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Service Manual - Genie Industries

1. 2 BLK7 BRN 6 47 BRN BRN E H GROUND BRN 5 BRN 2 46 BRN GROUND VOLTAGE OIL PRESSURE COOLANT TEMPERATURE GRNWHTA 1 GAUGE GAUGE GRN BLK 1 44 GR BI S P JIB DOWN GRN 1 43 GRN S P JIBUP ORG RED 1 42 OG BK 2ISM ORG BLK 1 41 OGIBK EH PULSE PICKUP WHT RED 26A 5 WHT 7 40 WHT 8 WHT 6 LIMIT SWITCH BRN GROUND BLU RED CR7 BLU RED 1 39 BU RD S P LP BU WT CR6 BLU WHT 1 38 BUMT S P GAS BLU BLK 1 37 STEER LEFT CABLE 8 WHT BLK 258 BLU BLU M H STEER RIGHT 2 BK RD CR3 BLK RED 1 35 BK RD S P RPM BLK 22A BLK WHT CR8 BLKAWHT 1 GLOW PLUG WHT 23A BLK CR3 BLK 1 33 BK 3 ISM BLK S P Bi gt CABLE 7 ENGINE START WHT RED 1 32 WT RD EH BRAKE WHT BLK 1 31 WI BK EH ED C ONc O 5 5 30 KS1 NO NO RED 5 RW 29 RDWTEH Onc D5 oq ena RESET RED BLK 1 28 RD BK M H TILT ALARM SERATA RD 4 ISM RED 1 27 RED EH RED S
2. M L K J H F E D C B A PLATFORM LEVEL SLAVE CYLINDER SECONDARY BOOM PRIMARY BOOM PRIMARY BOOM EXTENSION JIB BOOM 0 032 inch 0 025 inch LE gt TURNTABLE ROTATE PLATFORM ROTATE 3000 PSI S mi s ii 5 9 CU IN EV 5 pee pee pps soy MASTER x z n E HL by m jE dio m jE s2 3000 PSI 3000 PSI 2500 PSI 2500 PSI 2500 PSI 1 5 1 3 1 3 1 3 1 3 1 MET ar See 2 ONERE EE SS 1 gl HD 1 SCEN 4 3200 PSI I TM ae Oss lay o ME HM Qe Obs 2 1750 PSI 1600 PSI 1400 PSI 1800 PSI 42 4 T 3000 PSI ines 0 J di J2 PRI PR2 A 1750 PSI o l e o AM 1 I E T I yi I I I An I I I An wp 22045 Al x 0990 inet 2 EN Y X 0 1 GPM 9 1 E N 7 U gt _ OC GC l 43037 Genie Z 34 22 IC 6 26 Service Manual Section 6 Sc
3. BRN 6 47 BRNEH GROUND BRN 5 BRN 2 4 GROUND GRNWHT 1 45 GRN BLK 1 44 GRIBI S P JIB DOWN GRN 1 43 GRN SP JIB UP ORG RED 1 42 OG BK 2ISM ORG BLK 1 41 OG BK EH PULSE PICKUP WHT 7 40 WHT 6 LIMIT SWITCH BLU RED 1 39 LP BLUWHT 1 38 GAS BLU BLK 1 37 STEER LEFT BLU 1 36 BLU MH STEER RIGHT BK RD CR3 BLK RED 1 38 BK RD S P RPM BKIWT CRB BLKWHT 1 BKWT S P GLOW PLUG M BLK CR3 BLK 1 33 BK 3 ISM BLK S P START WHT RED 1 WT RD E H BRAKE WHT BLK 1 31 WT BK E H EDC REDS WHTA 30 EDC RW 29 ROWTEH 2WwD AWD REDIBLK 1 28 TILT ALARM RD 4 ISM RED 1 27 RED EH RED S P AUX PWR 26 Wr RD EH WT RD S P WATER TEMP SENDER 25 WT BK E H WT BK S P OIL PRESSURE SENDER WT 10 ISM 24 WARNING SENDER RDWT MH WHT 2 23 WHT SP KEYSWITCH PWR BLK CRS 22 BLK S P PWR PLAT WHT CR2 21 WHT SP DB IGNITION PWR RED CR17 20 RED S P 12V BATT SUPPLY GRNWHT 3 19 GRN BLK 3 18 GR BK S P PLAT ROT R GRN 3 17 GRN S P PLAT ROT L ORG RED 3 16 H Bks ORGIBLK 3 15 ORG BLK M H OG BK S P PLAT LEVEL DN Bus ORG MH ORG S P PLAT LEVEL UP WHT S BLU RED 3 13 DRV ENA LT BL
4. eee Fuel requirement SPECIFICATIONS diesel number 2 D Displacement 54 86 cuin Alternator 0 90 liters Output 30A Number of cylinders Starter motor Bore and stroke 2 83 2 90 inches Brush length new 0 5188 in 72 x 73 6 mm Team Horsepower Brush length minimum 0 3346 in Gross intermitent 26 9 3600 rpm 8 5 mm Firing order 1 2 3 Battery Compression ratio 22 1 12V Group 24 Compression pressure 412 to 469 ps Quantity 1 28 4 to 32 3 bar Ampere hour 75AH Low idle 1300 rpm Cold cranking ampere 875A High idle 3000 rpm Reserve capacity 25A rate 125 minutes Governor centrifugal mechanical Fan belt deflection 1 4 to 3 5 inch Valve clearance cold 0 0057 to 0 0072 in 7 to 9 mm 0 145 10 0 185 polt torque specifications Engine coolant at torque torque Bolt description size grade ft lbs Nm Capacity 3 3 quarts 3 1 liters Head cover cap nuts M7 5 to 6 7109 Lubrication system Head Bolts M10 47 to 50 64 to 69 Oil pressure 36 to 64 psi Bearing case bolts 1 M8 22 to 25 29 to 34 2 48 10 4 41 bar pearing case bolts 2 M9 36 to 40 49 to 54 Oil capacity 5 4 quarts Flywheel bolts M10 40 to 44 54 to 59 including filter 5 1 liters TES 7 Connecting rod bolts M8 30 to 35 41 to 46 Oil viscosity 10W 30 requirements Rocker arm bracket nuts 7 161019 22 to 26 Engine oil should have properties of API cla
5. REMOVE THIS WIRE WHEN LOAD SENSE OPTION IS REQUIRED gt 5 a 2H O44 WEDIBUCT LABEL DESCRIPTION m N 5 g P2 EMERGENCY STOP BUTTON o HORN BUTTON DP1 DRIVE CONTROLLER C BP1 BOOM FUNCTION SPEED CONTROLLER 51 AUXILIARY SWITCH TS2 START SWITCH 24 2 53 GLOW PLUG SWITCH z TS5 RPM SWITCH Qc Nu 9 TS6 TURNTABLE ROTATE SWITCH PO 5 g E 5 TS7 SECONDARY BOOM UP DOWN SWITCH m TS8 PRIMARY BOOM UP DOWN SWITCH 2 59 EXTEND RETRACT SWITCH rO Q TS10 PLATFORM LEVEL SWITCH o d TS11 PLATFORM ROTATE SWITCH u e m S Ts12 JIB UP DOWN SWITCH a 2 TS13 DRIVE HIGH LOW OUTPUT SWITCH TS14 DRIVE ENABLE SWITCH R2 250 OHM RESISTER DRIVE ENABLE LIGHT Ris 3 ES m Ne m 9 g 112 4 5 6 7 8 a R 2 zm 5 o a D o m s o i ag o HORSE POWER LIMITER e a 5 o lw 8 3k 2 i r as p m m ke p oi gt z lt m m m JO S B B x m gt o 5 gt E E T m EIE le lain 2 E m um 2 IE m Jc 210 253 SIS S 2 Ze P 99 9 a 89 5 zeska 515 gje B P B 2 Be e 2 9 5 419 P 3 E
6. 6 15 Ground Control Box Wiring Diagram Gasoline LPG Models from serial number 869 to 1186 6 16 Platform Control Box Wiring Diagram Diesel Models 6 17 Platform Control Box Wiring Diagram Gasoline LPG Models 6 18 Hydraulic Schematic 2WD Models before serial number 674 6 19 Hydraulic Schematic 2WD Models from serial number 674 to 1029 6 21 Hydraulic Schematic 2WD Models from serial number 1030 to 1186 6 23 Hydraulic Schematic 4WD Models before serial number 674 6 25 Hydraulic Schematic 4WD Models from serial number 674 to 1029 6 27 Hydraulic Schematic 4WD Models from serial number 1030 to 1186 6 29 Genie Z 34 22 IC Part No 43037 Service Manual First Edition TABLE OF CONTENTS Section Seven Repair Procedures gj gore o E 7 1 Platform Controls 1 1 Horsepower Limiter Board 7 2 ME BI EE 7 4 1 3 Foot SWIICH TTE 7 5 14 109916 SWIICIBs t Coena te ens 7 6 Platform Components 2 1 uuu 7 7 2 2 Platform Leveling Slave 7 7 2 3 Plattonmmn ROO oet m 7 8 J
7. 7 29 7 5 FICK PALS 2 Pm 7 29 7 6 Water Temperature and Oil Pressure Gauges 7 30 TI Vacuum OWiG cus Da eere aae cci 7 31 Ground Controls MESI EI 7 32 8 2 Toggle Switches See 1 4 Toggle Switches 22 2 7 33 8 3 Wago Components cerise adore de 7 33 5 9 1 Akay ite ei L L eoe 7 34 9 2 Lift St eer Pump ui u ee ni lenges 7 34 9 3 PUMP e code a doce heu vc derent 7 35 Function Manifolds 10 1 Function Manifold 7 38 10 2 Valve Adjustments Function 7 42 Genie Z 34 22 Part No 43037 Service Manual First Edition mr si Section Seven Repair Procedures continued Fuel and Hydraulic Tanks 11 1 Fuel Tank ate 11 2 Hydraulic Tank Turntable Rotation Components 12 1 Rotation Hydraulic Motor 2WD Steering Axle Components 13 1 Yoke and 13 2 Steering Cylinder 13 3 Rod ees 4WD Steering Axle Compo
8. 5 81 35 Traction Function 5 82 36 Machine Will Not Drive At Full 5 83 37 Machine Drives At Full Speed With Platform Raised or Extended 5 84 38 Drive Enable System Is 5 85 39 A Auxiliary Functions Inoperative 5 86 Part No 43037 Genie Z 34 22 IC ix Service Manual First Edition TABLE OF CONTENTS Section Six Schematics 6 1 Electrical Symbols Legend 6 2 Hydraulic Symbols Legend 6 3 Electrical Schematic Diesel Models before setrial numbet 869 uuu uuu 6 5 Electrical Schematic Diesel Models from serial number 869 to 1186 niic eiae 6 7 Electrical Schematic Gasoline LPG Models before serial number 869 6 9 Electrical Schematic Gasoline LPG Models from serial number 869 to 1186 6 11 Ground Control Box Wiring Diagram Diesel Models before serial number 869 tds ti e rre tren dte tore dena 6 13 Ground Control Box Wiring Diagram Diesel Models from serial number 869 1186 6 14 Ground Control Box Wiring Diagram Gasoline LPG Models before serial number 869
9. eu LO nannan P t 8 i PRI Electrical Schematic Diesel Models from serial number 869 to 1186 Section 6 Schematics I i I xs REDIBLK 1 REDIBLK 28 E H I E E S T i 4 B RED WHTHS EH 1 ware I i i i I 1 z 28 a liess 80 4 BLKIRED S 5 i I N Z T SERVICEHORN RELAY E i I 8 82 aka BLK RS EH 2 f 1 I D I e SERVICE HORN B ze 1 5 a EO 5 z MEET ou 480 5 BLK REDIRI E H 92 6 RPM SOLENOID I ae gt I 1 E i gu 8 00 99 z i 2 6 BLK WHT 41 E H UU 1 x ws GLOWPLUGS 1 1 i 4 i 0 4 prenne 1 1 iy Moo aeuo 1 H 1 oai i ere e i BLU eg nia 1 1 sta n kd S 8 8 i 8 4 RED EH BAT 1 peu I pem 1 0 1 ALTERNATOR roto i 1 ES 5 I it WHT 21 E H EX
10. 1 BLK R1 E H j I e e Eg i of 1 Lj Is STARTER MOTOR AUXILIARY E POWER RED RED 27 E H a 1 1 AUXILIARY AUXILIARY POWER RELAY POWER RED 1 x b I Loy ee AUXILIARY PUMP ale Es HC E S 2 1 g D RED RED BLK 1 ae RED BLK 28 E H X a i WHT 2 m RED WHT 23 E H gt LEVEL SENSOR gt 1 1 i i gt 1 s5 1 8 1 BLK RED BLK RED o9 M em SERVICE HORN RELAY 2 i 3 BLK2 02 5 i SERVICE HORN 1 a Ed als 2 EET ils 2 lt I gu i 5 BLK RED R4 E H a gt RPM SOLENOID 5 ul e 18 amp 5 BLK WHT R8 E H i i 3 q o CHOKE SOLENOID T 1 5 m ORG BLK 1 ORG BLK841 E H i 5 ji 1 i q 20 u E I RED E H PDT 1 m 1 1 i WHT 21 EH gt s t 0g lI BEC 5c gt 8 93 l 8 94 5 E 2 E H 3 ul Pc RED P RED 20 E H 7 15 5 5 gt lt E S E BATTERY 5 6 11 Section 6 Schematics Service Manual Electrical Schematic Gasoline LPG Models from serial number 869 to 1186 DRIVE ENABLE up T JIB BOOM 17 D
11. e 8 D 0 A 7 ALAS 0 ES inch 050 A 0 028 inch m ee U55258 UU eee J E N T3 T4 Part No 43037 Genie Z 34 22 6 24 Section 6 Schematics Hydraulic Schematic 2WD Models from serial number 1030 to 1186 Service Manual ey Hydraulic Schematic 4WD Models before serial number 674 B Section 6 Schematics B A CHARGE PRESSURE B A i 4 3500 PSI 3500 PSI L AUXILIARY 0 5 gt 4 LIFT STEER PUMP 3 0 GPM Ti DRIVE PUMP
12. B 16 Foot switch B 17 Engine idle select B 18 Fuel select gas LPG B 19 Drive enable system B 20 Drive brakes B 21 Drive speed stowed B 22 Drive speed raised B 23 Alarm package B 24 Hydraulic oil analysis Perform every 400 hours B 25 Replace diesel fuel fitter Checklist Y N R Refer to Table C C 1 Boom wear pads C 2 Turntable bearing bolts C 3 Free wheel configuration C 4 Grease rotation bearing C 5 Torque hub oil 1 A 17 Check the engine belt C 6 Hydraulic filters Perform every 200 hours C 7 Gasoline fuel filter A 18 Engine oil and filter Y N R Refer to Table B B 1 Check the radiator B 2 Check the engine choke gas LPG B 3 Check the exhaust B 4 Check the battery B 5 Electrical wiring B 6 Tires and wheels B 7 Brake configuration B 8 Torque hub oil level B 9 Glow plugs diesel B 10 Check engine RPM B 11 Key Switch C 8 Distributor cap gas LPG C 9 Spark plugs gas LPG C 10 Air LPG mixture gas LPG C 11 Air filter C 12 Ignition timing gas LPG C 13 Valve clearance gas LPG C 14 Platform rotator Checklist D Y NR Refer to Table D D 1 Hydraulic oil D 2 Engine coolant 0 3 Fuel lines Part No 43037 Genie Z 34 22 IC Section Scheduled Maintenance Inspections Servi
13. IGN START mE aces MODULE BRN GRD 4 85 LO s 7 KEY PWR 8 KEY BYPASS WHERE SS IGNJFUELON ENG FAULT BRN S ISM BLK RED R4 WHT 9 ISM BINED SED __ RED CB2 BLK 33D BLK 1 ISM T z BLK R1 E H WHT 21D BLK RE MH BLUIWHT RE EH BLU RED R7 ms cre L 1 1 1 1 BLK 22D BLUMWHT 38D BLK RED 9D RED BLI RE E H tune sa ORG TB14B ORG BLK TB15B RED 6 CR10 CR9 BRN GRD ORG BLK E H ORG E H PLATFORM LEVEL CUT OUT OPTION ES34GP4C Service Manual Section 6 Schematics ic Ground Control Box Wiring Diagram Gasoline LPG Models from serial number 869 to 1186 N M L K J G F D
14. RIGHT t E BRAKE 7 H 2 SPD _ e B LEFT BRAKE 2 SPEED seh MANIFOLD 150 175 PSI sil 4WD STEERING 8 TRACTION MANIFOLD 6 29 Genie Z 34 22 IC Part No 43037 Service Manual Section 6 Schematics a a Hydraulic Schematic 4WD Models from serial number 1030 to 1186 M L K H G F E D B A PLATFORM LEVEL SLAVE CYLINDER SECONDARY BOOM PRIMARY BOOM PRIMARY BOOM EXTENSION JIB BOOM 0 032 inch 9 Ho TURNTABLE ROTATE PLATFORM ROTATE 3000 PSI S r 3 5 9 CU IN 3 4 f el pT MASTER x E vip Oo wie MI Him o ip HI w Hemo 52 3000 PSI 3000 PSI 2500 PSI
15. 8 10 ft lbs 11 14 Nm 24 2 position way solenoid valve Platform level down 8 10 ft Ibs 11 14 Nm 25 Orifice 0 050 in 1 27 mm Xni Turntable rotate circuit 7 40 Genie Z 34 22 IC Part No 43037 Section 7 Repair Procedures Service Manual First Edition FUNCTION MANIFOLD 2 R 69666 AOOO 5 S lt ELD gt FU S77 amp SA l 0 3 3000 Genie Z 34 22 IC Part No 43037 Section 7 Repair Procedures Service Manual First Edition FUNCTION MANIFOLD 10 2 Valve Adjustments Function Manifold How to Adjust the Primary Boom Down Relief Valve 1 Connect 0 to 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 With the engine high rpm hold down the primary boom down switch with the primary boom fully lowered and observe the pressure reading on the pressure gauge 4 Turn the machine off Hold the relief valve and remove the cap item 6 function manifold 5 Adjust the internal hex socket Turn it clockwise to increase the pressure or counterclockwise to decrease the pressure Then install the relief valve cap AWARNING hazard Do not adjust
16. A 6 Check for Fuel Leaks A 7 Check the Hydraulic Oil Level A 8 Check for Hydraulic Leaks A 9 Check the Tire Pressure 10 Test the Platform and Ground Controls A 11 Test the Auxiliary Power Operation A 12 Test the Tilt Sensor A 13 Test the Limit Switches A 14 Perform 30 Day Service Every 50 hours perform the following engine maintenance procedure A 15 Clean the Air Filter Element 3 2 Genie Z 34 22 Part No 43037 Service Manual First Edition Table A continued Section 3 Scheduled Maintenance Inspections Tools are required New parts required MAINTENANCE TABLES Warm engine required Cold Dealer engine service required suggested Every 100 hours perform the following two engine maintenance procedures A 16 Drain the Fuel Filter Water Separator A Kubota Diesel Models A 17 Check the Engine Belt Every 200 hours perform the following engine maintenance procedure A 18 Replace the Engine Oil and Filter ES d ka Table B B 1 Check the Radiator B 2 Check the Engine Choke EN Kubota Gasoline LPG Models B 3 Check the Exhaust System B 4 Check the Battery B 5 Inspect the Electrical Wiring B 6 Inspect the Tires and Wheels including lug nut torque B 7 Confirm the Proper Brake Configuration B 8 Check the Oil Level in the Torque Hubs E d ki B 9 Check the Glow Plug
17. Continued from the previous page With key switch in ground position and both Emergency Stop switches pulled out to the on position activate the function enable toggle switch TS19 if equipped and the primary boom toggle switch TS22 on ground panel in down direction and check voltage on red blk 2 wire on boom function directional valve coil item T 12V or more Continued on the next page Section 5 Troubleshooting Flow Charts s With key switch in ground position and both Emergency Stop switches pulled out to the on position activate the function enable toggle switch TS19 if equipped and the primary boom toggle switch TS22 on ground panel in down direction and check voltage at TB2 With key switch in platform position both Emergency Stop switches pulled out to the on position and boom function speed controller turned to 9 activate footswitch and primary boom function toggle switch TS8 on platform control panel in down direction and check voltage TB2 Troubleshoot primary boom function toggle switch TS22 on ground control panel OR replace diode on TS22 OR repair open in red blk 2 wire circuit from TS22 to TB2 OR consult Genie Industries Service Department CHART 17 Repair open in red blk 2 wire circuit from TB2 to boom function directional valve coil item T OR repair open in ground circuit to manifold Troubleshoot primary boom function toggle
18. gt Charge pressure circuit 15 18 ft Ibs 20 24 Nm Diagnostic fitting u ic Testing Flow divider combiner valve Controls flow to drive motors in forward and reverse 25 30 ft lbs 34 41 Nm 5 Orifice 0 070 in 1 78 mm Dun Drive circuit 7 54 Genie Z 34 22 IC Part No 43037 Service Manual First Edition Section 7 Repair Procedures E as 2WD DRIVE MANIFOLD Plug Torque Specifications 6 Restart the engine Drive the machine in either direction and recheck the valve pressure Description Hex size Torque 7 Turn the engine off then remove the pressure SAE No 2 1 8 50 in lbs 6 Nm gauge SAE No 4 3 16 13 ft lbs 18 Nm Relief valve specifications SAE No 6 1 4 18 ft lbs 24 Nm Pressure 210 psi 14 5 bar SAE No 8 5 16 50 ft lbs 68 Nm SAE No 10 9 16 55 ft lbs 75 Nm SAE No 12 5 8 75 ft lbs 102 Nm 17 2 Valve Adjustments How to Adjust the Charge Pressure Relief Valve 1 Connect a 0 to 600 psi 0 to 414 bar pressure gauge to the test port located on the drive manifold 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 Start the engine from the platform controls 3
19. Part No 43037 Genie Z 34 22 IC Section 4 Scheduled Maintenance Procedures Service Manual First Edition TABLE D PROCEDURES D 3 5 Change the Fuel Lines Maintaining the fuel lines in good condition is essential to safe operation and good engine performance Failure to detect a worn cracked or leaking fuel line may cause an unsafe operating condition Explosion and fire hazard Engine fuels are combustible Replace the fuel lines in an open well ventilated area away from heaters sparks flames and lighted tobacco Always have an approved fire extinguisher within easy reach Perform this procedure with the engine off 1 Close the manual fuel shutoff valve located next to the fuel tank 2 Remove and replace the fuel line hoses and clamps according to the following illustrations Explosion and fire hazard Fuel may be expelled under pressure Wrap cloth around fuel hoses to absorb leaking fuel before disconnecting them Kubota Diesel models a hose from the injection pump to the injectors b hose from the fuel pump to the injection pump hose from the fuel filter to the fuel pump d hose from the fuel tank to the fuel filter e hose from the injector to the fuel tank 4 42 Genie Z 34 22 IC Part No 43037 Service Manual First Edition Section 4 Scheduled Maintenance Procedures Kubota Gasoline LPG Models a hose from the fuel filter to the
20. Continued from the previous page Check voltage to Repair open in wht wire terminal 30 on CR4 circuit from CR2 to CR3 to CR4 Check voltage at the blk Replace CR4 relay OR red wire on the 2 speed repair open in blk red solenoid wire circuit from terminal 87 on to 2 speed solenoid Check to see if 2 speed binds Check linkage or replace solenoid moves in and solenoid out freely moves freely Replace 2 speed solenoid Note resistance across solenoid terminals should be approximately 0 3 ohms 5 24 Genie Z 34 22 Part No 43037 Service Manual First Edition Section 5 Troubleshooting Flow Charts Chart 9 Engine Low Idle At the platform controls start engine and switch Inoperative rpm 1 maintained low idle Kubota turtle symbol Check defective Gasoline LPG voltage at blk rd wire i where it connects to the Models diode on the rpm select switch Check mechanical linkage from 2 speed solenoid to carburetor is Facil epum binding or defective red wire on the 2 speed solenoid solenoid Check voltage at the blk binds Check linkage or replace red wire on the 2 speed solenoid solenoid moves freely Check adjustment of linkage at low idle See Maintenance Section OR consult Genie Industries Service Department Part No 43037 Genie Z 34 22 5 25 Section 5 Troubleshooting Flow Charts Service Manual First Edit
21. Part No 43037 Genie Z 34 22 IC K 9 9 WHT BLK 5 E H TURNTABLE ROTATE RIGHT WHT 4 E H gt TURNTABLE ROTATE LEFT WHT BLK 3 RIGHT SWING f LEFT WHT 3 o 8 1 HM 1 2 m 8 158 n g BLK RED 1 PULS RPM 5 E T ENGINE SPEED x o c B ENGINE SPEED PISI 5 ws Yo RPM COIL m FLASHING BEACONS g RPM CUTOUT COIL RELAY FUEL RELAY RED WHT 23 E H RED BLK R6 E H G FUEL RELAY g gt g BLU RED 1 ts BLU RED R7 E H we eye LPG SOLENOID 59 BLUWHT 1 a BLUMWHT RE E H ANTEDIESEL VALVE 2 Ove BLUWHT R6 E H j p e yje FUEL PUMP gt FUEL t eas gt 1 BLK WHT n CHOKE RELAY BLK WHT 1 B 5 22 ENGINE 5 z BLK 1 E 366 e EET 2 PI gt EQ x ENGINE E rm B 5 5 WNT RED 26 z START o z 6 P WATER TEMP SENDER 5 mE 3 alo B a eee OIL PRESSURE SENDER 8 ps 22 WHT a HOUR METER t NOW EN A ae 522 u wa e if 1 18 L WHT 21 E H 1 4 IGNITION SYSTEM 00 Im 12 i a jobs 5
22. START INPUT MODULE RED 27D HE 4 BRN GRD R4 85 HE s REDRAR HO mereen 7 KEY PWR kevevrass hes HO HE to BRN 5 ISM BLK RED R4 E H BLI RED 35D RED CB2 BLK 330 4 BLK 1 ISM 1 BLK R1 E H WHTZID BLKIWHT RI mm 1 BLK 22D BLK RED 9D C BLKWHT 4D 10 9 h WH BRN GRD ORG BLK E H PLATFORM LEVEL CUT OUT OPTION ORG EH ES34D4C ES34D5E ORG BLK TB15B RED 6 ORG TB14B 10 9 BRN GRD PLATFORM LEVEL CUT OUT OPTION VOLTAGE OIL PRESSURE COOLANT TEMP TA WHT RED 26A BRN GROUND c WHT 21A WHT BLK 25A BLK 22A ES ONC rO NC KS1 NO NO WHT 23A gt O g TS15 RED 27A GRN 17A GRN BLK 18A BLK WHT 8A E o BLK 7A
23. o c B d y AMG AUS AT PIN 1 oN TAB Am l 2 E 1 8 EEE gaa a EE J _ 43037 Genie Z 34 22 IC 6 20 Service Manual Section 6 Schematics poma Hydraulic Schematic 2WD Models before serial number 674 Service Manual Sec Hydraulic Schematic 2WD Models from serial number 674 to 1029 tion 6 Schematics A B C D E F G K N B A CHARGE PRESSURE 1 UN NET L 3500 4 i1 PSI AUXILIARY PUMP gem 0 5 e p 3500 7 2 PSI E LIFT STEER 1 Pu TUN TH 1 PSI i 81 E S2 DRIVE PUMP I P1 mE T3 Q25PSI 4 J TANK 18 GALLONS 5 CHARGE PRESSURE APOT _ _ _ rol o ULM 6 W M4 I P IS PSI i RIGHT 7 0 025 REAR GAL LAB jn Aa BRAKE 7 4 g 2 SPD ze mu 2WD L EN Tou TRACTION BRAKE 2 SPEED REAR MANIFOLD 1 8
