D905 a rpm solenoid b low idle adjustment screw c lock nut
185. ust the Engine RPM 6 4 Flex Plate The flex plate acts as a coupler between the engine and the pump It is bolted to the engine flywheel and has a splined center to drive the pump How to Remove the Flex Plate 1 Support the drive pump with an appropriate lifting device Then remove all of the pump mounting plate to engine bell housing bolts 2 Carefully pull the pump away from the engine and secure it from moving Remove the flex plate mounting fasteners 4 Remove the flex plate from the engine Part No 128300 August 2007 Section 4 Repair Procedures REVA How to Install the Flex Plate 1 Install the flex plate onto the flywheel with the raised spline away from the flywheel b pump shaft pump coupler d flex plate e flywheel 2 Apply removable Loctite thread sealant to the flex plate mounting fasteners Torque the flex plate mounting fasteners to 36 ft Ibs 49 Nm 3 Install the coupler onto the pump shaft with the set screw towards the pump Leave a 1 2 inch 0 8 mm gap between the coupler and pump end plate 4 Apply removable Loctite thread sealant to the coupler set screw Torque the set screw to 65 70 ft lbs 88 95 Nm Component damage hazard Do not force the drive pump during installation or the flex plate teeth may become damaged A TEREX COMPANY Z 34 22 IC Part No 128300 KUBOTA D 905 ENGINE 6 5 Coolant Temperature and Oil Pressure Switches
186. ventilated area away from heaters sparks flames and lighted tobacco Always have an approved fire extinguisher within easy reach 1 Remove the cap from the fuel tank Part No 128300 Genie 2 34 22 IC CHECKLIST B PROCEDURES 2 Check for proper venting Result Air passes through the fuel tank cap Proceed to step 4 Result If air does not pass through the clean or replace the cap Proceed to step 3 Note When checking for positive tank cap venting air should pass freely through the cap 3 Using a mild solvent carefully wash the cap venting system Dry using low pressure compressed air Repeat this procedure beginning with step 2 4 Install the fuel tank cap onto the fuel tank 5 Remove the breather cap from the hydraulic tank 6 Checkfor proper venting O Result Air passes through the fuel tank cap Proceed to step 8 Result If air does not pass through the cap clean or replace the cap Proceed to step 7 Note When checking for positive tank cap venting air should pass freely through the cap 7 Using a mild solvent carefully wash the cap venting system Dry using low pressure compressed air Repeat this procedure beginning with step 6 8 Install the breather cap onto the hydraulic tank Section 3 Scheduled Maintenance Procedures August 2007 CHECKLIST B PROCEDURES REVA B 18 B 19 Perform Hydraulic Oil Analysis Test the Alarm Package if equipped Note Genie
187. viced Drive the machine to rotate the hub until the plugs are located one on top and the other at 90 degrees Remove both plugs and the Drive the machine until one plug is top and the other is at 90 degrees 4 Fill the hub with oil from the top hole until the oil level is even with the bottom of the side hole Refer to Section 2 Specifications 5 Install the plugs into the drive hub 6 Repeat this procedure for each torque hub Genie A TEREX 3 40 Z 34 22 IC Part No 128300 August 2007 Section 3 Scheduled Maintenance Procedures REVA D 4 Replace the Hydraulic Filters Note Genie requires that this procedure be performed every 1000 hours or annually whichever comes first Replacement of the hydraulic filters are essential for good machine performance and service life A dirty or clogged filter may cause the machine to perform poorly and continued use may cause component damage Extremely dirty conditions may require that the filter be replaced more often Hydraulic return filter Burn hazard Beware of hot oil ACAUTION Contact with hot oil may cause severe burns Note The return hydraulic filter is mounted on the hydraulic tank 1 Place a suitable container under the return filter 2 Clean the area around the oil filter then remove the filter with an oil filter wrench 3 Apply a thin layer of oil to the new oil filter gasket
188. washing of the machine may require that this procedure be performed more often 1 Loosen the wheel lug nuts Do not remove them 2 Block the non steer wheels and center a lifting jack of ample capacity under the steer axle 3 Raise the machine 6 inches 15 cm and place blocks under the drive chassis for support Crushing damage The machine ACAUTION may fall if not properly supported 4 Remove the lug nuts Remove the tire and wheel assembly 5 Check for wheel bearing wear by attempting to move the wheel hub side to side then up and down O Result There should be no side to side or up and down movement Skip to step 10 if there is no movement A TEREX Z 34 22 IC REV A 6 Remove the dust cap from the hub Remove the cotter pin from the castle nut 7 Tighten the castle nut to 158 ft lbs 214 Nm to seat the bearings Note Rotate the hub by hand while torquing the castle nut to make sure the bearings seat properly 8 Loosen the castle nut one full turn and then torque to 35 ft lbs 47 9 Check for wheel bearing wear by attempting to move the wheel hub side to side then up and down Result If there is no side to side or up and down movement continue with step 10 to grease the wheel bearings Result If there is side to side or up and down movement continue to step 10 and replace the wheel bearings with new ones Note When replacing a wheel bearing both the inner and outer be

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