24. D01 Flow divider combiner P 2277 riority Bi directional motor flow divider lt e o le Pilot operated flow nw control valve Bi directional variable Sequencing valve displacement pump Solenoid operated dump valve RIEN Cy 4 An DR Qo Shuttle valve j 2 speed P 22 bi directional motor 5 _ Counterbalance valve E Differential Pump prime mover sensing valve engine or motor Part No 43037 Genie Z 34 22 IC 6 3 Section 6 Schematics Service Manual First Edition _ i 6 4 Genie Z 34 22 IC Part No 43037 Service Manual Section 6 Schematics Electrical Schematic Diesel Models before serial number 869 1 2 a TBS WHT BLK 5 E H 4 RIGHT SWING LEFT WHT 4 E H WHT BLK 3 4 RIGHT LEFT SWING WHT 3 SELECT OPTION BLK RED 1 TS19 FUNCTION ENABLE TB35 THIGH RPM BLU WHT 1 BLK RED EET CR3 BLK WHT CR4 ENGINE TS2 GLOW PLUG TB34 RED WHT 23 E H I TS17 ENGINE GLOW PLUG BLK 1 ENGINE RED BLK WHT START START RELAY IGNJSTART MODULE 1
25. terminal 30 Hold start switch and Check ground to terminal bad check voltage at terminal 85 on 87 on good Replace 1 relay Check voltage at initiate oy Repair open in blk wire terminal starter solenoid circuit from to starter solenoid Repair open in ground to 1 Check repair or replace starter or starter solenoid 5 4 Genie Z 34 22 IC Part No 43037 Service Manual First Edition Section 5 Troubleshooting Flow Charts Engine Cranks Over But Will Not Start Kubota Gas LPG Models Be sure to check fuel levels gasoline LPG Be sure the fuel shut off valves are turned on gasoline LPG Be sure to check the engine oil level and the engine coolant level Fill as needed Be sure the choke is not sticking closed Perform the following tests in the gasoline mode only Hold start switch and less check battery voltage than while engine is cranking 11V Check battery condition OR check alternator OR check for short circuits OR check battery cables OR replace the battery more than 11V Check if radiator and or engine block feels excessively hot Check if engine coolant over temperature sending signal post has continuit to ground continuit not hot Remove wht wire from temperature sending unit Check continuity to ground on temperature sending unit no continuity no continuity Remove wht wir
26. that will cause death or serious injury Indicates the presence of a hazard AWARNING that may cause death or serious injury Indicates the presence of a hazard ACAUTION that will or may cause serious injury or damage to the machine Indicates special operation or maintenance information Indicates that a specific result is expected after performing a series of steps Part No 43037 Genie Z 34 22 IC 4 1 Section 4 Scheduled Maintenance Procedures Service Manual First Edition Table A Procedures A 1 Inspect the Operator s and Safety Manuals Maintaining the operator s and safety manuals in good condition is essential to safe machine operation Manuals are included with each machine 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 1 Check to be sure the storage container is present and in good condition 2 Check to make sure that the operator s responsibilities and safety manuals are present and complete in the storage container in the platform 3 Examine the pages of each manual to be sure that they are legible and in good condition 4 Always return the manuals to the storage container after use Contact your authorized Genie distributor or Genie Industries if replacement manuals are needed A 2 Inspect the Decals and Placards Maintaining a
27. Part No 43037 Genie Z 34 22 IC 6 18 Service Manual Section 6 Schematics Saas Ground Control Box Wiring Diagram Gasoline LPG Models from serial number 869 to 1186 Service Manual Section 6 Schematics Hydraulic Schematic 2WD Models before serial number 674 A B C D E F G H J K B A CHARGE PRESSURE 1 B _ _ L 1 3500 ru PSI AUXILIARY 5 1 e 3500 eT p 2 Z oe TUN 2 PSI T1 I pu eee 241 52 DRIVE PUMP P1 Q25PSI 4 m 4 9 TANK 18 GALLONS 5 CHARGE PRESSURE Soa APORT V etes T2 4 250 6 eR B iy PSI I P 150 175 PSI E t RIGHT 7 0 025 A SE GAL LAE n AD 7 BRAKE _ B 2SPD c 2WD L LEFT p Viae STEERING BRAKE 2 SPEED REAR 8 MANIFOLD BRAKE CYLINDER 150 175 PSI 0 085 inch 6 19 Genie Z 34 22 IC Part No 43037 Service Manual Section 6 Schematics Eui Hydraulic Schematic 2WD Models before serial nu
28. 4 AUX ON 4 516 2 TACHOMETER 8 START INPUT START 5 GROUND 6 BATTERY 8 KEY BYPASS 9 IGN FUEL ON Q 10 ENG FAULT TB33 1 BLK 0 7 KEY PWR WNT RED 26 TB24 WHT BLK 25 ES AUXILIARY POWER AUXILIARY TB27 POWER 1 RED WHT TURNTABLE ROTATE RIGHT TURNTABLE ROTATE LEFT RPM CUTOUT COIL RELAY RPM COIL GLOW PLUG RELAY FLASHING BEACONS WATER TEMP SENDER OIL PRESSURE SENDER CR2 ca CR2 TB21 BLK R1 E H CR1 RED 27 E H RED 1 RED RED BLK 1 mr E PRI NO 4 RED BLK 28 E H TB28 TB23 WHT 2 RED WHT 23 E H P3 HORN BLK RED BLK RED 3 BLK RED TB22 BLK 2 BLK RS5 E H KS1 PLAT RED 1 TB41 ORG BLK 1 CB1 BLK RED R4 E H CR8 BLK WHT 41 E H ORGI BLK 41 E H RED EH WHT 21 E H RED 20 E H BATTERY HOUR METER STARTER MOTOR FUEL SOLENOID AUXILIARY POWER RELAY AUXILIARY PUMP LEVEL SENSOR SERVICE HORN RELAY SERVICE HORN RPM SOLENOID GLOW PLU
29. 512 OR repair open in grn 43 wire circuit from 1526 TS12 to boom function directional valve coil item A OR consult Genie Industries Service Department If voltage to boom function directional valve coil item A from TS26 and TS12 has been restored and jib up function is still inoperative please continue troubleshooting from beginning of chart Part No 43037 Genie Z 34 22 IC Section 5 Troubleshooting Flow Charts Service Manual First Edition CHART 29 Disconnect wire to jib 00 pls 2 the directional valve infinite Replace jib up P page tem A Remove 9RmS directional valve coil and test resistance item A 4 to 8 ohms Exchange jib up and down directional valves item A B and activate jib up function Replace defective directional valve function inoperative Check for mechanical restrictions keeping jib up function from moving OR repair or replace jib cylinder OR replace jib cylinder counterbalance valves OR consult Genie Industries Service Department Install a 0 to 5000 PSI pressure gauge at the quick disconnect coupling on the boom function manifold and activate the jib up function less than 3200 PSI Repair or replace jib cylinder OR replace jib cylinder counterbalance valves OR platform rotate jib function manifold could have an internal fault Consult Genie Industries Service Departm
30. CHARGE PRESSURE aE 5 l 51 52 P1 n HYDRAULIC TANK T3 aS 150 175 PSI __ REAR 0 025 Mk EIGHT inch RIGHT B 8 25 0 e 4 M3 m 2252 mn 1 ty 67 BRAKE 2 SPEED REAR E E MANIFOLD E 150 175 5 4WD n MANIFOLD 6 25 Genie Z 34 22 IC Part No 43037 0 085 inch STEERING Section 6 Schematics m Hydraulic Schematic 4WD Models before serial number 674
31. 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
32. Hydraulic Schematic 4WD Models from serial number 674 to 1029 M L K J H G F E D PLATFORM LEVEL SLAVE CYLINDER 51 52 T3 SECONDARY BOOM PRIMARY BOOM PRIMARY BOOM EXTENSION JIB BOOM d 0 032 inch 0 025 inch wR AL by 2 TURNTABLE ROTATE PLATFORM ROTATE 3000 PSI 84 S 5 9 CU IN REV E 4 de n MASTER mo ib Him 3000 PSI 2500 PSI 2500 PSI 5 1 31 3 1 E 27 2 A 1 8 GPM Ei 1 4 3200 PSI m iF 1 ET D YM gt OL Ore I E 1600 PSI 1400 PSI 1800 PSI 3000 PSI 3 1 71 J1 J2 PRI PR2 De
33. 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 P dily injury hazard This procedure requires specific repair skills lifting equipment and a suitable workshop Attempting this procedure without these skills and tools may result in death or serious injury and significant component damage Dealer Service is strongly recommended 1 Rotate the turntable to the side until the boom is centered between the steer and non steer tires 2 Raise the primary boom to full height Do not extend it 3 Attach the strap from an overhead crane to the lug on the rod end of the secondary boom lift cylinder 4 From the bottom side of the cylinder remove the retaining fasteners from the secondary boom lift cylinder barrel end pivot pins 5 Use a slide hammer to remove the barrel end pins access the pins from the access holes in the bulkheads one on each side 6 Remove the pin retainer from the secondary boom lift cylinder rod end pivot pin Then use a soft metal drift to remove the pin 7 Carefully lower the cylinder down through the secondary boom enough to access the hydraulic hoses Do not pinch the hoses 8 Disconnect and plug the hydraulic hoses from the secondary boom lift cylinder C
34. 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 then secure the strap to the primary boom use this strap to lower the cylinder out of the upper mid pivot 8 Remove the pin retainer from the master cylinder rod end pivot pin Then use a soft metal drift to remove the pin 9 Remove the pin retainer from the master cylinder barrel end pivot pin Then 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 The pin should remain in one side of the upper secondary boom and upper mid pivot Crushing hazard The upper ACAUTION secondary boom and the upper mid pivot will fall if the pivot pin is completely removed 10 Use the strap around the rod end lug to lower the cylinder out of the machine 7 20 Genie Z 34 22 Part No 43037 Service Manual First Edition Section 7 Repair Procedures SS This page intentionally left blank Part No 43037 Genie Z 34 22 7 21 Section 7 Repair Procedures Service Manual First Edition Secondary Boom Components e Secondary Boom upper mid pivot NO upper compr
35. 1 7 bar bypass Genie Z 34 22 Part No 48037 Service Manual First Edition Section 2 Specifications Function manifold Function relief 3200 psi valve pressure 220 7 bar Boom down relief 1400 psi Function relief 96 6 bar Secondary boom down relief 1600 psi valve pressure 110 3 bar Primary boom extend relief 1800 psi valve pressure 124 1 bar Turntable rotate relief pressure 1750 psi before serial number 674 120 7 bar replaced by counterbalance valves after serial number 673 Auxiliary pump Type Fixed displacement gear pump Displacement 0 5 gom 1 9 L min Auxiliary pump 3400 psi relief pressure 234 5 bar SPECIFICATIONS Part No 43037 Genie Z 34 22 IC Section 2 Specifications Service Manual First Edition SPECIFICATIONS Bolt Torque Specifications per Torque Dry Torque Dry Torque Dry Torque Dry Torque Dry Torque Dry inch inch pounds foot pounds Newton meters inch pounds foot pounds Newton meters No 10 24 43 5 60 7 2 49 6 68 8 1 4 inch 20 96 11 144 16 28 120 14 168 19 5 16 inch 18 17 23 25 34 24 19 28 25 34 3 8 inch 16 30 41 45 61 24 35 48 50 68 7 16 inch 14 50 68 70 95 20 55 75 80 109 1 2 inch 13 75 102 110 149 20 90 122 120 163 9 16 inch 12 110 149 150 204 18 120 163 170 231 5 inch 11 150 204 220 298 18 170 231 240 326 inch 10 260 353 380 515 16 300 407 420
36. 12V or more Check voltage at center terminal on start switch 12V Hold start switch and check voltage at either side terminal on start switch Hold start switch and check voltage at terminal TB33 Hold start switch and check voltage at terminal 3 on ign start module 12V Check voltage at terminal 6 on ign start module Hold start switch and check voltage at terminal 1 on ign start module 12V Continued on the next page Chart 1 Check battery condition OR check alternator OR check battery cables OR replace the battery Trace circuit back through the key switch emergency stop button and repair open Replace start toggle switch 2 Repair blk wire circuit from start switch to TB33 OR replace diode at start switch because of open Repair blk wire circuit from TB33 to ign start module terminal 3 Repair open in CB2 OR in power supply wire to terminal 6 on ign start module Repair open in ground wire to terminal 5 on ign start module Part No 43037 Genie Z 34 22 IC Section 5 Troubleshooting Flow Charts Service Manual First Edition CHART 1 Hold start switch and Repair open in blk wire the check voltage at terminal ov from terminal 1 on ign page 186 start module Check voltage at termina Repair open in red wire 30 on from CB2 to
37. 25 30 ft lbs 34 41 Nm 7 Relief valve 1800 psi 124 bar Inest Primary Boom extend 25 30 ft lbs 34 41 Nm 8 Proportional solenoid valve Duns System flow regulating circuit 10 12 ft lbs 14 16 Nm 9 position 4 way spool valve Eu Steer left right 10 12 465 14 16 Nm 10 Flow regulator valve 0 1 gpm Differential sensing circuit 10 12 ft lbs 14 16 Nm 11 Differential sensing valve Gunn All 22 2 2 10 12 ft lbs 14 16 Nm 12 Diagnostic fitting 2 2 00 1 Testing 13 Priority flow regulator valve 1 0 gpm A Steering ect 10 12 ft Ibs 14 16 Nm 14 Relief valve 3200 psi 221 bar Bum System relief 25 30 ft lbs 34 41 Nm 15 2 position 3 way solenoid valve Primary boom retract 8 10 ft lbs 11 14 Nm 16 2 position 3 way solenoid valve Primary DOOM 8 10 ft Ibs 11 14 Nm Plug Torque Specifications Description Hex Size Torque Description Hex Size Torque SAE No 2 1 8 50in Ibs 6Nm SAE No 8 5 16 50 ft Ibs 68 Nm SAE No 4 3 16 13 ft lbs 18 Nm SAE No 10 9 16 55 ft lbs 75 Nm SAE No 6 1 4 18 ft lbs 24 Nm SAE No 12 5 8 75 ft lbs 102 Nm 7 38 Genie Z 34 22 IC Part No
38. ENGINESPEED go z E HIGH RPM gt 4 o REDMWHT 23 E H RED BLK amp Re EH ls 2 8 BLU RED 1 F BLU RED R7 E H 5 o eo 5 BLUMHTA oF BLUWHT RG E H 8 Sa 2 oS BLU WHT R6 E H a oe p LP 4 FUEL i 1 BLK WHT n e pM BLK WHT 1 5 22 ENGINE tr 29 gt T z BLK 1 2 eos g Eu 5 528695555 Bo ENGINE 8 Fs 29 WNT RED 26 SEE 2 5 9 ENGINE 2 re ee 3 WHT BLK 25 START elelgleleiglelelgle 1 BLK F l5 m pe 22 WHT sf aon m 628 L__ WHT 21 E H i 00 5 00 i 5 a ps 2 BLK R1 E H e o Eg t AUXILIARY z POWER RED 27 E H 3 AUXILIARY gt i POWER RED 1 OFN 1 1 8 16 Eg le edi ee 8 27 m 2 RED RED BLK 1 RED BLK 28 E H a LI 2 8 WHT 2 B RED WHT 23 E H gt UA 4 6 4 BLKRED BLK RED 3 BLK RED Ap Z um 2 A E go BLK 2 i ae BLK R5 E H 2 tr 28 85 z BLK REDHRA E H s i BLK WHT R8 E H q eed 4 1 _ IND REGU ORG BLK 1 ORG BLK 41 E H 1 E STA ul u 1 c c
39. Genie Service Manual Part No 43037 Rev B January 2007 Z 34 221C from serial number 100 to 1186 Introduction Service Manual First Edition Important Read understand and obey the safety rules and operating instructions in the appropriate Genie Z 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 troubleshooting and 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 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 printings of this and other manuals Please write to the technical publications team in care of Genie Industries PO Box 97030 Redmond WA 98073 9730 USA If you have any ques
40. Result No function should operate the machine should stop Kubota Diesel models All functions should stop immediately The engine will shut off after 2 to 3 seconds As a Safety feature selecting and operating the ground controls will override the platform controls including the Emergency Stop button TABLE A PROCEDURES A 11 Test the Auxiliary Power Operation Detection of auxiliary power system malfunctions is essential for safe machine operation An unsafe working condition exists if the auxiliary powered functions do not operate in the event of a main power loss Auxiliary power is designed for short term emergency use only Excessive use will result in battery drain and component damage 1 Turn the key switch to ground control and pull out the Emergency Stop button to the on position Simultaneously hold the auxiliary power switch on while activating each function through a partial cycle Result Each function should operate smoothly 3 Turn the key switch to platform control 4 Atthe platform controls pull out the Emergency Stop button to the on position then press down the foot switch acd Q o Simultaneously hold the auxiliary power switch on while activating each function through a partial cycle Result Each function should operate smoothly Part No 43037 Genie Z 34 22 Section 4 Scheduled Maintenance Procedures Service Manual First Edition
41. Be sure mechanical linkage is not binding or defective Be sure 2 speed solenoid grounding wires are free of corrosion and have full continuity to ground Start engine and switch rpm select to high idle rabbit symbol and check to see if the 2 speed solenoid pulls in solenoid does not pull in Check voltage at blk red wire on rpm select switch 12V Check voltage at TB35 oy 12V Check voltage at V terminal 30 on CR3 12V 0 Check ground wire to bad terminal 85 on CR3 good Check voltage to ov terminal 87 on CR3 12V Check voltage at initiate terminal 86 on CR4 12V Continued on the next page solenoid pulls in Chart 8 Check high idle adjustment see Maintenance Section Check voltage at center terminal on rpm select Repair open in circuit supplying 12V to center switch terminal of switch 12V Replace rpm select toggle switch or replace diode Repair open in blk red wire circuit from toggle switch to TB35 Repair open in blk red wire circuit from TB35 to terminal 30 on CR3 Repair open in ground wire to terminal 85 on CR3 Replace CR3 relay Repair open in blk red wire circuit from CR3 to CR4 Part No 43037 Genie Z 34 22 IC Section 5 Troubleshooting Flow Charts Service Manual First Edition CHART 8 Check ground wire to terminal 85 on CR4 Repair ground wire to terminal 85 on CR4
42. CR3 to CR4 Genie Z 34 22 IC Part No 43037 Service Manual First Edition Section 5 Troubleshooting Flow Charts Check ground wire to terminal 85 on CR4 Repair ground wire to Continued from the terminal 85 on previous page Check voltage to Repair open in wht wire terminal 30 on CR4 circuit from CR2 to CR3 to CR4 Check voltage at the Replace relay blk red wire on the OR repair open in 2 speed solenoid blk red wire circuit from terminal 87 to 2 speed solenoid solenoid Check if 2 speed binds Check linkage or solenoid moves in and replace solenoid out freely moves freely Replace 2 speed solenoid Note resistance across solenoid terminals should be approximately 0 3 ohms CHART 10 Part No 43037 Genie Z 34 22 Section 5 Troubleshooting Flow Charts Service Manual First Edition Chart 11 Engine Low Idle inoperative Kubota Diesel Models Check if mechanical linkage from 2 speed solenoid to fuel injection system is binding or defective Isolate the platform and ground rpm switches check individually and replace defective switch At platform controls start engine and switch rpm select switch to maintained low idle turtle symbol Check volts at blk red wire on rpm select switch Check voltage at the red wire on the 2 speed solenoid Replace relay solenoid Chec
43. N Q D V 0 T AM I I Z T An I T T I pi I DUI A I M I I pi oosa ien W 9 oso T2 X E mE ee ee ss 21 43037 Genie Z 34 22 IC 6 28 Section 6 Schematics u Hydraulic Schematic 4WD Models from serial number 674 to 1029 Service Manual Section 6 Schematics m Hydraulic Schematic 4WD Models from serial number 1030 to 1186 A B C D E F G H 9 K B A CHARGE PRESSURE B A 1 1 7 3500 PSI 4 Kamus PSI eT Pv AUXILIARY 2 7 a a 320 8 H 3 DRIVE PUMP 22210 HYDRAULIC TANK CHARGE PRESSURE T 5 6 150 175 PSI_ C 0 025 X FRONT
44. Schematics Electrical Schematic Gasoline LPG Models from serial number 869 to 1186 Section 6 Schematics Service Manual LEE Ground Control Box Wiring Diagram Diesel Models before serial number 869 Section 6 Schematics Service Manual eS Ground Control Box Wiring Diagram Diesel Models before serial number 869 A B C D OIL PRESSURE COOLANT TEMP VOLTAGE WHT RED 26A BRN GROUND Eu WHT 21A 2 WHT BLK 25A BLK 22A WHT 23A y y Onc O KS1 NO NO Nc Tes 05 RED 27A GRN 17A 3 BLK WHT 8A O TS25 7523 WHT RED 3A J Bi RED 1A HM RED BLK 2A 4 TS24 TS22 bj BLU 10A BLU BLK 11A TS26 5 7817 TS16 I WHT 4A 5 WHT BLK 5A OOO C rj TS20 CB2 RED 20A GRN 43A GRN BLK 44A ORG 14A ORG BLK 15A 6 RED R1430 BLK WHT 34A BLK 33A BLK RED 35A LABEL DESCRIPTION Pt EMERGENCY STOP BUTTON KS1 KEY SWITCH 7 TS15 AUXILIARY SWITCH TS16 ENGINE START SWITCH TS17 ENGINE GLOW PLUG SWITCH TS19 ENGINE RPM
45. TABLE A PROCEDURES A 12 A 13 Test the Tilt Sensor Test the Limit Switches The tilt sensor sounds an alarm in the platform Detecting limit switch malfunctions is essential to when the incline of the drive chassis exceeds safe machine operation The drive limit switches 4 5 degrees are used to restrict drive speed when the boom is Select a level test area The tilt alarm should not be sounding prior raised The drive enable limit switch activates a signal light to inform the operator that the platform is over the steering wheels and stops drive to the test movement unless the drive enable override switch 1 Turn the key switch to platform control Then is used Improperly functioning limit switches will pull out the Emergency Stop button to the on allow the boom to raise and or drive into an unsafe position at both the ground and platform controls position Drive Limit Switch 2 Open the engine side cover and press down on one side of the tilt sensor 1 With the engine off and the boom in the stowed position visually inspect the drive limit switches Result After a 1 5 second delay the alarm in for the following the platform should sound Broken or missing rollers or arms Missing fasteners Loose wiring 2 Manually activate the primary boom drive limit Switch a primary boom drive limit switch b boom extend drive limit switch secondary boom drive limit switch Result The driv
46. TS19 if equipped and the turntable rotate toggle switch TS20 on ground panel in right direction and check voltage at TB5 With key switch in platform position both Emergency Stop switches pulled out to the on position and boom function speed controller turned to 9 activate footswitch and turntable rotate function toggle switch TS6 on platform control panel in right direction and check voltage at TB5 Troubleshoot turntable rotate function toggle switch TS20 on ground control panel OR replace diode on 1520 OR repair open in wht blk 5 wire circuit from TS20 to TB5 OR consult Genie Industries Service Department CHART 23 Repair open in wht blk 5 wire circuit from TB5 to boom function directional valve coil item O OR repair open in ground wire circuit to manifold item O Troubleshoot turntable rotate function toggle Switches TS20 and 56 on ground and platform control panels OR replace diodes on TS20 and 756 OR repair open in wht blk 5 wire circuit from TS20 and TS6 to TB5 OR consult Genie Industries Service Department If voltage to 5 from TS20 and TS6 has been restored and turntable rotate right function is still inoperative please continue troubleshooting from beginning of chart Part No 43037 Genie Z 34 22 IC Section 5 Troubleshooting Flow Charts Service Manual First Edition R CHART 23 Disconnect wire to 0 or turntable rotate right infini
47. The primary boom cable track can be damaged if it is twisted a link separation point b lower clip 1 Use a 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 4 2 Primary Boom How to Shim the Primary Boom Measure each wear pad Replace the pad if it is 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 Extend and retract the boom through an entire cycle Check for tight spots that could cause scraping or binding Always maintain squareness between the outer and inner boom tubes How to Remove the Primary Boom AWARNING P ily injury hazard This procedure requires specific repair skills lifting equipment and a suitable workshop Attempting this procedure without these skills and tools may cause death or serious injury and significant component damage Dealer service is strongly recommended Perform this procedure with the boom in the stowed position 1 Remove the platform See 2 1 How to Remove the Platform 2 Remove the platform rotator See 2 3 How to Remove the Platform Rota
48. 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 cylinder is equipped with counterbalance valves to prevent movement in the event of a hydraulic line failure How to Remove the Slave Cylinder 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 Then 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 retaining ring from the barrel end pivot pin 5 Use a soft metal drift and drive the rod end pivot pin out 6 Use a soft metal drift and drive the barrel end pivot pin out 7 Carefully pull the cylinder out of the boom 8 Disconnect and tag the hydraulic hoses from the slave cylinder and connect them together with a connector 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 Part No 43037 Genie Z 34 22 Section 7 Repair Procedures Service Manual First Edition PLATFORM COMPONENTS How t
49. held open m d Water temperature 181 switch normally open NO I Tilt sensor Relay contact T circuits normally open connect Limit switch normally open held closed PRA S t zD t i Connecti IL Relay panel no terminal Auxiliary pump iA 99000 iUo _ n Oil pressure switch Drive motor normally closed Circuits crossing gg FED El i i Toggle switch SPDT IE Curtis motor a e controller Rotary OEM Diode flow control Vacuum switch FWD REV normaly open 222545 s es S Pale Toggle switch Lit 2500 Dual pole Resistor relay controller 12V 6V Battery Drive control 6 2 Genie Z 34 22 IC Part No 43037 Service Manual First Edition Section 6 Schematics Hydraulic Symbols Legend 2 Doubl ti Pressure gauge cylinder idc M X H NE 0 038 f Solenoid operated Orifice with size proportional valve Filter K 7 Check valve Solenoid operated 2 pos x 3 way directional valve Fixed displacement TI Variable orifice or pump shut off valve lt gt C Relief valve Solenoid operated 3 pos ee i 4 directional valve i lt tt I
50. on ground control panel OR repair open in wht red 6 wire circuit from TS20 to TB6 OR consult Genie Industries Service Department Repair open in wht red 6 wire circuit from TB6 to boom function proportional valve coil item D OR repair open in ground wire circuit to valve coil item D Troubleshoot turntable rotate function toggle switches TS20 and TS6 on ground and platform control panels OR repair open in wht red 6 wire circuit from 1520 to TB6 and from TS6 to red wire on boom function speed controller OR consult Genie Industries Service Department If voltage to TB6 from TS20 and TS6 has been restored and turntable rotate right function is still inoperative please continue troubleshooting from beginning of chart Genie Z 34 22 IC Part No 43037 Service Manual First Edition With key switch in ground position and both Emergency Stop switches pulled out to the on position activate the function enable toggle switch TS19 if equipped and the turntable rotate toggle switch TS20 on ground panel in right direction and check voltage on wht blk 5 wire on boom function directional valve coil item Continued from the previous page Continued on the next page 12V or more Section 5 Troubleshooting Flow Charts s With key switch in ground position and both Emergency Stop switches pulled out to the on position activate the function enable toggle switch
51. 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 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 Startthe 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 Release the foot switch and stop the engine Move the fuel select switch 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 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 B 19 Test the Drive Enable System Proper drive enable system operation is essential to safe machine operation When the primary boom is past the non steering wheels drive movement is stopped
52. then remove the flex plate from the engine How to Install the Flex Plate 1 Install the flex plate onto the flywheel with the raised spline against the flywheel b L a pump b pump shaft pump coupler d flex plate e flywheel Part No 43037 Genie Z 34 22 IC Section 7 Repair Procedures Service Manual First Edition KUBOTA WG 750 ENGINE 2 Install the coupler onto the pump shaft with the set screw towards the pump Leave a 1 32 inch 0 8 cm gap between the coupler and pump end plate 3 Apply removable Loctite thread sealant to the coupler set screw Torque the set screw to 36 ft lbs 49 Nm Component damage hazard Do ACAUTION not force the drive pump during installation or the flex plate teeth may become damaged 7 6 Water Temperature and Oil Pressure Gauges The water temperature gauge is an electrical gauge The sending unit has limit contacts that are factory set The contacts will close at 230 F 109 C When the contacts close the engine will shut off to prevent damage and will not start until the temperature drops below the contact point Temperature will be indicated when the key is on and the Emergency Stop Button is pulled out to the ON position Component damage hazard ACAUTION Do not crank the engine with the over temperature light on The oil pressure gauge is an electrical gauge The sending unit has limit contacts that are factory set The contacts wi
53. 1 OR repair open in wht wire circuit supplying 12V to terminal 1 12V or more Continued on the next page Genie Z 34 22 IC Part No 43037 Service Manual First Edition Section 5 Troubleshooting Flow Charts CHART 33 Switch rpm select switch 610 7V 5 to rabbit with foot switch pre horsepower limiter terminal 3 Continued from the previous page press down foot switch and check voltage at terminal 3 on ov horsepower limiter Check voltage at Repair open in org blk org blk wire on engine 610 7V wire circuit from alternator alternator to TB41 6 to 7V Repair or replace alternator Press down foot switch and check voltage at Replace horsepower limiter board L terminal 10 on horsepower limiter 9 to 12V Press down foot switch and check voltage at Repair open in red wire circuit from horse power limiter board to drive control terminal 6 terminal 6 on drive controller 9 to 12V Continued on the next page Part No 43037 Genie Z 34 22 5 79 Section 5 Troubleshooting Flow Charts CHART 33 previous page Continued from the Disconnect drive pump EDC wires press down foot switch hold drive controller in full forward position and check voltage across terminals 4 and 5 on drive controller Press down foot switch hold drive controller in full forward position and check vo
54. 1km h 1km h 40 ft 40 sec 40 ft 40 sec 12 2 m 40 sec 12 2 m 40 sec Gradeability stowed 37 96 45 96 Boom function speeds maximum from platform controls with 500 Ibs in platform Hydraulic Specifications Hydraulic fluid Dexron equivalent Drive pump Type bi directional variable displacement piston pump Displacement 1 71 cu in per revolution 28 cc Displacement 2 3000rpm 22 gpm 2500 psi 172 bar 83 3 L min Hydraulic tank suction line filter 25 micron with 5 psi 34 bar bypass Drive manifold 2A TO S0Seconds Motor shift brake relief pressure 210 psi Jib boom down 15 to 21 seconds 14 5 bar Primary boom up 16 to 22 seconds 4WD front motor 7 gpm flow regulators 26 5 L min Primary boom down 28 to 34 seconds Primary boom extend 24 to 30 seconds aw D eat Imolor 14 gpm flow regulators 53 L min Primary boom retract 14 to 20 seconds 2WD rear motor 22 Secondary boom up 16 to 22 seconds flow regulators 83 3 L min Secondary boom down 29 to 35 seconds Front drive motors 4WD models Turntable rotate 355 100 to 106 seconds Displacement per revolution 1 52 cu in Platform rotate 160 4 to 7 seconds 25 cc Rear drive motors Displacement per revolution 2 8 46 Function pump Type Fixed displacement gear pump Displacement 0 24 cu in per revolution 4cc Hydraulic tank return line filter 10 micron with 25 psi
55. 3000 PSI 2500 PSI Pi 1 51 3 1 3 1 3 1 3 1 T3 AS EE EP E E cM Re a MONS 1 ol 1 8200 PSI m je ag i c lg HM o Oe AX 1600 PSI 1400 PSI 1800 PSI B B B Jt J2 PRI PR2 3000 PSI 1500 PSI 3 1 3 1 0 025 inch He Ola o lo F AM T I I X I I p I p T Ap T D 0 028 inch e X w oso Ti pe J E ee J T3 T4 Part No 43037 Genie Z 34 22 IC 6 30 Section 6 Schematics nc I Hydraulic Schematic 4WD Models from serial number 1030 to 1186 Service Manual First Edition Section 7 Repair Procedures Observe and Obey 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 Repairs Start Read understand and obey the safety rules and operating instructions in the Genie Z 34 22 IC Operator s Manual Be sure that
56. 45 cm 4WD model 6 5 cm 16 5 cm acd Wheel width 10 in Operational dimensions 25 4 cm 18cm Height platform maximum 34 ft 8 in 10 6 Wheel lugs 4WD 9 5 8 18 Height working maximum 40 ft 8 in 12 4m Wheel lugs 2WD Front 8 5 18 8 5 18 22 ft 4 in 6 8m Rear 9 5 8 18 9 5 8 18 Turntable tailswing 0 Tire pressure 2WD 45 psi 100 psi Wheelbase 6 ft 2 in 1 9 m 3 1 bar 6 89 bar Minimum turning circle 13 ft 1 in 4m 4WD a ps outside 3 1 bar Minimum turning circle 5ft 8in 1 7m Lug nut torque 125 ft lbs 169 5 Nm inside Platform dimensions Turntable rotation 355 355 Length 56 in Platform rotation 180 180 TER 2 Width 30 in FI ties uid capaciti 76 om Fuel tank it 12 gall He OD capa 500 Ibs 227 kg Hydraulic tank capacity 18 gallons 68 1 liters Hydraulic system capacity 22 gallons including tank 83 3 liters Torque hubs 17 ounces 0 5 liters Continuous improvement of our products is Genie policy Product specifications are subject to change without notice Part No 43037 Genie Z 34 22 IC 2 1 Section 2 Specifications Service Manual First Edition SPECIFICATIONS Performance Specifications Drive speeds maximum 2WD 4wD Boom stowed high range 4 5 mph 4 0 mph 7 2 km h 6 4 km h 40 ft 6 1 sec 12 2 m 6 1 sec 40 ft 6 8 sec 12 2 m 6 8 sec Boom raised or extended 0 6 mph 0 6 mph
57. 52 Genie Z 34 22 IC Part No 43037 Service Manual First Edition Section 5 Troubleshooting Flow Charts 2 22 5 Oor Disconnect wire to infini Ad ihe turntable rotate left ae Replace turntable rotate page directional valve coil left directional valve coil item P Remove coil item P and test resistance 4108 ohms Exchange turntable rotate left and right directional valve s item P O and activate turntable rotate left function Replace defective directional valve function inoperative Install a 0 to 3000 PSI Check for mechanical pressure gauge at the restrictions keeping quick disconnect turntable rotate left coupling on the boom function from moving function manifold and OR the 0 050 orifice activate the turntable item X could be rotate left function plugged OR repair ydraulic motor or worm gear OR consult Genie less than 1750 PSI Industries Service Department Reset turntable rotate left relief item H pressure OR replace turntable rotate left relief valve item H OR repair hydraulic motor or worm gear OR boom function manifold could have an internal fault Consult Genie Industries Service Department Part No 43037 Genie Z 34 22 IC 5 53 Section 5 Troubleshooting Flow Charts Service Manual First Edition Chart 23 Turntable Rotate Right Function inoperative Be sure a
58. B 18 Test the Fuel Select Kubota Gasoline LPG Models 4 24 B 19 Test the Drive Enable 4 24 B 20 Test the Drive Brakes 4 25 B 21 Test the Drive Speed Stowed 4 26 vi Genie Z 34 22 IC Part No 43037 Service Manual First Edition mu Section Four TABLE OF CONTENTS Scheduled Maintenance Procedures continued B 22 Test the Drive Speed Raised or Extended Position 4 26 B 23 Test the Alarm Package Optional Equipment 4 27 B 24 Perform Hydraulic Analysis 4 28 B 25 Replace the Diesel Fuel Filter Water Separator Element Kubota Diesel Models 4 29 C 1 Check the Primary Boom Wear Pads 4 30 C 2 Check the Turntable Rotation Bearing Bolts 4 30 C 3 Check the Free wheel Configuration 4 31 4 Grease the Turntable Rotation Bearing Worm Drive Gear 4 32 C 5 Replace the Torque Hub 4 33 C 6 Replace the Hydraulic Filters 044 4 33 C 7 Replace the Gasoline Fuel Filter Kubota Gasoline LPG Models 4 34 C 8 Clean or Replace the Distributor and Rotor Kubota Gaso
59. D OR open in ground wire circuit to valve coil item D Troubleshoot platform level function toggle switches TS24 and TS10 on ground and platform control panels OR repair open in wht red 6 wire circuit from TS24 to TB6 and from TS10 to red wire on boom function speed controller OR consult Genie Industries Service Department If voltage to TB6 from 7824 TS10 has been restored and platform level up function is still inoperative please continue troubleshooting from beginning of chart Genie Z 34 22 Part No 43037 Service Manual First Edition Continued from the previous page With key switch in ground position and both Emergency Stop switches pulled out to the on position activate the function enable toggle switch TS19 if equipped and the platform level toggle switch TS24 on ground panel in up direction and check voltage on org 14 wire on boom function directional valve coil item M 12V or more Continued on the next page Section 5 Troubleshooting Flow Charts s aT With key switch in Emergency Stop switches pulled out to the on position activate the function enable toggle switch TS19 if equipped and theplatform level toggle switch TS24 on ground panel in up direction and check voltage at TB14 With key switch in platform position both Emergency Stop switches pulled out to the on position and boom function speed cont
60. Exchange secondary boom down and up directional valves item R Q and activate secondary boom down function Replace defective directional valve function inoperative Install a 0 to 3000 PSI Check for mechanical pressure gauge at the restrictions keeping quick disconnect secondary boom from coupling on the boom moving OR repair function manifold and cylinder or cylinder activate the secondary counterbalance valve boom down function OR consult Genie Industries Service less than 1600 PSI Department Reset secondary down relief item J pressure OR replace secondary down relief valve item J OR repair cylinder or cylinder counterbalance valve OR boom function manifold could have an internal fault Consult Genie Industries Service Department 5 44 Genie Z 34 22 Part No 43037 Service Manual First Edition Section 5 Troubleshooting Flow Charts Primary Boom Extend Function inoperative Be sure all other functions operate normally If primary boom extend function operates normally from the ground controls but not from the platform controls troubleshoot the platform controller or diode See Repair Section If primary boom extend function operates normally from the platform controls but not from the ground controls troubleshoot the ground control toggle switch OR diode OR resistor See Repair Section With key switch in ground position and both E
61. Inspection 3 7 Scheduled Maintenance Procedures Lu uu uuu C 4 1 A 1 Inspect the Operator s and Safety Manuals 4 2 2 Inspect the Decals and 4 2 Inspect for Damage Loose or Missing Parts 4 3 4 Check the Engine Oil Level 4 3 A 5 Check the Engine Coolant Level 4 4 A 6 Check for Fuel Eeaks oett rene 4 4 A 7 Check the Hydraulic Oil Level 4 5 8 Check for Hydraulic LeaKs 2 enn 4 5 Part No 43037 Genie Z 34 22 IC Service Manual First Edition TABLE OF CONTENTS Section Four Scheduled Maintenance Procedures continued A 9 Check the Tire gt 00 cnet nee erede 4 6 A 10 Test the Platform and Ground 4 6 A 11 Test the Auxiliary Power 4 7 A 12 Test the Tilt 4 8 A 13 Test the Limit Switches we u nied 4 8 A 14 Perform 30 Day 4 10 A 15 Clean the Air Filter Element 00000000 4 10 A 16 Drain the F
62. MANIFOLD BRAKE 150 175 PSI 6 21 Genie Z 34 22 43037 Service Manual Section 6 Schematics Hydraulic Schematic 2WD Models from serial number 674 to 1029 L K J H G F E D PLATFORM LEVEL SLAVE CYLINDER 1 SECONDARY BOOM PRIMARY BOOM PRIMARY BOOM EXTENSION JIB BOOM d 0 032 inch 0 025 inch o ME Ho 2 x TURNTABLE ROTATE PLATFORM ROTATE 3000 PSI 4 Lj Li _ S 5 9 CU IN REV e E MEE MASTER TN Tm 9 H Ue E 3000 PSI 3000 PSI 2500 PSI 2500 PSI 1 51 3 1 3 1 3 1 4 REED R L TL M es J E 8 GPM 5 4 320
63. See Repair Section If platform level up function operates normally from the platform controls but not from the ground controls troubleshoot the ground control toggle switch OR diode OR resistor See Repair Section With key switch in ground position and both Emergency Stop switches pulled out to the on position activate the function enable toggle switch TS19 if equipped and the platform level toggle switch TS24 on ground panel in up direction and check voltage on wht red 6 wire on boom function proportional valve coil item D Continued on the next page 12V or more With key switch in ground position and both Emergency Stop switches pulled out to the on position activate the function enable toggle switch TS19 if equipped and the platform level toggle switch TS24 on ground panel in up direction and check voltage at TB6 With key switch in platform position both Emergency Stop switches pulled out to the on position and boom function speed controller turned to 9 activate footswitch and platform level toggle switch TS10 on platform control panel in up direction and check voltage at TB6 Troubleshoot platform level function toggle Switch TS24 on ground control panel OR repair open in wht red 6 wire circuit from TS24 to TB6 OR consult Genie Industries Service Department Repair open in wht red 6 wire circuit from TB6 to boom function proportional valve coil item
64. ULM 6 W M4 2 22 450475 PSI i RIGHT 1 025 A REAR LAB jn Ea BRAKE ve 7 4 g 2 SPD 219 mE 2WD L 7 TM TRACTION BRAKE 2 SPEED REAR MANIFOLD 1 8 MANIFOLD BRAKE 150 175 PSI 6 23 Genie Z 34 22 43037 Service Manual Section 6 Schematics Hydraulic Schematic 2WD Models from serial number 1030 to 1186 M K J D PLATFORM LEVEL SLAVE CYLINDER n 1 SECONDARY BOOM PRIMARY BOOM PRIMARY BOOM EXTENSION JIB BOOM n pisce 2 Q Ww i J uf X TURNTABLE ROTATE PLATFORM ROTATE 3000 PSI 84 LJ 64 i 5 9 CU IN IRE T ie mE 7 9 MASTER E E o IE omw HL o HM owI d E H i Lil x 2 82 3000 PSI 3000 PSI 2500 PSI 3000 PSI 2500 PSI _ 1 51 3 1 3 1 3 1 3 1 i ANDE 1 G1 un X P1 p 4 3200 PSI e 4 pe Ns ES lop ME NIE HM DM OT m 1600 PSI 1400 PSI 1800 PSI qus md LCS PN p 31 3 1 9 059 Ee
65. a 0 to 5000 PSI Check for mechanical pressure gauge at the restrictions keeping quick disconnect primary boom from coupling on the boom moving OR repair function manifold and oylinder or cylinder activate the primary counterbalance valve boom up function OR consult Genie Industries Service Department less than 3200 PSI Repair cylinder or cylinder counterbalance valve OR boom function manifold could have an internal defect Consult Genie Industries Service Department Part No 43037 Genie Z 34 22 IC 5 35 Section 5 Troubleshooting Flow Charts Service Manual First Edition Chart 17 Primary Boom Down Function inoperative Be sure all other functions operate normally If boom down function operates normally from the ground controls but not from the platform controls troubleshoot the platform controller or diode See Repair Section If boom down function operates normally from the platform controls but not from the ground controls troubleshoot the ground control toggle switch OR diode OR resistor See Repair Section With key switch in ground position and both Emergency Stop switches pulled out to the on position activate the function enable toggle switch TS19 if equipped and the primary boom toggle switch TS22 on ground panel in down direction and check voltage on wht red 6 wire on boom function proportional valve coil item D 12V or more Continu
66. a safety chock on the secondary 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 The lift cylinder safety chock is available through Genie part number 36555 2 Checkto ensure that each turntable bearing bolt is torqued in specified order to 190 foot pounds 258 Newton meters 1 Bolt torque sequence 3 Remove the safety chock Lower the boom to the stowed position Genie Z 34 22 IC Part No 43037 Service Manual First Edition Section 4 Scheduled Maintenance Procedures 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 190 foot pounds 258 Newton meters 9 Q 1 6 0920 013 94 149 015 i2 gt 10 Bolt torque sequence TABLE C PROCEDURES C 3 Check the Free wheel Configuration 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 property 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
67. all necessary tools and parts are available and ready for use 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 orr position with the key removed Wheels chocked All exernal AC power disconnected from the machine 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 Then to re assemble perform the disassembly steps in reverse order Identify symptoms Malfunction Troubleshoot discovered problem still exists Perform repair Return to service problem solved General Repair Process Symbols Legend Indicates the presence of a hazard A DANGER that will cause death or serious injury Indicates the presence of a hazard AWARNING that may cause death or serious injury Indicates the presence of a hazard ACAUTION that will or may cause serious injury or damage
68. and free of debris that could get into the hydraulic system and cause severe component damage Dealer service is recommended 1 Disconnect the electrical connection at the electronic displacement controller EDC located on the drive pump 2 Tag disconnect and plug the hydraulic hoses on 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 3 Support the pump and remove the two drive pump mounting bolts Carefully remove the pump Part No 43037 Genie Z 34 22 Section 7 Repair Procedures Service Manual First Edition HYDRAULIC PUMPS How to Prime the Pump 1 Connect a 0 to 6000 psi 0 to 414 bar pressure gauge to the test port on the drive pump 2 Kubota Gasoline LPG models Remove the high tension lead from the center of the ignition coil Electrocution hazard Contact with ACAUTION electrically charged circuits may result in death or serious injury Remove all rings watches and other jewelry Kubota Diesel models Hold the manual fuel shutoff valve clockwise to the cLosEp 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 7 36 Genie Z 34 22 IC Part No 43037 Service Manual First Edition Sect
69. axle 3 Raise the machine 6 inches 15 cm and place blocks under the chassis 4 Remove the lug nuts then the tire and wheel assembly 5 Remove the cotter pin then the clevis pin from both the steering cylinder and the tie rod weldment axle king pin pin retainer yoke torque hub cotter and clevis pin steering cylinder tie rod m 6 Tag disconnect cap the hydraulic hoses from the drive motor and plug them Cap the drive motor hydraulic fittings 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 Remove the drive motor mounting fasteners Slide the drive motor shaft out of the torque hub and then remove it 8 Remove the retaining fasteners from the king pins Do not remove the pins 9 Attach a strap from a lifting device to the yoke torque hub assembly and support it 10 Use a soft metal drift to drive the king pins down and out AWARNING Crushing hazard The yoke torque hub assembly will fall when the king pins are removed if it is not properly supported 11 Place the yoke torque hub assembly on a flat surface with the torque hub down Remove the bolts that secure the yoke to the torque hub Specifications Lubricated Dry Lug nut torque 94 ft lbs 125 ft lbs 127 Nm 169 Nm Part No 43037 Genie Z
70. boom circuit 6 2 position way spool valve Basics S 2 a etis 8 10 ft Ibs 11 14 Nm How to Check the Resistance of a Valve Coil 1 Turn the key switch to the position disconnect the wires from the valve coil to Plug Torque Specifications be tested 2 Coils with 2 terminals Connect the leads from Description Hex Size Torque P 3 the ohmmeter to the valve coil terminals 1 in SARNO S fs Sirpa M Coils with 1 terminal Connect the positive SAE No 4 3 16 13 ft lbs 18 Nm lead from the ohmmeter to the valve coil terminal then connect the negative lead from SAE No 6 1 4 18 ft lbs 24 Nm the ohmmeter to the internal ring of the valve SAE No 8 5 16 50 ft lbs 68 Nm coil SAE No 10 9 16 55 ft lbs 75 Nm Valve coil specification SAE No 12 5 8 75 ft lbs 102 Nm 2 position 3 way valve 10V 5 5 to 6 50 Part No 43037 Genie Z 34 22 7 13 Section 7 Repair Procedures Service Manual First Edition 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 ACAUTION Component damage hazard
71. but not from the ground controls troubleshoot the ground control toggle switch OR diode OR resistor See Repair Section With key switch in ground position and both Emergency Stop switches pulled out to the on position activate the function enable toggle switch TS19 if equipped and the primary boom toggle switch TS22 on ground panel in up direction and check voltage on wht red 6 wire on boom function proportional valve coil item D Continued on the next page 12V or more With key switch in ground position and both Emergency Stop switches pulled out to the on position activate the function enable toggle switch TS19 if equipped and the primary boom toggle switch TS22 on ground panel in up direction and check voltage at TB6 With key switch in platform position both Emergency Stop switches pulled out to the on position and boom function speed controller turned to 9 activate footswitch and primary boom function toggle switch TS8 on platform control panel in up direction and check voltage at TB6 Troubleshoot primary boom function toggle switch TS22 on ground control panel OR repair open wht red 6 wire circuit from TS22 to TB6 OR consult Genie Industries Service Department Chart 16 Repair open in wht red 6 wire circuit from TB6 to boom function proportional valve coil item D OR repair open in ground wire circuit to valve coil item D Troubleshoot
72. 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 Part No 43037 Genie Z 34 22 IC Section 7 Repair Procedures Service Manual First Edition SECONDARY BOOM COMPONENTS 20 Lower the booms to the stowed position 21 Pull all the cables and hoses through the upper mid pivot Component damage hazard ACAUTION Cables and hoses can be irreparably damaged if they are kinked or pinched 22 Position the strap from the overhead crane approximately two feet from the platform end of the primary boom Measure from the end of the primary boom tube 23 Remove the pin retainers from the upper mid pivot to upper compression arm pivot pins Use a soft metal drift to remove the pins 24 Swing the compression arms down and out of the way Secure them from moving 25 Remove the pin retainers from the upper mid pivot to upper secondary boom pivot pin Use a soft metal drift to remove the pin 26 Carefully remove the entire primary boom assembly from the machine primary boom assembly jib boom assembly platform master cylinder primary lift cylinder and upper mid pivot Crushing hazard If the overhead AWARNING crane is not properly attached the primary boom assembly may become unbalanced and fall when it is removed from the machine Do not remove the assembly from machine until it is properly balanced 27 P
73. compression arm pivot pins Use a slide hammer and remove the pin 45 Remove the pin retainers from the lower mid pivot to lower secondary boom pivot pins Use a soft metal drift to remove the pin SECONDARY BOOM COMPONENTS 46 Remove the lower mid pivot from the machine AWARNING Crushing hazard If the overhead crane is not properly attached the lower mid pivot may become unbalanced and fall when it is removed from the machine 47 Attach the strap from the crane to the control box side lower compression arm 48 Remove the pin retainer from the lower compression arm to turntable pivot pin Use a slide hammer and remove the pin Remove the arm from the machine Repeat for the engine side lower compression arm Crushing hazard If the overhead AWARNING crane is not properly attached the lower compression arms may become unbalanced and fall when it is removed from the machine 49 Attach the strap from the crane to the lower secondary boom 50 Remove the pin retainer from the lower secondary boom to turntable pivot pin Use a soft metal drift to remove the pin 51 Remove the lower secondary boom from the machine AWARNING Crushing hazard If the overhead crane is not properly attached the lower secondary boom may become unbalanced and fall when it is removed from the machine Part No 43037 Genie Z 34 22 Section 7 Repair Procedures Service Manual First Edition SECONDARY BOOM COMPONENTS 5 2
74. decrease the pressure Then install the relief valve cap AWARNING Tip over hazard Do not adjust the relief valves higher than specified 6 Repeat steps 2 through 5 and recheck the valve pressure Secondary boom down relief valve specifications Pressure 1800 psi 124 bar Pressure 1600 psi 110 bar Part No 43037 Genie Z 34 22 IC Section 7 Repair Procedures Service Manual First Edition EEE eT FUNCTION MANIFOLD How to Check the Resistance of a Valve Coil 1 Turn the key switch to the orr position and disconnect the wires from the valve coil to be tested 2 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 Valve coil specifications 2 position 3 way solenoid valve 10V 5 5 6 50 Proportional solenoid valve 12V 4 5 20 7 44 Genie Z 34 22 Part No 43037 Service Manual First Edition Section 7 Repair Procedures Fuel and Hydraulic Tanks 11 1 Fuel Tank How to Remove the Fuel Tank ADANGER 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 ADANGE
75. e TS25 17523 WHT RED 3A m C 2 Jj RED 1A HM m RED BLK 2A C TS24 TS22 BLU 10A BLU BLK 11A TS26 6 TS21 TS17 TS16 F WHT 4A WHT BLK 5A 5 E C EN t1 Eo TS20 2 819 CB2 CB1 RED 20A GRN 43A GRN BLK 44A ORG 14A ORG BLK 15A RED R1 30 BLK WHT 34A BLK 33A BLK RED 35A LABEL DESCRIPTION Pt EMERGENCY STOP BUTTON KS1 KEY SWITCH 1815 AUXILIARY SWITCH TS16 ENGINE START SWITCH TS17 ENGINE GLOW PLUG SWITCH TS19 ENGINE RPM SWITCH TS20 TURNTABLE ROTATE SWITCH TS21 SECONDARY BOOM UP DOWN SWITCH TS22 PRIMARY BOOM UP DOWN SWITCH TS23 BOOM EXTEND RETRACT SWITCH TS24 PLATFORM LEVEL SWITCH TS25 PLATFORM ROTATE SWITCH TS26 JIB UP DOWN SWITCH CIRCUIT BREAKER CONTROLS 10 CB2 CIRCUIT BREAKER ENGINE 10A HM HOUR METER Rt RESISTOR 5 OHM BOOM FUNCTIONS EH ENGINE HARNESS MH MANIFOLD HARNESS Service Manual C Section 6 Schematics Esas JY c l Ground Control Box Wiring Diagram Diesel Models from serial number 869 to 1186 B A CABLE 8 CABLE 7 CABLE 6 CABLE 5 CABLE 1 ENGINE MANIFOLD HARNESS d
76. foot switch Move the primary boom switch to the pown position hold for a moment and then release it Move the secondary boom switch to the pown 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 Q Result The travel alarm should sound when the drive control handle is moved off center in either direction 4 28 Genie Z 34 22 IC Part No 43037 Service Manual First Edition Section 4 Scheduled Maintenance Procedures B 25 Replace the Diesel Fuel Filter Water Separator Element Kubota Diesel Models Kubota engine specifications require that this procedure be performed every 400 hours Replacing the diesel 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 DNI 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 Perform this procedure wit
77. function toggle switch TS25 on ground control panel OR replace diode on TS25 OR repair open in grn 17 wire circuit from 7525 to boom function directional valve item C OR consult Genie Industries Service Department CHART 27 Repair open in grn 17 wire circuit from TB17 to boom function directional valve coil item C OR repair open in ground circuit to manifold item Troubleshoot platform rotate function toggle switches TS25 and 1511 on ground and platform control panels OR replace diodes on 1525 and TS11 OR repair open in org wire circuit from 7525 and TS11 to boom function directional valve item C OR consult Genie Industries Service Department If voltage to boom function directional valve coil item C from TS25 and TS11 has been restored and platform rotate left function is still inoperative please continue troubleshooting from beginning of chart Part No 43037 Genie Z 34 22 Section 5 Troubleshooting Flow Charts Service Manual First Edition ee TA CHART 27 Disconnect wire to o platform rotate left infinite directional valve coil ohms Replace platform rotate item C Remove coil left directional valve coil and test resistance Continued from the previous page 4 to 8 ohms Exchange platform rotate left and right function directional valves item operates D and activate platform rotate left function R
78. idle rabbit and foot switch symbol Move the drive select switch to high range machine on level ground symbol 10 Press down the foot switch and re adjust the A potentiometer to the previous voltage setting in step 6 11 Be sure that the boom is in the stowed position then drive the machine and observe how the engine rpm reacts to drive control handle movement If the engine surges or hunts adjust the C potentiometer counterclockwise until surging is minimized Under an extreme load an excessive counterclockwise adjustment to the C potentiometer will cause the engine to stall The C potentiometer adjustment is a compromise between engine stability surging and engine rpm droop PLATFORM CONTROLS 12 Disconnect the volt meter 13 Raise the primary boom above the drive limit Switch a drive limit switch 14 Drive the machine for 40 feet 12 m and record the elapsed time Repeat this step in the opposite drive direction 15 Adjust the B potentiometer to obtain the correct raised drive speed of 1 foot per second 30 5 cm per second 16 Close the platform control box lid and install the fasteners Drive speed specifications Stowed position high range 2WD 4WD 40 86 1 sec 40 6 8 sec 12 2 m 6 1 12 2 m 6 8 sec 40 ft 6 1 sec 40 ft 6 8 sec 12 2 m 6 1 sec 12 2 m 6 8 sec Kubota Gas LPG Models Kubota Diesel Models 40 feet 40 seconds 12 meters 40
79. lifting jack of ample capacity 15000 Ibs 6804 kg under the drive chassis between the non steering wheels 3 Liftthe 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 5 Manually rotate each non steering wheel brake disengage position brake engage position 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 Part No 43037 Genie Z 34 22 IC 4 31 Section 4 Scheduled Maintenance Procedures Service Manual First Edition TABLE C PROCEDURES C 4 5 Locate the grease fitting on the worm drive Grease the Turntable Rotation ROUSING Bearing and Worm Drive Gear 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 a grease fitting 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 7 Grease each tooth on the outside of the AW
80. lower secondary boom Pull all the cables and hoses to the back of the turntable 37 Remove the LPG hose from the tank and then remove the LPG tank this is to access the barrel end mounting pin Genie Z 34 22 IC Part No 43037 Service Manual First Edition Section 7 Repair Procedures 38 Disconnect the battery cables from the battery then remove the battery hold down and battery this is to access the barrel end mounting pin 39 Remove the retaining fasteners from the secondary boom lift cylinder barrel end pivot pins 40 Attach the strap from the crane to the lug on the rod end of the secondary boom lift cylinder 41 Tag disconnect and plug the hydraulic hoses from the secondary boom lift cylinder 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 42 Use a slide hammer to remove the barrel end pins access the pins from the access holes in the bulkheads one on each side Then remove the cylinder from the machine AWARNING Crushing hazard If the overhead crane is not properly attached the secondary boom lift cylinder may become unbalanced and fall when itis removed from the machine 43 Attach the strap from the crane to the lower mid pivot 44 Remove the pin retainers from the lower mid pivot to lower
81. 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 orr position with the key removed Wheels chocked All exernal AC power disconnected from the machine Before Troubleshooting Read understand and obey the safety rules operating instructions printed in the Genie 2 34 22 IC Operator s Manual Be sure that all necessary tools and test equipment are available and ready for use Read each appropiate flow chart thoroughly Attempting shortcuts may produce hazardous conditions Be aware of the following hazards and follow generally accepted safe workshop practices Crushing hazard When testing ADANGER or replacing any hydraulic component always support the structure and secure it from movement Electrocution hazard Contact A DANGER with electrically charged circuits may result in death or serious injury Remove all rings watches and other jewelry 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 Perform all troubleshooting on a firm level surface Two persons will be required to safely perform some troubleshooting procedures Part No 43037 Genie Z 34 22 5 1 Sect
82. 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 Refer to B 7 in this section Confirm the Proper Brake Configuration Select a test area that is firm level and free of obstructions 1 Mark a test 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 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 TABLE B PROCEDURES 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 Braking high range paved surface 3 to 4 ft 0 91 to 1 22 m Stopping distance The brakes must be able to hold the machine on any slope it is able to climb Part No 43037 Genie Z 34 22 Section 4 Scheduled Maintenance Procedures Service Manual First Edition TABLE B PROCEDURES B 21 Test the Drive Speed Stowed Position Prope
83. 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 may result in death or serious injury and significant component damage Dealer service is strongly recommended Before cylinder removal is considered bleed the cylinder to be sure that there is no air in the closed loop See 2 2 How to Bleed the Slave Cylinder 1 Remove the rear turntable cover 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 an overhead crane to the pivot end of the primary boom Do not lift it Part No 43037 Genie Z 34 22 IC Section 7 Repair Procedures Service Manual First Edition PRIMARY BOOM COMPONENTS 5 Secure the upper secondary boom to the pivot end of the primary boom with a strap this will prevent the upper secondary boom from falling when the master cylinder barrel end pin is removed from the cylinder 6 Tag disconnect and plug the master cylinder hydraulic hoses Cap the fittings on the cylinder AWARNING Bodily injury hazard Spraying hydraulic oil can penetrate and
84. on good Replace CR8 terminal 85 on CR8 bad Repair open in ground wire on terminal 85 on CR8 Repair open in circuit supplying 12V to choke switch Replace toggle switch OR replace diode Genie Z 34 22 IC Part No 43037 Service Manual First Edition Section 5 Troubleshooting Flow Charts sania sana s J sss CHART 5 Hold ground control Repair open in red wire choke switch and check circuit from from choke voltage at red wire on switch to fuel select center terminal of fuel switch select switch Hold ground control Replace fuel select choke switch and check switch voltage at blk wht wire on fuel select switch Continued from the previous page Hold ground control Repair open in blk wht choke switch and check wire circuit from fuel voltage at TB34 select switch to TB34 Hold ground control Repair open in blk wht choke switch and check wire circuit from TB34 to otage at terminal 86 terminal 86 on CR8 on CR8 Check ground wire circuit on terminal 85 on CR8 Repair open in ground wire circuit Replace CR8 and hold ground control choke switch Consult Genie Industries Service Department choke does not work choke works Continued on the next page Part No 43037 Genie Z 34 22 IC 5 17 Section 5 Troubleshooting Flow Charts Service Manual First Edition CHART 5 Turn keyswitch to platform contro
85. or either Emergency Stop button fails to stop all the machine functions Each function should operate smoothly and be free of hesitation jerking and unusual noise 1 Start the engine from the ground controls 2 Do not hold the function enable switch to either side Attempt to activate each boom and platform function toggle switch Result All boom and platform functions should not operate 3 Hold the function enable switch to either side and activate each boom and platform function toggle switch Result All boom and platform functions should operate through a full cycle Descent alarm if equipped should sound while boom is lowering Machines equipped with Platform Level Control Disable Function The platform level toggle switch will not operate when the boom is raised past the drive speed limit switch Genie Z 34 22 IC Part No 43037 Service Manual First Edition Section 4 Scheduled Maintenance Procedures 4 Push in the Emergency Stop button to the position Result No function should operate the machine should stop 5 Turn the key switch to platform control and pull out the Emergency Stop button to the on position at both the ground and platform controls 6 Start the engine from the platform controls 7 Operate each machine function through a full cycle Result All machine functions should operate smoothly 8 Push in the Emergency Stop button to the position
86. quick disconnect platform rotate right coupling on the boom function from moving function manifold and OR the 0 030 orifice activate the platform item E could be rotate right function plugged OR repair LEON motor consult Genie less than 3200 PSI Industries Service Department Repair hydraulic rotation motor OH platform rotate jib function manifold could have an internal fault Consult Genie Industries Service Department Part No 43037 Genie Z 34 22 IC 5 69 Section 5 Troubleshooting Flow Charts Service Manual First Edition Chart 29 Jib Boom Up Function inoperative Be sure all other functions operate normally If jib boom up function operates normally from the ground controls but not from the platform controls troubleshoot the platform controller or diode See Repair Section If jib boom up function operates normally from the platform controls but not from the ground controls troubleshoot the ground control toggle switch OR diode OR R1 resistor See Repair Section With key switch in ground position and both Emergency Stop switches pulled out to the on position activate the function enable toggle switch TS19 if equipped and thejib toggle switch TS26 on ground panel in up direction and check voltage on wht red 6 wire on boom function proportional valve coil item D 12V or more Continued on the next page With key switch in ground position and both Emergency S
87. relays 1 Turn the key switch to the position and remove the key 2 Label and then disconnect all the wiring from the relay to be tested 3 Connect the leads from an ohmmeter to each terminal combination and check for continuity Terminals 85 and 86 represent the coil and should not be tested in any other combination Test Desired result terminal 85 to 86 85 to 950 terminal 87 to 87a amp 30 no continuity infinite terminal 87a to 30 continuity zero Q 4 Connect 12V DC to terminal 85 and a ground wire to terminal 86 then test the following terminal combinations Test Desired result terminal 87a to 87 amp 30 no continuity infinite terminal 87 to 30 continuity zero Q O 85 87 87a L O 86 30 Relay Schematic 7 UN 87 86 9748 gs 30 Terminal Numbers Genie Z 34 22 IC Part No 43037 Service Manual First Edition Section 7 Repair Procedures a GROUND CONTROLS 8 2 Toggle Switches See 1 4 Toggle Switches 8 3 Wago Components How to Remove a Wago Component AWARNING Electrocution hazard Contact with electrically charged circuits may cause death or serious injury Remove all rings watches and other jewelry A small screwdriver is provided and should be used when removing a Wago component Thi
88. s ZEB Z 9 l e 5 T T ES34D3E SPARE WIRES GRN WHT 45 1 RED JIB ORG RED 3 ORG RED 42 1 ES34GP3E gira SIC LHM gir ouo 1 Service Manual Section 6 Schematics ey Platform Control Box Wiring Diagram Gasoline LPG Models A REMOVE THIS WIRE WHEN LOAD SENSE OPTION IS REQUIRED E a GOOS 999 gt E mt 2 2 4 PAS LABEL DESCRIPTION g P2 EMERGENCY STOP BUTTON HORN BUT
89. side OR replace solenoid Continued from the previous page Check voltage at red wird Repair open in red wire on terminal 30 of CR2 circuit from battery to CB2 to CR1 to CR2 Hold start switch and Hold start switch and Repair open in blk wire check voltage at terminal check voltage at terminal 12V from terminal 86 CR 86 of CR2 9 on ign start module to terminal 9 on ign start module Check voltage at termina oy Repair open in power 7 on start lockout supply wire to terminal module on ign start module Replace the ign start module OR consult Genie Industries Service Department good Repair open in ground wire to Check ground to terminal no 85 on CR2 good Continued the next page 5 12 Genie Z 34 22 Part No 43037 Service Manual First Edition Crank engine and check oy voltage at terminal 2 on ign start module Continued from the previous page 6 to 7V While cranking engine foy yes 15 seconds check continuity to ground on terminal 10 on ign start module Is continuity maintained no Check voltage at termina joy 4 on ign start module Replace ign start OR consult Genie Industries Service Department Section 5 Troubleshooting Flow Charts s Crank engine and check voltage at org blk 41 wire on alternator 6 to 7V Repair open
90. switches TS22 and TS8 on ground and platform control panels OR replace diodes on 7822 and TS8 OR repair open red blk 2 wire circuit from TS22 and TS8 to TB2 OR consult Genie Industries Service Department If voltage to TB2 from TS22 and TS8 has been restored and primary boom down function is still inoperative please continue troubleshooting from beginning of chart Part No 43037 Genie Z 34 22 IC Section 5 Troubleshooting Flow Charts Service Manual First Edition CHART 17 Oor infinite ohms Disconnect wire to primary boom down directional valve coil item T Remove coil and test resistance Replace primary boom down directional valve coil item T Continued from the previous page 4 to 8ohms function Exchange primary boom operates Replace defective down and up directional directional valve valves item T S and activate primary boom down function function inoperative Install a 0 to 3000 PSI Check for mechanical pressure gauge at the restrictions keeping quick disconnect primary boom from coupling on the boom moving OR repair function manifold and cylinder or cylinder activate the primary counterbalance valve boom down function OR consult Genie Industries Service less than 1400 PS Department Reset primary down relief item K pressure OR replace primary down relief valve item K OR repair cylinder or cylinder counterbal
91. switches pulled out to the on position activate the function enable toggle switch 7519 if equipped and theplatform rotate toggle switch TS25 on ground panel in left direction and check voltage on wht red 6 wire on boom function proportional valve coil item D 12V or more Continued on the next page With key switch in ground position and both Emergency Stop switches pulled out to the on position activate the function enable toggle switch 7519 if equipped and theplatform rotate toggle switch TS25 on ground panel in left direction and check voltage at TB6 With key switch in platform position both Emergency Stop switches pulled out to the on position and boom function speed controller turned to 9 activate footswitch and platform rotate toggle Switch TS11 on platform control panel in left direction and check voltage at TB6 Troubleshoot platform rotate function toggle switch TS25 on ground control panel OR repair open wht red 6 wire circuit from TS25 to TB6 OR consult Genie Industries Service Department Repair open in wht red 6 wire circuit from TB6 to boom function proportional valve coil item D OR open in ground wire circuit to valve coil item D Troubleshoot platform rotate function toggle switches TS25 and TS11 on ground and platform control panels OR repair open in wht red 6 wire circuit from TS25 to TB6 and from TS11 to red wire on boom function speed contr
92. terminal 30 on CR6 With keyswitch on no good ground position and Emergency Stop switch pulled out crank engine and check voltage at terminal 87 CR6 Check ground wire on Repair open in ground terminal 485 of CR6 i wire Replace CR6 Continued on the next page Genie Z 34 22 IC Part No 43037 Service Manual First Edition Section 5 Troubleshooting Flow Charts g s CHART 2A Hold start switch and Repair open blu wht check voltage at blu wht wire circuit CR6 to anti wire on anti diesel valve diesel valve on engine carburetor Continued from the previous page Hold start switch and Repair open in blu wht check voltage at blu wht wire circuit from anti R6 wire on gasoline fuel diesel valve to fuel pump pump Reconnect the two wires to vacuum switch and check for fuel line blockage OR replace anti diesel valve OR see Kubota service manual for troubleshooting fuel pump and or carburetor OR Consult Genie Hold start switch does engine fire Go to chart 2B Industries Service Department Part No 43037 Genie Z 34 22 IC 5 9 Section 5 Troubleshooting Flow Charts Service Manual First Edition Chart 2B Engine Runs While Cranking Then Dies Kubota Gas LPG Models voltage at terminal 2 on ign start module While cranking engine for 15 seconds check continuity to ground on terminal 10 ign start modu
93. tested 2 Coils with 2 terminals Connect the leads from Description Hex Size Torque 9 the ohmmeter to the valve coil terminals 1 in fs Spes S qum Coils with 1 terminal Connect the positive SAE No 4 3 16 13 ft lbs 18 Nm lead from the ohmmeter to the valve coil terminal then connect the negative lead from SAE No 6 1 4 18 ft lbs 24 Nm the ohmmeter to the internal ring of the valve SAE 8 5 16 50 ft lbs 68 Nm coil SAE No 10 9 16 55 ft lbs 75 Nm Valve coil specification SAE No 12 5 8 75 ft lbs 102 Nm 2 position 3 way valve 10V 5 5 to 6 50 7 12 Genie Z 34 22 IC Part No 43037 Service Manual First Edition Section 7 Repair Procedures MMM R JIB BOOM COMPONENTS 3 4 Jib Boom Platform Rotate Manifold Components after serial number 1029 The jib boom platform rotate manifold is mounted to the jib boom Index Schematic No Description Item Function Torque 1 2 position way spool valve A teet Does 8 10 ft Ibs 11 14 Nm 2 2 position way spool valve ID usus Platform rotate right 8 10 ft lbs 11 14 Nm 3 2 position way spool valve Platform rotate 8 10 ft lbs 11 14 Nm 4 Orifice 0 025 in 0 64 mm E s Platform rotate circuit 5 Orifice 0 028 in 0 71 mm E uus Platform rotate and jib
94. the lock nut and recheck the rpm Kubota Diesel models Low idle 1300 rpm High idle 3000 rpm Part No 43037 Genie Z 34 22 Section 4 Scheduled Maintenance Procedures Service Manual First Edition TABLE B PROCEDURES B 11 Test the Key Switch Proper key switch action and response is essential to safe machine operation The machine can be operated from the ground or platform controls and the activation of one or the other is accomplished with the key switch Failure of the key switch to activate the appropriate control panel could cause a hazardous operating situation 1 Pull out the Emergency Stop button to the on position at both the ground and platform controls 2 Turn the key switch to platform control 3 Check the machine functions from the ground controls Result The machine functions should not operate 4 Turn the key switch to ground control 5 Checkthe machine functions from the platform controls Result The machine functions should not operate 6 Turn the key switch to the orr position Result No function should operate the machine should stop B 12 Test the Emergency Stop Buttons Properly functioning Emergency Stop buttons are essential for safe machine operation An improperly operating Emergency Stop button may fail to shut off power and stop all machine functions resulting in a hazardous situation As a safety feature selecting and operating the gr
95. the voltage or counterclockwise to decrease the voltage 7 Turnthe boom function speed controller to the 9 position 8 Setthe max out Press down the foot switch then move the primary boom switch to the uP position Adjust the voltage to 8 5 to 9 0V DC Turn the max out trimpot adjustment screw clockwise to increase the voltage or counterclockwise to decrease the voltage Boom function speed controller specifications Threshold 5 00 to 6 00V DC Max out 8 5 to 9 0V DC 1 2 Diodes How to Test a Diode 1 Connect the leads from an ohmmeter to each end of the diode 2 Re connect the leads from the ohmmeter to the opposite ends from step 1 of the diode The diode should have resistance in one direction and not the other 7 4 Genie Z 34 22 IC Part No 43037 Service Manual First Edition Section 7 Repair Procedures E esl PLATFORM CONTROLS 1 3 Foot Switch How to Test the Foot Switch 1 Turn the key switch to the orr position and separate the wiring quick disconnect plug from the platform toe board 2 Do not press down the foot switch Connect the leads from an ohmmeter or continuity tester to each wire combination listed below and check for continuity Test Desired result red to black continuity zero red to white no continuity infinite black to white no continuity Do not use the color of the connector as a guide for these tests Use the actual wire color to iden
96. 0 Install a new cotter pin Bend the cotter pin to lock it 11 Install the dust cap then the tire and wheel assembly Torque the wheel lug nuts to 125 foot pounds 169 5 Nm 13 2 Steer Cylinder How to Remove a Steer Cylinder 1 Tag disconnect and plug the hydraulic hoses from the steering cylinder Cap the fittings 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 2 Remove the cotter pin Then remove the clevis pin from each end of the steer cylinder 3 Remove the steer cylinder Always use a new cotter pin when installing a clevis pin 13 3 Tie Rod How to Remove the Tie Rod 1 Remove the cotter pin then remove the clevis pin from each end of the tie rod 2 Remove the tie rod Always use a new cotter pin when installing a clevis pin Genie Z 34 22 IC Part No 43037 Service Manual First Edition Section 7 Repair Procedures 4WD Steer Axle Components 14 1 Yoke and Hub How to Remove the Yoke and Hub The yoke installation utilizes bushings and a thrust washer that require periodic replacement depending upon the application The drive motor must be removed before the torque hub and yoke can be removed 1 Loosen the wheel lug nuts Do not remove them 2 Block the non steer wheels and then center a lifting jack under the steer
97. 0 PSI p F o NME pod Ors p PN 1600 PSI 1400 PSI 1800 PSI 6 3000 PSI 1500 PSI a Je PR1 PR2 m x fo Se x o l e o AM I I I I ZP I I y Mr I pi T T A aen I Z T I pi 7 0 030 inch 2 W K T2 EE s 8 43037 7 34 22 6 22 Service Manual Section 6 Schematics ee Hydraulic Schematic 2WD Models from serial number 674 to 1029 Service Manual Sec m Hydraulic Schematic 2WD Models from serial number 1030 to 1186 tion 6 Schematics A B C D E F G K N B A CHARGE PRESSURE 1 PEE 3500 4 i1 PSI AUXILIARY PUMP gem 0 5 e p 3500 t 2 PSI E LIFT STEER 1 Pu RUN TE 79 PSI 81 D _ 52 DRIVE PUMP P1 m T3 Q25PSI 4 J O nw 18 GALLONS o 5 CHARGE PRESSURE ETE RE vb lt o
98. 00 remove the wire and connector plate from the three individual glow plugs Then one glow plug at a time check the resistance between the glow plug and machine ground Result The resistance should be approximately 1 8Q for each individual glow plug 3 Turn the key switch to ground control and pull out the Emergency Stop button to the oN position 4 Connect the red lead from volt meter to the number three glow plug Connect the black lead to ground 5 Hold the glow plug switch in the on position Result The volt meter should read 12 volts B 10 Check and Adjust the Engine RPM 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 Kubota Gasoline LPG Models 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 Result Low idle should be 1600 rpm Skip to step 3 if the low idle rpm is correct 2 Turn the low idle adjustment screw on the carburetor clockwise to increase rpm or counterclockwise to decrease rpm Kubota Gasoline LPG idle adjustments a solenoid boot b high idle adjustment nut C spring lock nut d low idle adjustment e carburetor Genie Z 34 22 IC Part
99. 1 RED E H BAT BAT rt 1 I 4 i WHT 21 E H EXCT 31 T IB 1 L I x e lt C RED RED 20 E H BATTERY N Lo N ES34GP1 D TURNTABLE ROTATE RIGHT TURNTABLE ROTATE LEFT RPM COIL FLASHING BEACONS RPM CUTOUT COIL RELAY FUEL RELAY FUEL RELAY LPG SOLENOID ANTI DIESEL VALVE FUEL PUMP CHOKE RELAY WATER TEMP SENDER OIL PRESSURE SENDER HOUR METER IGNITION SYSTEM STARTER MOTOR AUXILIARY POWER RELAY AUXILIARY PUMP LEVEL SENSOR SERVICE HORN RELAY SERVICE HORN RPM SOLENOID CHOKE SOLENOID ALTERNATOR Part No 43037 Genie Z 34 22 IC 6 9 Section 6 Schematics Service Manual before serial number 869 Electrical Schematic Gasoline LPG Models DRIVE ENABLE uP T JIB BOOM Dow RIGHT PLATFORM ROTATE LEFT uP PLATFORM LEVEL DOWN EXTEND PRIMARY BOOM RETRACT i 8 uP PRIMARY BOOM DOWN i g 8 uP SECONDARY BOOM DOWN BRN2 BLU RED 3 BLUWHT 3 WHTIBLK 1 WHTIRED t RED WHT 1 WHTIRED 3 REDIBLK 3 BLUIBLK S up JB BOOM DOWN GRN BLK 1 RIGHT T PLATFORM ROTATE f LEFT i GRNBLKS m eva p f EXTEND PRIMARY BOOM RETRACT up PRIMARY BOOM i 1 DOWN uP T SECONDARY BOOM 1
100. 1 DOWN 1 WHT BLK831 E H WHTIREDIG2 E H BLUMGS EH BLU BLK S7 E H B WHT RED EH PLATFORM LEVEL CUT OUT OPTION ORGIBLKHS EH BLK 7 EH BLKIWHTIS E H REDH EH REDIBLK 2 EH BLUHO EH BLU BLKHTI EH GROUND DRIVE ENABLE LIMIT SWITCH WHT 12 EH ne DRIVE EDC BRAKE RELEASE STEER LEFT STEER RIGHT MOTOR STROKE SECONDARY UP LIMIT SWITCH BOOM UP LIMIT SWITCH BOOM EXTEND LIMIT SWITCH BOOM FLOW CONTROL PLATFORM JIB PLATFORM ROTATE PLATFORM LEVEL UP PLATFORM LEVEL DWN PRIMARY BOOM EXTEND PRIMARY BOOM RETRACT PRIMARY BOOM UP PRIMARY BOOM DWN SECONDARY BOOM UP SECONDARY BOOM DWN DECENT ALARM OPTIONAL ES34GP2D 6 10 Genie Z 34 22 IC Part No 43037 Service Manual Section 6 Schematics Ea ee Electrical Schematic Gasoline LPG Models before serial number 869 Service Manual Electrical Schematic Gasoline LPG Models from serial number 869 to 1186 Section 6 Schematics
101. 10 Start the engine from the ground controls Allow the engine to run for 30 seconds then turn the engine off TABLE A PROCEDURES Kubota Engine WG 750 3 9 quarts Oil capacity including filter 3 25 liters Cil viscosity requirements 10W 40 Use oils meeting classification SF labeled SF CC or SF CD for improved wear protection Units ship with 10W 40 SG CC Cil filter Genie Part Number 22106 Kubota Engine D 905 5 4 quarts Cil capacity including filter 5 1 liters Cil viscosity requirements 10W 40 Engine oil should have properties of API classification CC SE CD SE CC SF or CD SF grades Units ship with 10W 40 SG CC Cil filter Genie Part Number 31744 11 Check the oil filter and the oil drain valve for leaks 12 Swing the engine pivot plate back to its original position and make sure the pull pin locks into the hole 13 Check the engine oil level dipstick Add oil if needed Part No 43037 Genie Z 34 22 IC 4 13 Section 4 Scheduled Maintenance Procedures Service Manual First Edition Table B Procedures B 1 Check the Radiator Maintaining the radiator in good condition is essential for good engine performance Operating a machine with a damaged or leaking radiator may result in engine damage Also restricting air flow through the radiator i e dirt or debris will affect the performance of the cooling system A frequent check allows the inspector to identify changes in th
102. 18 2 Valve Adjustments How to Adjust the Charge Pressure Relief Valve 1 Connect a 0 to 600 psi 0 to 41 bar pressure gauge to the test port located on the drive manifold AWARNING ri 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 Start the engine from the platform controls Drive the machine slowly in either direction and observe the pressure reading on the pressure gauge 4 Turn the engine off Hold the relief valve and remove the cap index 2 5 Adjust the internal hex socket Turn it clockwise to increase the pressure or counterclockwise to decrease the pressure Then install the valve cap Genie Z 34 22 IC Part No 43037 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 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 Phone 34 93 579 5042 Fax 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
103. 3037 Genie Z 34 22 5 83 Section 5 Troubleshooting Flow Charts Service Manual First Edition Chart 37 Machine Raise boom off drive ee limit switch turn isplacement controller rive pump Replace or Drives At machine off and check EDC wires E drive ee continuity between pump move drive undstrand repair Full Speed ground and terminal 6 controller to full forward facility With on horsepower limiter position and check board voltage between Platform pe 4 an on drive controller Raised Or Extended Remove machine no continuity Replace horsepower from service limiter board immediately Be sure boom n ive limi eck continuity in epair open in org wire Switch or between ground circuit from TB40 to boom extend drive and TB40 horsepower limiter limit switch is not board terminal 6 being held down or no continuity up Repair limit switch wiring Be sure wiring to OR replace boom lift limit switches is drive limit switch OR replace boom extend drive limit switch intact and shows no signs of tampering Be sure orange wire cable 1 is properly attached to terminal 6 of the horsepower limiter board 5 84 Genie Z 34 22 IC Part No 43037 Service Manual First Edition Section 5 Troubleshooting Flow Charts Chart 38 Drive Enable Do rot hold the drive Will folding the drive Troubleshoot enable switch and enable switc
104. 34 22 Section 7 Repair Procedures Service Manual First Edition 4WD STEER AXLE COMPONENTS 14 2 Steer Cylinder How to Remove a Steer Cylinder 1 Tag disconnect and plug the hydraulic hoses from the steer cylinder Cap the fittings 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 cotter pin Then remove the clevis pin from each end of the steer cylinder 3 Remove the steer cylinder Always use a new cotter pin when installing clevis pin 14 3 Tie Rod How to Remove the Tie Rod 1 Remove the cotter pin then remove the clevis pin from each end of the tie rod 2 Remove the tie rod Always use a new cotter pin when installing a clevis pin 7 50 Genie Z 34 22 IC Part No 43037 Service Manual First Edition Section 7 Repair Procedures Brake and Two Speed Manifold 15 1 Brake and Two Speed Manifold Components The Brake and Two Speed Manifold is located under the drive chassis cover at the non steer end Index Schematic No Description Item Function Torque 1 2 position 3 way solenoid valve 8 10 ft lbs 11 14 Nm 2 2 position way solenoid valve Bus 2 Speed suene eee 8 10 ft lbs 11 14 Nm Part No 43037 Genie Z 34 22 IC 7 51 Section 7 Repa
105. 40 Service Manual no improvement symptoms improve Check all drive speeds and monitor for recurring symptoms Possible contamination in hydraulic system Part No 43037 Genie Z 34 22 5 81 Section 5 Troubleshooting Flow Charts Service Manual First Edition Chart 35 Traction Any pe of 1 roblem consult Genie Fu nction Service inoperative Depariment Be sure all other functions operate normally 5 82 Genie Z 34 22 IC Part No 43037 Service Manual First Edition Section 5 Troubleshooting Flow Charts Machine Will Not Drive At Full Speed Be sure all other functions operate normally Be sure the free wheel valve is closed on the drive pump Be sure the drive speed select switch is on high range machine on level surface symbol Chart 36 With boom fully stowed and orange wire from cable 1 disconnected Repair or replace boom lift drive limit switch or boom extend limit from TB40 check TB40 switch for continuity to ground no continuity With boom fully stowed and orange wire from cable 1 disconnected from TB40 check horsepower limiter board terminal 6 for continuity to ground Orange wire shorted to ground repair orange wire circuit from TB40 to horsepower limiter board no continuity Re adjust or replace horsepower limiter board See Repair section OR consult Genie Industries Service Department Part No 4
106. 43037 Section 7 Repair Procedures Service Manual First Edition FUNCTION MANIFOLD 2 R 669666 AOOO 5 S lt ELD gt FU S77 amp SA l 0 3 3000 39 Genie Z 34 22 IC Part No 43037 Section 7 Repair Procedures Service Manual First Edition FUNCTION MANIFOLD Function Manifold Components continued The function manifold is mounted to the turntable under the ground controls Index Schematic No Description Item Function Torque 17 2 position 3 way solenoid valve Secondary boom 8 10 ft Ibs 11 14 Nm 18 2 position 3 way solenoid valve Pass Turntable rotate left 8 10 ft lbs 11 14 Nm 19 2 position way solenoid valve Platform level up 8 10 ft lbs 11 14 Nm 20 2 position way solenoid valve Uns Primary boom extend 8 10 ft Ibs 11 14 Nm 21 2 position 3 way solenoid valve Primary boom down 8 10 ft Ibs 11 14 Nm 22 2 position way solenoid valve FU seas Secondary boom down 8 10 ft lbs 11 14 Nm 23 2 position way solenoid valve Turntable rotate right
107. 43037 Service Manual First Edition 16 Drain the Fuel Filter Water Separator Kubota Diesel Models Engine specifications require that this procedure be performed every 100 hours Poor fuel quality or very wet conditions may necessitate performing this procedure more often 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 ADANGER Explosion and fire hazard Engine mL 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 Perform this procedure with the engine off 1 Loosen the vent plug located on the fuel filter water separator head Fuel filter water separator a head bolt b filter bowl c drain plug d vent plug e separator head Section 4 Scheduled Maintenance Procedures TABLE A PROCEDURES 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 Tighten the vent plug and clean up any spills or wet surfaces If the fuel bowl is completely drained you must prime the fuel filter water separator before starting the engine Refer to B 25 in this section Replace The Diesel Fuel Filter
108. 570 7 8 inch 9 430 583 600 814 14 470 637 660 895 1 inch 8 640 868 900 1221 12 700 949 1000 1356 Torque specifications for lubricated bolts are 25 less than dry torque specifications for each bolt size These bolt torque specifications are for general use only Specification may vary depending on application of bolt 2 4 Genie Z 34 22 IC Part No 43037 Service Manual First Edition Kubota WG 750 Engine Section 2 Specifications eee Starter motor SPECIFICATIONS Displacement 42 21 cuin Brush length new 0 669 in 0 74 liters Number of cylinders 3 Brush length wear limit Bore amp stroke 2 68 x 2 68 inches 68 x 68 mm Brush spring tension 50 to 91 ounces 13 7 to 25 5 Newtons Horsepower Gross intermitent 24 5 3600rpm Battery Firing order 1 2 3 12 Group 24 Low idle 1600 rpm Quantity High idle 3000 rpm Ampere hour 75AH Governor centrifugal ball Cold cranking ampere 875A mechanical Reserve capacity 25A rate 125 minutes Compression ratio 9 1 Fuel pump Compression pressure approx 128 to 185 psi 2 84 psi 8 815 12 7 bar Static pressure 5 Pressure psi of lowest cylinder must be at least 90 of highest cylinder Minimum volume flow 1 pint 500 Valve clearances cold 0 0057 to 0 0072 inches 0 145 to 0 085 mm Lubrication system
109. ARNING Crushing hazard Keep hands turntable rotation bearing away from the cylinder and all SSS moving parts when lowering the Lubricant Type Multipurpose grease secondary boom 6 Pump grease into the gear until you see it coming out of the side of the gear housing The lift cylinder safety chock is available through Genie part number 36555 2 Locate the grease fitting on the inside of the bearing in the middle of the turntable 3 Pump grease into the turntable rotation bearing 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 4 Remove the safety chock Lower the boom to the stowed position 4 32 Genie Z 34 22 IC Part No 43037 Service Manual First Edition Section 4 Scheduled Maintenance Procedures C 5 Replace the Torque Hub Oil 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 Then drive the machine until one of the two plugs is at the lowest point 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 5 App
110. C Part No 43037 Service Manual First Edition Section 5 Troubleshooting Flow Charts CHART 30 Continued from the Disconnect wires to jib previous page down directional valve ohms Replace jib down coil item B Remove directional valve coil coil and test resistance item B 4 to 8 ohms Exchange jib up and function down directional valves operates Replace defective item A B and activate directional valve jib down function function inoperative Install a 0 to 5000 PSI Check for mechanical pressure gauge at the restrictions keeping jib quick disconnect down function from coupling on the boom moving OR repair or function manifold and replace jib cylinder OR activate the jib down replace jib cylinder function counterbalance valves OR consult Genie Industries Service less than 3200 PSI Department Repair or replace jib cylinder OR replace jib cylinder counterbalance valves OR platform rotate jib function manifold could have an internal fault Consult Genie Industries Service Department Part No 43037 Genie Z 34 22 IC 5 75 Section 5 Troubleshooting Flow Charts Service Manual First Edition Chart 31 Steer Left Start the engine from or the the platform press down steer microswitch in Function foot switch hold the controller handle Inoperative steer switch left and check voltage at terminal 8 on the drive controller blu wire Be s
111. CHART 4 Part No 43037 Genie Z 34 22 Section 5 Troubleshooting Flow Charts Service Manual First Edition Chart 5 Engine Choke inoperative Kubota Gasoline LPG Models Be sure the fuel select switch is in the gasoline position Be sure the choke solenoid to carburetor linkage is in place and properly attached Be sure choke solenoid plunger can be manually pushed into the solenoid and the linkage in turn rotates the choke plate linkage Hold choke switch and start switch and check voltage at blk wht R8 wire on choke solenoid Hold choke switch and start switch and check voltage at terminal 87 on with blk wht wire attached ov Check voltage at oV terminal 30 on CR8 12V Hold choke switch and 12V start switch and check voltage at terminal 86 on CR8 Turn keyswitch to ground control position and check voltage on center terminal of choke switch Hold ground control choke switch and check voltage at blk wht wire where it connects to the diode Continued on the next page au Check solenoid ground bad eee in ground good Replace solenoid Note Resistance across solenoid terminals should be approximately 0 3 ohms Repair open in blk wht R8 wire from CR8 terminal 87 to choke solenoid Repair open in wht wire circuit from terminal 87 on CR2 to terminal 30 on to terminal 30 on CR8 Check ground
112. CT I ttf I s lg d SES cos 2 z gg 8185 1 B Jg a E P a 8 i 8 REDI20 EH E BATTERY 5 43037 Genie Z 34 22 IC 6 7 Section 6 Schematics Service Manual Electrical Schematic Diesel Models from serial number 869 to 1186 BRN2 BLUIRED 3 DRIVE ENABLE RED WHT uP JIB BOOM Down I 1 BRNJIB RIGHT PLATFORM ROTATE LEFT uP PLATFORM LEVEL i DOWN i PRIMARY BOOM RETRACT i g l i uP PRIMARY BOOM DOWN 1 8 1 Bog uP SECONDARY BOOM DOWN I 5g BLU WHT 3 WHTIBLK 1 WHTIRED 1 BLU BLK 1 REDIWHT 1 WHTIRED 3 RED BLI 3 BLUIBLK S m s g GRN BLK I RIGHT PLATFORM ROTATE LEFT I g GRNBLKS we PLATFORM LEVEL DOWN j EXTEND PRIMARY BOOM T RETRACT up PRIMARY BOOM i 1 DOWN 1 up T SECONDARY BOOM 11 DOWN WHTIBLKIGT EH WHT RED 32 E H BLUIGS EH BLU BLK 37 E H WHT RED EH CUT OUT OPTION E E ORG 14 EH ORGBLKHS EH BLK7 E H BLKIWHTIS E H REDH EH REDIBLK 2 EH BLUHO EH BLU BLK TI EH W
113. Contact with electrically charged circuits may result in death or serious injury Remove 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 Retum to Perform service problem repair solved Part No 43037 Genie Z 34 22 IC 6 1 Section 6 Schematics Service Manual First Edition Electrical Symbols Legend 15 i c 18 Circuit breaker 2 Foot switch T PLAT da Brake release Wire color plug with cable 5 GAND number Key switch 5 Solenoid or Ground PSH relay coil deut Pressure switch HORN P4 Terminal Ab P Horn button je normally open n LSS Spark plug Limit switch Do Quick disconnect u 06 terminal ep Emergency Stop button 5 Light NC normally closed 4 BLK 21 821 I 5 Limit switch 1 T circuits connect normally closed at terminal
114. Drive the machine slowly in either direction and observe the pressure reading on the pressure gauge 4 Turn the engine off Hold the relief valve and remove the cap index 2 5 Adjust the internal hex socket Turn it clockwise to increase the pressure or counterclockwise to decrease the pressure Then install the valve cap Part No 43037 Genie Z 34 22 IC 7 55 Section 7 Repair Procedures Service Manual First Edition 4WD Drive Manifold 18 1 4WD Drive Manifold Components The drive manifold is mounted inside the drive chassis at the non steer end Index Schematic No Description Item Function Torque 1 Diagnostic Testing 2 Directional control valve Diverts all flow to steer end drive motors when in high range 25 30 ft lbs 34 41 Nm 3 Flow divider combiner valve E uum Controls flow to flow divider combiner valves 5 6 25 30 ft lbs 34 41 Nm Orifice plug 0 052 in 1 32 mm Gees Drive circuit steer end Flow divider combiner valve eue Controls flow to steer end drive motors in forward and reverse 25 30 ft lbs 34 41 Nm 6 Flow divider combiner valve Controls flow to non steer end drive motors in forward and reverse 25 30 ft lbs 34 41 Nm Orifice plug 0 070 1 78 mm C unos Drive cir
115. First Edition Section 5 Troubleshooting Flow Charts Chart 14 Ground Does the engine start Start the engine from Repair open in red wire Controls from the ground the ground controls and circuit from key switch to controls check the voltage on the function switches center pole red wire of inoperative the platform level switch Platform Controls Operate Troubleshoot the Normal ly functions individually Be sure all other munictions Mie d Check voltage at red Repair open in red wire normally including wire on ground controls circuit from emergency platform controls contact of the key switch stop button to the the red wire checked key switch should originate at the emergency stop button Check voltage at red Check if key switch Replace key switch wire at ground controls internal cam is activating contact for ground contact on the key ground contact controls Switch Replace key switch Repair open in red wire circuit from key switch to function switches Part No 43037 Genie Z 34 22 IC 5 31 Section 5 Troubleshooting Flow Charts Service Manual First Edition Chart 15 Platform Controls inoperative Ground Controls Operate Normally Be sure all cables are in good condition with no kinks or abrasions Start engine from the platform then press ov down the foot switch and check voltage at terminal 1 of the horsepower limiter Test and replace foot switch OR
116. GS ALTERNATOR ES34D1D Part 43037 Genie Z 34 22 IC 6 5 Section 6 Schematics Service Manual Electrical Schematic Diesel Models before serial number 869 DRIVE ENABLE uP JIB BOOM DOWN BRNJIB RIGHT PLATFORM ROTATE LEFT PLATFORM LEVEL EXTEND PRIMARY BOOM RETRACT uP PRIMARY BOOM DOWN uP SECONDARY BOOM DOWN BRN2 BLU RED 8 BLUWHT 3 WHT BLK 1 WHT RED t WHT RED 3 uP JIB BOOM DOWN GRNIBLKA RIGHT PLATFORM ROTATE LEFT GRNIBLK3 uP PLATFORM LEVEL DOWN EXTEND PRIMARY RETRACT PRIMARY BOOM DOWN RED BLK 3 uP SECONDARY BOOM DOWN BLUIBLK S WHT BLK831 E H WHTIREDIG2 E H BLUI3S EH BLU BLK S7 E H WHTIRED EH z 5 5 8 5 8 ORGHA4 EH ORGIBLKHS EH BLKI EH BLKWHT 8 EH REDH EH REDIBLK 2 EH BLUHO EH BLU BLKHTI EH WHT612 E H gt Y RED WHT 25 E H GROUND DRIVE ENABLE LIMIT SWITCH BRAKE RELEASE STEER LEFT STEER RIGHT MOTOR STROKE SECONDARY UP LIMIT SWITCH BOOM UP LIMIT SWITCH BOOM EXTEND LIMIT SWITCH BOOM FLOW CONTROL PLATFORM JIB PLATFORM ROTATE PLATFORM LEVEL UP PLATFORM LEVEL DWN PRIMARY BOOM EXTEND PRIMARY BOOM RETRACT PRIMARY BOOM UP PRIMARY BOOM DWN SECONDARY 800M UP SECONDARY BOOM DWN DECENT ALARM OPTIONAL ES34GP2D 6 6 Genie Z 34 22 IC Part No 43037 Service Manual Section 6 Schemat
117. HT 1 BKWT S P GLOW PLUG oe BLK CR3 33 BK 31SM BLK S P START WHT RED 1 32 WI RD EH BRAKE WHT BLK 1 31 WT BK E H ED C RED 5 WHT 1 30 EDC 1 29 RDWTEH 2WD AWD RED BLK t 28 TILT ALARM RD 4ISM RED 1 27 RED S P AUX PWR 26 wrmD EH WT RD S P WATER TEMP SENDER 25 WI BK EH WT BK S P OIL PRESSURE SENDER WT 10 ISM 24 WHT E H WARNING SENDER RDWT M H WHT 2 23 WHT S P KEYSWITCH PWR BLK CRS 22 BLK S P PWR TO PLAT WHT CR2 21 WHTEH WHT SP DB IGNITION PWR RED CRI7 20 nED EH RED S P 12V BATT SUPPLY GRNWHT 3 19 GRN BLK 3 18 GR BK S P PLAT ROT R GRN 3 17 GRN S P PLAT ROT L ORG RED 3 16 H ORG BLK 3 15 ORG BLK M H OG BK S P PLAT LEVEL DN Bks oneMH ORG S P PLAT LEVEL UP WHT S BLU RED 3 13 DRV ENA LT BLK 5 BLUWHT 3 12 WHT E H DPV ENA BLU BLK 3 11 BLUBLK MH BU BK S P SEC BOOM DN BLU 3 10 BLUMH BLU S P SEC BOOM UP BK RD CRS BLK RED 3 E HORN BLKWHT 3 8 BLKWHTMH BKAT S P BOOMRETRACT BLK 3 BLK SP BOOM EXTEND WHT RED 3 6 WT RD S P BOOM FUNCTION F C WHT BLK 3 5 WHTIBLKMH WT BK S P TURN ROT L WHT 3 4 WHT M H WHT S P TURN ROT R RED WHT 3 3 RDWT SP RED BLK 3 2 REDBLKMH RD BK S P PRI BOOM DOWN RED 3 1 REDMH RED S P PRI BOOM UP D 1 sTARTRELAY HE 2 IGN START
118. HTHZ EH gt Y RED WHT 25 E H GROUND DRIVE ENABLE LIMIT SWITCH BRAKE RELEASE STEER LEFT STEER RIGHT MOTOR STROKE SECONDARY UP LIMIT SWITCH BOOM UP LIMIT SWITCH BOOM EXTEND LIMIT SWITCH BOOM FLOW CONTROL PLATFORM PLATFORM ROTATE PLATFORM LEVEL UP PLATFORM LEVEL DWN PRIMARY BOOM EXTEND PRIMARY BOOM RETRACT PRIMARY BOOM UP PRIMARY BOOM DWN SECONDARY BOOM UP SECONDARY BOOM DWN DECENT ALARM OPTIONAL ES34GP2E 6 8 Genie Z 34 22 IC Part No 43037 Section 6 Schematics Electrical Schematic Diesel Models from serial number 869 to 1186 Service Manual Section 6 Schematics Electrical Schematic Gasoline LPG Models before serial number 869 m E Ibi SWING i E WHT 4 E H Ibi WHT BLK 3 RIGHT SWING WHT 3 gt E 53 55 Eq BLK RED 1 p HIGH RPM IT 2 8
119. K 5 BLUWHT 3 12 WHTEH DRV ENA BLUIBLK 3 11 BLU BLK M H BUIBK S P SEC BOOM DN BLU 3 to BLU S P SEC BOOM UP BK RD CR5 BLK RED 3 E HORN BLKWHT 3 8 BLKWHTMH BKIWT S P BOOM RETRACT 7 BLKMH BLK S P BOOM EXTEND WHT RED 3 WRAMH WT RD S P BOOM FUNCTION F C WHT BLK 3 5 WHT BLK M H WT BK S P TURN ROT L WHT 3 4 WHT M H WHT S P TURN ROT R REDIWHT 3 3 RDNT S P RED BLK 3 2 RED BLK M H RD BK S P PRI BOOM DOWN RED 3 1 RED M H RED S P PRI BOOM UP D HE 1 START RELAY HE IGN START BLK 33B smarmeur MODULE k HE BRN GRD R4 85 LC s SERE HE 6 BATTERY 5 keyewa ies HE tenveuet on 8 HE 10 ENG FAUT BRN 5 ISM RED 6 ISM BLK RED 35D RED CB2 BLK 33D ey LI BLK 1 ISM 1 Eg E BLK R1 E H WHTZID BLK R5 M H 5 cL BLK 22D BLK RED 8D BLKWHT 34D Part No 43037 Genie Z 34 22 6 14 Service Manual Section 6 Schematics EU ma e R Ground Control Box Wiring Diagram Diesel Models from serial number 869 to 1186 Section 6 Schematics Service Manual a PUES Ground Control Box Wiring Diagram Gasoline LPG Models before serial number 869 Section 6 Schematics prac Ground Control Box Wiring Diagram G
120. No 43037 Service Manual First Edition Section 4 Scheduled Maintenance Procedures 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 counterclockwise to decrease the rpm 6 Tighten the spring lock nut Then recheck the rpm Kubota Gas LPG Models Low idle 1600 rpm High idle 3000 rpm Kubota Diesel models 1 Connect an rpm gauge to the engine and then start the engine from the ground controls Result Low idle should be 1300 rpm Skip to step 3 if the low idle rpm is correct TABLE B PROCEDURES 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 Diesel idle adjustments lock nut high idle adjustment nut low idle adjustment screw rpm solenoid ao oo 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
121. OW PLUG M BLK CR3 BLK 1 38 BK 3 ISM BLK S P ENGINE START WHT RED 1 32 WT RD EH BRAKE WHT BLK 1 31 WT BK E H ED C RED 5 WHT 1 30 ED C RAN 1 29 2WD AWD RED BLK 1 28 RD BKMH TILT ALARM RD 4 ISM RED 1 27 RED EH RED S P POWER 26 WI RD EH WI RD S P WATER TEMP SENDER 25 WI BK EH WT BK S P OIL PRESSURE SENDER WT 10 ISM 24 WHT E H WARNING SENDER RDAVT M H WHT 2 23 RD WT EH WHT S P KEYSWITCH POWER BLK CRS BLK 2 22 BLK S P POWER TO PLATFORM WHT CR2 21 WHT EH WHT SP DB IGNITION POWER RED CR17 20 RED EH RED S P 12V BATTERY SUPPLY GRNMWHT 3 19 GRN BLK 3 18 GR BK S P PLATFORM ROTATE RIGHT GRN 3 17 GRN S P PLATFORM ROTATE LEFT ORG RED 3 16 T Bike ORG BLK 3 15 ORG BLK M H OG BK S P PLATFORM LEVEL DOWN Bus ORG 3 14 ORG MH ORG S P PLATFORM LEVEL UP WHT 5 BLU RED 3 13 DRIVE ENABLE LIGHT BLK 5 BLUWHT 3 12 WHT EH DRIVE ENABLE BLU BLK 3 11 BLU BLK MH SECONDARY BOOM DOWN BLU 3 10 BLUM SECONDARY BOOM UP BK RD CRS BLK RED 3 9 HORN BLKWHT 3 8 BLKWHT M H BKWT S P BOOM RETRACT BLK 3 7 BLKMH BLK S P BOOM EXTEND WHT RED 3 6 WR M H WT RD S P BOOM FUNCTION FLOW CONTROL WHT BLK 3 5 WHT BLK MH WT BK S P TURNTABLE ROTATE LEFT WHT 3 4 WHT M H WHT S P TURNTABLE ROTATE RIGHT RED WHT 3 3 RD WT S P RED BLK 3 2 RED BLK MH RD BK S PRIMARY BOOM DOWN RED 3 1 RED MH RED S P PRIMARY BOOM UP D kon LO 1 sTARTRELAY at
122. OWN BRN JIB RIGHT 7 PLATFORM ROTATE f LEFT 1 T PLATFORM LEVEL f DOWN EXTEND PRIMARY BOOM RETRACT 8 up PRIMARY BOOM DOWN i 8 1 up SECONDARY BOOM DOWN i b I BRN 2 BLU RED 3 BLUWHT3 BLUIBLK 1 REDWHT 1 WHT RED 3 uP JIB BOOM DOWN GRNIBLK 1 RIGHT PLATFORM ROTATE LEFT GRNBLK 3 uP PLATFORM LEVEL DOWN ORGBLK 3 EXTEND PRIMARY BOOM RETRACT BLKWHT 3 uP PRIMARY BOOM DOWN REDIBLK S uP 7 SECONDARY BOOM DOWN 1 WHT BLK S1 EH WHT RED S2 E H BLU 6 E H BLU BLK 37 E H WHT RED EH ORGH4EH ORG BLK 15 E H BLAW7 EH BLKWHT S E H RED BLK 2 E H BLUMO EH BLU BLK 1 E H g 4 g E a 8 CUT OUT OPTION GROUND DRIVE ENABLE SWITCH gt BRAKE RELEASE STEER LEFT STEER RIGHT REDWHT 25 EH MOTOR STROKE SECONDARY UP LIMIT SWITCH BOOM UP LIMIT SWITCH BOOM EXTEND LIMIT SWITCH BOOM FLOW CONTROL PLATFORM JIB PLATFORM PLATFORM LEVEL PLATFORM LEVEL DWN PRIMARY BOOM EXTEND PRIMARY BOOM RETRACT PRIMARY BOOM UP PRIMARY BOOM DWN SECONDARY BOOM UP SECONDARY BOOM DWN DECENT ALARM OPTIONAL ES34GP2E 6 12 Genie Z 34 22 IC Part No 43037 Section 6
123. Oil pressure 28 to 64 psi operating temp 3850 rpm 1 9 to 4 4 bar Oil capacity 3 9 quarts including filter 3 25 liters Oil viscosity requirements 10W 30 Use oils meeting API classification SF labeled SF CC or SF CD for improved wear protection Part No 43037 Genie Z 34 22 IC 2 5 Section 2 Specifications SPECIFICATIONS Ignition System Service Manual First Edition Bolt torque specifications torque torque Ignition spark advance 20 BTDC Bolt description size ft lbs Nm Ignition coil primary 1 810 1 62 Head cover cap nuts M6 3104 4 to 6 resistance 75 F 24 C Head Bolts 8 29 to 33 37 to 42 Ignition coil secondary 10 7 to 14 5 resistance 75 F 24 C Bearing case bolts 1 M6 9to 12 13 to 16 Spark plug type NGKBCP4ES 11 Bearing case bolts 2 M7 19 to 22 26 to 30 Spark plug gap 0 039 to 0 043 inches Flywheel bolts M10 40 to 44 54 to 59 1 0 to 1 1 mm Connecting rod bolts M6 11 to 14 26 to 30 Engine coolant Rocker arm bracket nuts M6 7108 10 to 11 Capacity 3 1 quarts 29 liters Idle gear shaft nuts M6 7108 10 to 11 Alternator Spark plug M14 14 to 18 20 to 24 Output 30A Crankshaft bolt M12 72 to 79 98 to 108 Fan belt deflection 1 4 to 3 s inch 7109 mm Genie Z 34 22 IC Part No 43037 Service Manual First Edition Kubota D 905 Engine Section 2 Specifications
124. P AUILIARY POWER GRN BLK 18A 26 WI RD EH WT RD S P WATER TEMP SENDER 3 lt CABLE 6 25 WT BK E H WT BK S P OIL PRESSURE SENDER BLK WHT 8A WT 10 ISM 24 WHTEH WARNING SENDER GOHA RD WT M H WHT 2 23 WHT S P KEYSWITCH POWER TS25 523 WHT RED 3A BLK CR5 BLK 2 22 BLK S P POWER TO PLATFORM I WHT CR2 21 WHT EH WHT SP DB IGNITION POWER RED 1A 3 RED CR17 20 RED EH RED S P 12V BATTERY SUPPLY HM REDIBLK 2A GRNWHT 3 19 45 GRN BLK 3 18 GR BK S P PLATFORM ROTATE RIGHT ORG TB14B 77 GRN 3 17 GRN S P PLATFORM ROTATE LEFT O TS24 TS22 ORG RED 3 16 4 ORG BLK TB15B opt Bike ORG BLK 3 15 ORG BLK M H OG BK S P PLATFORM LEVEL DOWN BEBE BLU 10A ORG 3 14 ORG MH ORG S P PLATFORM LEVEL UP 826 BLUIBLK 11A WHT 5 BLU RED 3 13 DRIVE ENABLE LIGHT BLK S BLU WHT 3 12 WHTEH DRIVE ENABLE CR10 CR9 BLU BLK 3 11 BLU BLK M H BU BK S P LI CABLE 1 SECONDARY BOOM DOWN O TS21 BLU 3 10 BLU MH BLU S P SECONDARY BOOM UP EN Sie BK RD CRS BLK RED 3 9 HORN BLKWHT 3 8 BLKWHT MH BKIWT S P BOOM RETRACT 3Sib sima BLK 3 BLK MH BLK S P BOOM EXTEND 6 4 BRN GRD SI WHT RED 3 WI R M H WT RD S P BOOM FUNCTION FLOW CONTROL 5 BLK 5A WHT BLK 3 5 WHT BLK MH WI BK S P TURNTABLE ROTATE LEFT E H 1 TS20 WHT 3 4 WHTMH WHT S P TURNTABLE ROTATE RIGHT ORG EH 0099 CABLE 2
125. R Explosion and fire hazard When transferring fuel connect a grounding wire between the machine and pump or container 1 Raise the secondary boom so the upper mid pivot is approximately 12 feet 3 7 m off the ground 2 Turn the LPG shutoff valve to the cLosEp position on the LPG tank 3 Remove the LPG hose from the tank and then remove the tank from the machine 4 Remove the mounting fasteners from the LPG bottle bracket then remove the bracket from the machine 5 Turn the manual fuel shutoff valve to the cLosEp position on the fuel tank 6 Kubota Gasoline LPG models Disconnect drain and plug the fuel hose Kubota Diesel models Disconnect drain and plug the supply and return fuel hoses Cap the fuel return fitting on the fuel tank 7 Remove the mounting fasteners from the tank strap on the underside of the tank mounting tray 8 Use an appropriate lifting device to remove the tank from the machine Clean the fuel tank and inspect for rust and corrosion before installing 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 Component damage hazard The ACAUTION work area and surfaces where this procedure will be performed must be clean and free of debris that could get into
126. RED WHT 3 3 RD WT S P e TS19 CB mE RED BLK 3 2 RED BLK MH RD BK S P PRIMARY BOOM DOWN id RED 20A RED 3 1 RED MH RED S P PRIMARY BOOM UP PLATFORM LEVEL CUT OUT OPTION m p B A GRN BLK 44A ORG 14A BLK R1 86 1 START RELAY ORG BLK 41D ORG BLK 15A 2 TACHOMETER CABLE 3 IGN START RED R1430 O 3 STARTINPUT RED 27D MODULE BLU WHT 38A C 4 Aux oN BRN GRD R4 85 C 5 GROUND BLU RED 39A R2 127 BATTERY BLKWHT 344 7 KEvPWR BLK 33A 8 KEY BYPASS BLK RED 35A 9 IGN FUEL ON WHT 24D LABEL DESCRIPTION ENGINE 2 10 ENG FAULT BRN 5 ISM Pt EMERGENCY STOP BUTTON BLK RED R4 E H 90 cm KEY SWITCH CCC cre 1815 AUXILIARY SWITCH 7 CB2 TS16 ENGINE START SWITCH Buc TS17 ENGINE CHOKE SWITCH ICR1 CR2 4 1518 ENGINE FUEL SELECT SWITCH BLK 1 ISM 1519 ENGINE RPM SWITCH 1 7520 TURNTABLE ROTATE SWITCH TS21 SECONDARY BOOM UP DOWN SWITCH 22 PRIMARY BOOM UP DOWN SWITCH Q 1823 BOOM EXTENDIRETRAGTISWITOH BLK R5 M H BLUMWHT R6 E H BLU RED R7 E H Tee TS24 PLATFORM LEVEL SWITCH TS25 PLATFORM ROTATE SWITCH CRE lore cra 1526 JIB UP DOWN SWITCH CIRCUIT BREAKER CONTROLS 10 1 8 2 CIRCUIT BREAKER ENGINE 10A t HM HOUR METER O Rt RESISTOR 5 OHM BOOM FUNCTIONS BLK 22D BLU WHT 38D EH ENGINE HARNESS BLK RED 9D RED BLK RE E H BLU RED 390 BLKWHT 34D ESS4GPSE MH MANIFOLD HARNE
127. Remove all rings watches and other jewelry a horsepower limiter board 3 Connect the black lead from a DC volt meter to the no 2 terminal and the red lead to the no 10 terminal p 12V DC or greater ground engine rpm sensor q not used not used low drive speed limit switch s not used not used not used output to drive controller Horsepower limiter board a potentiometer maximum voltage output to the controller in the stowed position b potentiometer maximum voltage output to the drive controller in the boom raised position C potentiometer reaction rate or how fast the voltage output reacts to the change in engine rpm 7 2 Genie Z 34 22 IC Part No 43037 Service Manual First Edition Section 7 Repair Procedures 4 Start the engine from the platform controls 5 Move the engine idle control switch to foot switch activated high idle rabbit and foot switch symbol 6 Press down the foot switch and adjust the A potentiometer counterclockwise to increase voltage or clockwise to decrease voltage A potentiometer specifications all models Voltage setting 8 5 V DC 7 Move the engine idle control switch to low idle turtle symbol 8 Press down the foot switch and then adjust the C potentiometer to obtain a OV DC voltage reading 9 Move the engine idle control switch to foot Switch activated high
128. S25 PLATFORM ROTATE SWITCH TS26 JIB UP DOWN SWITCH CIRCUIT BREAKER CONTROLS 10A CIRCUIT BREAKER ENGINE 10A HM HOUR METER Rt RESISTOR 5 OHM BOOM FUNCTIONS EH ENGINE HARNESS MH MANIFOLD HARNESS 6 15 Genie Z 34 22 IC Part No 43037 H 8 7 CABLE 6 5 1 2 CABLE 3 DOO b D D ENGINE MANIFOLD HARNESS BLK 7 BRN 6 47 BRN BRN GROUND BRN 5 BRN 2 46 BRN GROUND GRNWHT 1 45 GRN BLK 1 44 GRIBK S P JIB DOWN GRN 1 43 GRN S P JIB UP ORG RED 1 42 OG BK 2ISM ORG BLK 1 41 OG BKE H PULSE PICKUP WHT 7 ORG 1 40 WHT 8 LIMIT SWITCH BLU RED CR7 BLU RED 1 39 LP BU WT CR6 BLU WHT 1 38 GAS BLU BLK 1 37 STEER LEFT BLU 1 36 BLU M H STEER RIGHT BK RD CR3 BLK RED 1 35 BK RD S P RPM BLKWHT CR8 BLKWHT 1 34 GL
129. SS Part No 43037 Genie Z 34 22 IC 6 16 Service Manual Section 6 Schematics Saas Ground Control Box Wiring Diagram Gasoline LPG Models from serial number 869 to 1186 Section 6 Schematics uuu Platform Control Box Wiring Diagram Diesel Models Section 6 Schematics Platform Control Box Wiring Diagram Diesel Models A B D Service Manual SPARE WIRES GRN WHT 45 1 RED JIB ORG RED 3 ORG RED 42 1 girona SIP LHM gir 5uo gir ania 6 17 Genie Z 34 22 IC Part No 43037 C 6056 tS vISL d
130. SWITCH TS20 TURNTABLE ROTATE SWITCH TS21 SECONDARY BOOM UP DOWN SWITCH TS22 PRIMARY BOOM UP DOWN SWITCH TS23 BOOM EXTEND RETRACT SWITCH TS24 PLATFORM LEVEL SWITCH TS25 PLATFORM ROTATE SWITCH TS26 JIB UP DOWN SWITCH CIRCUIT BREAKER CONTROLS 10 8 CB2 CIRCUIT BREAKER ENGINE 10A HOUR METER Ri RESISTOR 5 OHM BOOM FUNCTIONS EH ENGINE HARNESS MH MANIFOLD HARNESS 6 13 Genie Z 34 22 IC Part No 43037 CABLE 8 CABLE 7 CABLE 6 OS ENGINE MANIFOLD HARNESS a ORG TB148 ORG BLK TB15B RED 6 BRN 6 47 BRNEH GROUND BRN S BRN 2 46 GROUND GRNWHT 1 45 GRNIBLK 1 4 GR BK S P JIB DOWN GRN 1 43 GRN S P JIB UP ORG RED 1 42 OG BK 2ISM ORG BLK 1 41 OG BK E H PULSE PICKUP wHrT ORG 40 wre WHT 6 LIMIT SWITCH BLU RED 1 39 LP BLUMWHT 1 38 GAS BLU BLK 1 37 STEER LEFT BLU t 36 BLUMH STEER RIGHT BK RD CR3 BLK RED 1 35 BK RD S P RPM BKWT CRB BLKW
131. TON DP1 DRIVE CONTROLLER O BP1 BOOM FUNCTION SPEED CONTROLLER TS1 AUXILIARY SWITCH Ts2 START SWITCH zi g CHOKE SWITCH 2 GL TS4 FUEL SELECT SWITCH N 5 a Q TS5 RPM SWITCH z Z JJ g TS6 TURNTABLE ROTATE SWITCH zi TS7 SECONDARY BOOM UP DOWN SWITCH PRIMARY BOOM UP DOWN SWITCH U Ove O TS9 EXTEND RETRACT SWITCH S3 TS10 PLATFORM LEVEL SWITCH O S s Q PLATFORM ROTATE SWITCH go 2 b d m TS12 JIB UP DOWN SWITCH TS13 DRIVE HIGH LOW OUTPUT SWITCH DRIVE ENABLE SWITCH R2 250 OHM RESISTER Rs o DRIVE ENABLE LIGHT gt C O 8 O 9 9 112 4 5 6 7 8 da 2 2 22 m O4 424 o9 a L DP1 E i I ale e slo O_O DEP HORSE POWER LIMITER 14 g 2 T lt T 5 L 2 e I 5 glg gels s g 2 B e Pp 2 9 zizlee ee fale 215 5 x x x CG x x x cx 2 2 0 2 9 8 xz Bx 8 Z Je Z b 913 5 515 p pm 91515 5 Z S 5 2 9 6 5 2 olo 0 5 mg 2 5 2 E oe 2 m N lg 7 m x E m OQ x Oi m k Ea 5 5 E 9 o gum 5 E e e eo E t
132. Water Separator for instructions on how to prime the fuel filter water separator 4 Start the engine from the ground controls and check the fuel filter water separator for leaks Part No 43037 Genie Z 34 22 Section 4 Scheduled Maintenance Procedures Service Manual First Edition TABLE A PROCEDURES A 17 Check the Engine Belt Kubota engine specifications require that this procedure be performed every 100 hours Maintaining the engine belt is essential to good engine performance and service life The machine will not operate properly with a loose or defective belt and continued use may cause component damage AWARNING Bodily 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 Inspect the engine belt for Cracking Glazing Separation Breaks 2 Check the engine belt for proper tension A 18 Replace the Engine Oil and Filter Kubota engine specifications require that this procedure be performed every 200 hours Perform this procedure more often if dusty conditions exist or the machine is subjected to extended low idle operation Periodic replacement of the engine oil and filter is essential to good engine performance Operating the machine with an improper oil level or neglecting periodic oil and filter ch
133. With key switch in ground position and both Emergency Stop switches pulled out to the on position activate the function enable toggle switch TS19 if equipped and the ext ret boom toggle switch TS23 on ground panel in retract direction and check voltage on blk wht 8 wire on boom function directional valve coil item V Continued from the previous page 12V or more Continued on the next page Section 5 Troubleshooting Flow Charts s With key switch in ground position and both Emergency Stop switches pulled out to the on position activate the function enable toggle switch TS19 if equipped and the ext ret boom toggle switch TS23 on ground panel in retract direction and check voltage at TB8 With key switch in platform position both Emergency Stop switches pulled out to the on position and boom function speed controller turned to 9 activate footswitch and ext ret boom toggle switch TS9 on platform control panel in retract direction and check voltage to TB8 Troubleshoot ext ret boom function toggle switch TS23 on ground control panel OR replace diode on TS23 OR repair open in blk wht 8 wire circuit from TS23 to TB8 OR consult Genie Industries Service Department CHART 21 Repair open in blk wht 8 wire circuit from TB8 to boom function directional valve coil item V OR repair open in ground wire circuit to manifold item V Troubleshoot ext ret boom fu
134. Y BOOM COMPONENTS 16 Attach a similar lifting device to the lift cylinder 17 Use the crane to lift the primary boom toa horizontal position 18 Place support blocks under the cylinder across the secondary boom 19 Remove the pin retaining fastener from the 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 20 Lower the rod end of the lift cylinder onto support blocks Protect the cylinder rod from damage 21 Remove the hose clamp brackets from the underside of the primary boom 22 Remove the hose clamp from the side of the primary boom 23 Remove the limit switch cam mounting fastener Note the position of the cam before removing it 24 Remove the pin retaining fastener from the boom pivot pin 25 Remove the boom pivot pin with a soft metal drift then carefully remove the boom from the machine AWARNING Crushing hazard If the overhead crane is not properly attached the boom may become unbalanced and fall when it is removed from the machine Part No 43037 Genie Z 34 22 Section 7 Repair Procedures Service Manual First Edition PRIMARY BOOM COMPONENTS How to Disassemble the Primary Boom 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 bo
135. afety 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 your top priority Read each procedure thoroughly This manual and the decals on the machine use signal words to identify the following Indicates the presence of a hazard ADANGER that will cause death or serious injury Indicates the presence of a hazard AWARNING that may cause death or serious injury Indicates the presence of a hazard ACAUTION that will or may cause serious injury or damage to the machine Indicates special operation or maintenance information other protective clothing if the situation amp Be sure to wear protective eye wear and 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 Workplace Safety Be sure to keep sparks flames and W lighted tobacco away from flammable and 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 could get into machine components and cause damage Be sure that your workshop or work area is properly ventilated and well lit Be sure any forklift overhead crane o
136. ance valve OR boom function manifold could have an internal defect Consult Genie Industries Service Department 5 38 Genie Z 34 22 IC Part No 43037 Service Manual First Edition Section 5 Troubleshooting Flow Charts Secondary Boom Up Function inoperative Be sure all other functions operate normally If secondary boom up function operates normally from the ground controls but not from the platform controls troubleshoot the platform controller or diode See Repair Section If secondary boom up function operates normally from the platform controls but not from the ground controls troubleshoot the ground control toggle switch OR diode OR resistor See Repair Section With key switch in ground position and both Emergency Stop switches pulled out to the on position activate the function enable toggle switch TS19 if equipped and the secondary boom toggle switch TS21 on ground panel in up direction and check voltage on wht red 6 wire on boom function proportional valve coil item D Continued on the next page 12V or more With key switch in ground position and both Emergency Stop switches pulled out to the on position activate the function enable toggle switch TS19 if equipped and the secondary boom toggle switch TS21 on ground panel in up direction and check voltage at TB6 With key switch in platform position both Emergency Stop switches pull
137. and the indicator light turns on The drive enable switch must be used to reactivate drive function and should inform the operator that the machine will move in the opposite direction that the drive and steer controls are moved An improperly functioning drive enable system may allow the machine to be moved into an unsafe position 1 Start the engine from the platform controls 2 Rotate the turntable to the right until the primary boom is past the right non steer wheel Result The drive enable indicator light should turn on 3 Slowly move the drive control handle off center C Result The drive function should not operate 4 Hold the drive enable toggle switch to either side and slowly move the drive control handle off center Result The drive function should operate Collision hazard Always use the ACAUTION color coded direction arrows on the platform control panel and the drive chassis to identify which direction the machine will travel Genie Z 34 22 IC Part No 43037 Service Manual First Edition Section 4 Scheduled Maintenance Procedures 5 Rotate the turntable to the left until the primary boom is past the left non steer wheel Result The drive enable indicator light should come on 6 Repeat steps 3 and 4 B 20 Test the Drive Brakes Proper brake action is essential to safe machine operation The drive brake function should operate smoothly free of hesitation jerking and unusual
138. anges can damage engine components A daily check of elapsed machine hours against the hours noted on the oil filter will allow the inspector to anticipate and perform oil and filter changes at the 200 hour interval Bodily injury hazard Beware of ACAUTION hot engine parts and oil Contact with hot engine oil and or engine parts may cause severe burns Perform this procedure after warming the engine to normal operating temperature 1 Remove the oil filler cap located on the valve cover 2 Pull the end of the oil drain hose out from under the engine 3 Open the drain valve on the oil pan and allow all of the oil from the engine to drain into a suitable container Dispose of the oil properly 4 Close the drain valve 1 4 to 3 inch 7to9mm Belt deflection Genie Z 34 22 IC Part No 43037 Service Manual First Edition Section 4 Scheduled Maintenance Procedures 5 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 oil filter 6 Clean the area around the oil filter then use an oil filter wrench and remove the filter 7 Applyathin layer of oil to the new oil filter gasket Then install the filter and tighten it securely by hand 8 Use a permanent ink marker to write the date and number of hours from the hour meter on the oil filter 9 Fill the engine with new oil per specifications and install the filler cap
139. ap the cylinder fittings AWARNING add 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 9 Remove the cylinder through the top of the secondary boom Genie Z 34 22 IC Part No 43037 Service Manual First Edition Section 7 Repair Procedures 6 1 Timing Adjustment Complete information to perform this procedure is available in the Kubota D 905 Workshop Manual Kubota code number 97897 02432 Genie part number 31742 6 2 Glow Plugs How to Check the Glow Plugs See the scheduled maintenance procedure B 9 Check The Glow Plugs Kubota Diesel Models 6 3 Engine RPM RPM Adjustment See the scheduled maintenance procedure B 10 Check and Adjust 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 Kubota D 905 Engine 2 Carefully pull the pump away from the engine and secure it from moving 3 Remove the flex plate mounting fasteners then remove the flex plate from the engine How to Install the Flex Plate 1 Install the flex plate onto the flywheel with the ra
140. art switch and check voltage at blu wht wire on anti diesel valve on carburetor Continued on the next page Chart 7 Replace fuel select switch Repair open in blu wht wire circuit from fuel select switch to TP38 to TB38 Repair open in blu wht wire circuit from TB38 to terminal 30 on CR6 Repair open in red blk wire circuit from vacuum switch to CR6 Repair open in ground wire to terminal 85 on CR6 Repair open in blu wht wire circuit from CR6 terminal 87 to anti diesel valve OR replace CR6 Part No 43037 Genie Z 34 22 IC Section 5 Troubleshooting Flow Charts Service Manual First Edition CHART 7 Continued from the previous page Replace anti diesel valve Check resistance of anti diesel valve 24 to 25 ohms Hold start switch and Repair open in blu wht check voltage at blu wht wire between fuel on fuel pump next to solenoid and fuel pump fuel tank 12V Check ground wire to fuel pump good Repair ground wire less than Install a pressure gauge 7 psi to the fuel pump more than 7 psi Replace fuel pump Reconnect starter check anti diesel and fuel valve for defects OR see Kubota service manual for carburetor troubleshooting Genie Z 34 22 IC Part No 43037 Service Manual First Edition Section 5 Troubleshooting Flow Charts Engine High Idle Inoperative Kubota Gasoline LPG Models
141. asoline LPG Models before serial number 869 A B Service Manual VOLTAGE OIL PRESSURE COOLANT TEMPERATURE 4 GAUGE GAUGE GAUGE 1 WHT RED 26A AL BRN GROUND E WHT 21A WHTIBLK 25A BLK 22A WHT 23A P Onc O 5 i ae KS1 NO NO Onc O Ql TS15 exta RED 27A i GRN 17A OQO e TS25 523 WHT RED 3A J a Ri RED 1A HM RED BLK 2A L r O LO O TS24 TS22 M M BLU 10A 926 BLUIBLK 11A TO ooo 4 60 O HX TS17 TS16 NL N TS18 WHT 4A A WHT BLK 5A OO O Ly TS20 TS19 u 3i CB2 1 gt RED 20A GRN 43A GRNBBLK MA ORG MA ORGIBLK 15A RED R1 30 BLUMWHT 38A BLU RED 39A BLKIWHT 34A BLK 33A BLK RED 35A LABEL DESCRIPTION Pi EMERGENCY STOP BUTTON KEY SWITCH 1815 AUXILIARY SWITCH 1816 ENGINE START SWITCH 817 ENGINE CHOKE SWITCH ENGINE FUEL SELECT SWITCH 1819 ENGINE RPM SWITCH TS20 TURNTABLE ROTATE SWITCH SECONDARY BOOM UP DOWN SWITCH TS22 PRIMARY BOOM UP DOWN SWITCH 1823 BOOM EXTEND RETRACT SWITCH Ts24 PLATFORM LEVEL SWITCH T
142. atform controller or diode See Repair Section If secondary boom down function operates normally from the platform controls but not from the ground controls troubleshoot the ground control toggle switch OR diode OR resistor See Repair Section With key switch in ground position and both Emergency Stop switches pulled out to the on position activate the function enable toggle switch TS19 if equipped and the secondary boom toggle switch TS21 on ground panel in down direction and check voltage on wht red 6 wire on boom function proportional valve coil item D Continued on the next page 12V or more With key switch in ground position and both Emergency Stop switches pulled out to the on position activate the function enable toggle switch TS19 if equipped and the secondary boom toggle switch TS21 on ground panel in down direction and check voltage at TB6 With key switch in platform position both Emergency Stop switches pulled out to the on position and boom function speed controller turned to 9 activate footswitch and secondary boom toggle Switch TS7 on platform control panel in down direction and check voltage at TB6 Troubleshoot secondary boom function toggle switch TS21 on ground control panel OR repair open wht red 6 wire circuit from TS21 to TB6 OR consult Genie Industries Service Department Repair open in wht red 6 wire circuit from TB6 to bo
143. battery vent caps and check the specific gravity of each battery cell with a hydrometer 5 Checkthe battery acid level of the battery If needed replenish with distilled water to the bottom of the battery fill tube Do not overfill 6 Install the battery vent caps Part No 43037 Genie Z 34 22 IC Section 4 Scheduled Maintenance Procedures Service Manual First Edition TABLE B PROCEDURES B 5 Inspect the Electrical Wiring 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 ground control box Turntable manifold wiring 2 Start the engine from the ground controls 3 Raise the secondary boom until the lower 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 se
144. ble motors and torque hubs Boom components and wear pads Dents or damage to machine Tires and wheels Engine and related components Limit switches Alarms service horn and beacon Nuts bolts and other fasteners Platform entry mid rail or gate Cracks in welds or structural components Compartment covers and latches TABLE A PROCEDURES 4 Check the Engine Oil Level Maintaining the proper engine oil level is essential to good engine performance and service life Operating the machine with an improper oil level can damage engine components Check the oil level with the engine off 1 Check the oil level dipstick Result The oil should be at the full mark on the dipstick Add oil as needed Kubota Engine WG 750 3 9 quarts Oil capacity including filter 3 25 liters Oil viscosity requirements 10W 40 Extreme operating temperatures may require the use of alternative engine oils For oil requirements refer to the Engine Operator s Manual on your machine Units ship with 10W 40 Kubota Engine D 905 5 4 quarts Oil capacity including filter 5 1 liters Oil viscosity requirements 10W 40 Extreme operating temperatures may require the use of alternative engine oils For oil requirements refer to the Engine Operator s Manual on your machine Units ship with 10W 40 Part No 43037 Genie Z 34 22 4 3 Section 4 Scheduled Maintenance Procedures Service Manual First Edit
145. bota Diesel Models 5 11 Engine Will Not Start On LPG But Will Start On Gasoline Kubota Gasoline LPG Models u uy u amia uuu usa aqasha 5 14 Engine Choke Inoperative Kubota Gasoline LPG Models 5 16 Engine Glow Plugs Inoperative Kubota Diesel Models 5 19 Engine Will Not Start On Gasoline But Will Start On LPG Kubota Gasoline LPG Models 5 21 8 Engine High Idle Inoperative Kubota Gasoline LPG Models 5 23 9 Engine Low Idle Inoperative Kubota Gasoline LPG Models 5 25 10 Engine High Idle Inoperative Kubota Diesel Models 5 26 11 Engine Low Idle Inoperative Kubota Diesel Models 5 28 12 Functions Inoperative Engine Starts and Runs 5 29 13 AllLift and Steer Functions Inoperative Drive Function Operational 5 30 14 Ground Controls Inoperative Platform Controls Operate Normally 5 31 15 Platform Controls Inoperative Ground Controls Operate Normally 5 32 16 Primary Boom Up Function Inoperative 2 5 33 17 Primary Boom Down Function Inoperative 5 36 18 Secondary Boom Up Function Inoperative 5 39 19 Secondary Bo
146. carburetor b fuel filter c hose from the fuel filter to the fuel pump d hose from the fuel pump to the fuel shutoff valve not shown 3 Clean up any fuel that may have spilled during this procedure 4 Startthe engine from the ground controls then inspect the fuel filter and hoses for leaks Explosion and fire hazard If a fuel LAELLA leak is discovered keep any additional personnel from entering the area and do not operate the machine Repair the leak immediately Once air has been introduced into the diesel fuel injection system the injectors must be bled before the engine is restarted See Maintenance procedure B 25 Replace the Diesel Fuel Filter Water Separator Element Kubota Diesel Models for information on how to bleed the fuel system TABLE D PROCEDURES Part No 43037 Genie Z 34 22 IC Section 4 Scheduled Maintenance Procedures Service Manual First Edition EET 4 44 Genie Z 34 22 IC Part No 43037 Service Manual First Edition Section 5 Troubleshooting Flow Charts Troubleshooting Flow Charts 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 Unless otherwise specified perform each repair procedure with the
147. ce Manual First Edition SS aaa 3 8 Genie Z 34 22 IC Part No 43037 Service Manual First Edition Section 4 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 Scheduled maintenance inspections shall be completed daily quarterly annually and every 2 years as specified on the Maintenance Inspection Report AWARNING Failure to properly complete each inspection when required may cause death serious injury or substantial machine damage M Immediately tag and remove from service a damaged or malfunctioning machine Repair any machine damage or malfunction before operating machine Keep records all inspections for three years Unless otherwise specified perform each 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 orr position with the key removed Wheels chocked All exernal AC power disconnected from the machine 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 DANGER Indicates the presence of a hazard
148. ck the Oil Level in the Torque Hubs Failure to maintain proper torque 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 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 necessary remove the top 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 Repeat this procedure for each torque hub Drive Torque Hub Oil Capacity 17 fl oz 051 Type SAE 90 multipurpose hypoid gear oil API service classification GL5 Part No 43037 Genie Z 34 22 IC 4 17 Section 4 Scheduled Maintenance Procedures Service Manual First Edition TABLE B PROCEDURES B 9 Check the Glow Plugs Kubota Diesel Models Maintaining the glow plugs in good condition is essential to good engine performance and service life Improperly functioning glow plugs will cause the engine to perform poorly and may result in component damage Perform this procedure with the engine turned off 1 Connect the leads from an ohmmeter between the far left glow plug and machine ground Result The resistance should be approximately 1 0Q 2 Ifthe ohm reading is different than 1
149. component damage Result If the pressure gauge reads 3000 psi 206 bar immediately stop cranking the engine The pump is good Result If pressure fails to reach 3000 psi 206 bar the pump is bad and will need to be serviced or replaced Genie Z 34 22 IC Part No 43037 Service Manual First Edition Section 7 Repair Procedures 6 Remove the pressure gauge and reconnect the hydraulic hose 7 Kubota Gasoline LPG models Reconnect the high tension lead to the ignition coil How to Remove the Lift Steer Pump 1 Disconnect and cap 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 bolts Carefully remove the pump HYDRAULIC PUMPS 9 3 Drive Hydraulic Pump The drive hydraulic pump is a bi directional variable displacement piston pump The pump output is controlled by the electronic displacement controller EDC located on the pump The only adjustment that can be made to the pump is the neutral or null adjustment Any internal service to the pump should only be performed at an authorized Sundstrand Sauer service center How to Remove the Drive Hydraulic Pump Component damage hazard The ACAUTION work area and surfaces where this procedure will be performed must be clean
150. condary booms Jib boom to platform cable harness Inside of the platform control box B 6 Inspect the Tires and Wheels including lug nut torque Maintaining the tires and wheels in good condition is essential to safe operation and good performance Tire and or wheel failure could result a machine tip over Component damage also result if problems are not discovered and repaired in a timely fashion 1 Check the tire surface and sidewalls for cuts cracks punctures and unusual wear 2 Check each wheel for damage bends and cracked welds 3 Check each lug nut for proper torque Tire Specifications 2WD Models 4WD Models Industrial tire 9 14 5 LT 100 psi 6 89 bar Rough terrain tire 10 16 5 NHS 10 16 5 NHS 45psi 3 1 bar 45 psi 3 1 bar Lug nut torque Lubricated Dry 94 ft lbs 125 ft lbs 127 Nm 169 Nm Genie Z 34 22 IC Part No 43037 Service Manual First Edition Section 4 Scheduled Maintenance Procedures B 7 Confirm the Proper Brake Configuration 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 disengage position arf Bes ar M brake engage position TABLE B PROCEDURES B 8 Che
151. cuit steer end Check valve Direction control circuit 15 18 ft lbs 20 24 Nm Relief valve 210 psi 14 5 bar Bu Charge pressure circuit 15 18 ft Ibs 20 24 Nm 10 Pilot operated check valve Smoothes the shift from low to high range 15 18 ft lbs 20 24 Nm 11 Shuttle valve 3 position 3 way that gets hot 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 7 56 Genie Z 34 22 IC Part No 43037 Section 7 Repair Procedures Service Manual First Edition 4WD DRIVE MANIFOLD 57 Genie Z 34 22 Part No 43037 Section 7 Repair Procedures Service Manual First Edition 4WD DRIVE MANIFOLD Plug Torque Specifications 6 Restart the engine Drive the machine in either direction and recheck the valve pressure Description Hex size Torque 7 Turn the engine off then remove the SAE No 2 50 in Ibs 6 Nm pressure gauge SAE No 4 3 16 13 ft lbs 18 Nm Relief valve specifications SAE No 6 1 4 18 ft lbs 24 Nm Pressure 210 psi 14 5 bar SAE No 8 5 16 50 ft lbs 68 Nm SAE No 10 9 16 55 ft lbs 75 Nm SAE No 12 5 8 75 ft lbs 102 Nm
152. d the carburetor Then connect the fuel hoses to the filter 3 Clean up any fuel that may have spilled during the replacement procedure 4 Startthe machine from the ground controls then inspect the fuel filter and hoses for leaks A DANGER 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 TABLE C PROCEDURES C 8 Clean or Replace the Distributor Cap and Rotor Kubota Gasoline LPG Models A distributor cap and rotor that are clean and free of damage wear and corrosion are essential to good engine performance and service life A dirty or worn cap and rotor may cause the engine to perform poorly and continued use may cause component damage Extremely dirty conditions may require that the cap and rotor be cleaned or replaced more often Perform this procedure with the engine off 1 Remove the distributor access cover from the side of the engine to access the distributor distributor access cover 2 Label and disconnect the coil and spark plug wires from the distributor cap 3 Remove the cap and rotor from the distributor Part No 43037 Genie Z 34 22 Section 4 Scheduled Maintenance Procedures Service Manual First Edition TABLE C PROCEDURES 4 Clean the cap and rotor using electrical contact cleaner or a damp cloth 5 Completely dry the cap and rotor Mois
153. duled Maintenance Procedures B 3 Check the Exhaust System 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 Bodily injury hazard Do not AWARNING 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 on the engine pivot plate located under the pump Swing the engine pivot plate away from the machine to access the exhaust system 2 Be 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 TABLE B PROCEDURES B 4 Check the Battery Proper battery condition is essential to good machine performance and operational safety Improper fluid levels or damaged cables and connections can result in engine component damage and hazardous conditions Bodily injury hazard Batteries AWARNING contain acid Avoid spilling or contacting battery acid Neutralize battery acid spills with baking soda and water 1 Put on protective clothing and eye wear 2 Be sure that the battery cable connections are free of corrosion 3 Be sure that the battery hold downs and cable connections are tight 4 Remove the
154. e 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 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 At the platform controls move the engine idle control switch to high idle rabbit symbol Result The engine should change to high idle TABLE B PROCEDURES Move the engine idle control switch to low idle turtle symbol Result The engine should change to low idle Move the engine idle control switch to foot switch activated high idle rabbit and foot switch symbol Result The engine should not change to high idle Press down the foot switch Result The engine should change to high idle Part No 43037 Genie Z 34 22 4 23 Section 4 Scheduled Maintenance Procedures Service Manual First Edition TABLE B PROCEDURES B 18 Test the Fuel Select Operation Kubota Gasoline LPG Models The ability to select and switch between gasoline and LPG fuels as needed is essential to
155. e behind the 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 4 Install the new filter and tighten it securely by hand Clean up any oil that may have spilled during the replacement procedure Suction oil filter Genie part number 43686 7 Replace the Gasoline Fuel Filter Kubota Gasoline LPG Models Replacing the gasoline 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 ADANGER Explosion and fire hazard Engine fuels are combustible Replace the fuel filter in an open well ventilated area away from heaters sparks flames and lighted tobacco Always have an approved fire extinguisher within easy reach Perform this procedure with the engine off 1 Disconnect the fuel hoses from the filter then remove the filter Kubota Gasoline LPG models a hose from the fuel filter to the carburetor b fuel filter hose from the fuel filter to the fuel pump Genie Z 34 22 IC Part No 43037 Service Manual First Edition Section 4 Scheduled Maintenance Procedures 2 Install the new fuel filter Genie part no 23168 with the flow direction arrow on the filter pointing towar
156. e condition of the radiator that might indicate cooling system problems AWARNING Bodily 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 Inspect the radiator for leaks and physical damage 2 Clean the radiator fins of debris and foreign materials B 2 Check the Engine Choke Kubota Gasoline LPG Models A properly functioning choke is essential to good engine performance An improperly functioning choke will result in difficulty with engine starting 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 a carburetor b linkage c linkage lock nuts d choke solenoid 2 Turn the key switch to ground control and then pull out the ground control Emergency Stop button to the position 3 While operating the choke switch inspect the choke solenoid Result The choke solenoid should be fully retracted when the choke switch is activated 4 Turn the key switch to platform control 5 Pull out the platform control Emergency Stop button to the ow position and then operate the choke switch and listen for choke solenoid operation Genie Z 34 22 IC Part No 43037 Service Manual First Edition Section 4 Sche
157. e from TB24 and check continuity to ground no continuity Repair short in wht wire circuit from terminal 10 start lock out module to TB24 OR consult Genie Industries Service Department Go to Chart 2A Remove 1 spark plug and ground spark plug body Crank engine and observe spark good spark weak or no spark See Kubota service manual for troubleshooting ignition system Disable starter by removing blk wire at the starter solenoid hold start switch and check voltage at positive terminal of ignition coil Continued on the next page Chart 2 hot Check engine coolant level OR check radiator fins for clogging OR check engine fan belts OR see Kubota service manual for troubleshooting an overheating engine continuit Replace temperature switch sender Repair short in wht red continuity wire circuit from TB24 to temperature sender Part No 43037 Genie Z 34 22 IC Section 5 Troubleshooting Flow Charts Service Manual First Edition CHART 2 Hold start switch and check voltage at wht 21 on terminal 87 of CR2 Continued from the previous page Repair open in wht 21 wire to ignition coil Check voltage at red Repair open in red wire wire on terminal 30 of CR2 circuit from battery to CB2 to CR1 to CR2 Hold start switch and check voltage at terminal 9 on ign start module Hold start switch and check voltage at te
158. e limit switch arm should move freely and spring return to center A distinct click should be felt and heard Genie Z 34 22 IC Part No 43037 Service Manual First Edition Section 4 Scheduled Maintenance Procedures 3 Manually activate the boom extend limit switch Result The drive limit switch arm should move freely and spring return to center A distinct click should be felt and heard 4 Start the engine from the ground controls 5 Raise the secondary boom 5 feet 1 5 6 Manually activate the secondary boom limit switch Result The drive limit switch arm should move freely and spring return to center A distinct click should be felt and heard Lower the boom to the stowed position Turn the key switch to the platform controls Slowly move the drive control handle off center o N Result The machine should move at normal drive speeds 10 Raise the primary boom 5 feet 1 5 m 11 Slowly move the drive control handle off center Result The machine should move at a reduced drive speed 12 Lower the boom to the stowed position 13 Raise the secondary boom 5 feet 1 5 m 14 Slowly move the drive control handle off center Result The machine should move at a reduced drive speed 15 Lower the boom to the stowed position 16 Extend the primary boom 3 feet 0 9 m 17 Slowly move the drive control handle off center Result The machine should move at a reduced drive speed Dr
159. ed on the next page With key switch in ground position and both Emergency Stop switches pulled out to the on position activate the function enable toggle switch TS19 if equipped and the primary boom toggle switch TS22 on ground panel in down direction and check voltage at TB6 With key switch in platform position both Emergency Stop switches pulled out to the on position and boom function speed controller turned to 9 activate footswitch and primary boom toggle Switch TS8 on platform control panel in down direction and check voltage at TB6 Troubleshoot primary boom function toggle switch TS22 on ground control panel OR repair open wht red 6 wire circuit from TS22 to TB6 OR consult Genie Industries Service Department Repair open in wht red 6 wire circuit from TB6 to boom function proportional valve coil item D OR repair open in grn yel ground wire But to valve coil item Troubleshoot primary boom function toggle switches TS22 and TS8 on ground and platform control panels OR repair open in wht red 6 wire circuit from 7922 to TB6 and from 788 to red wire on boom function speed controller OR consult Genie Industries Service Department If voltage to TB6 from TS22 and TS8 has been restored and primary boom down function is still inoperative please continue troubleshooting from beginning of chart Genie Z 34 22 IC Part No 43037 Service Manual First Edition
160. ed out to the on position and boom function speed controller turned to 9 activate footswitch and secondary boom function toggle switch TS7 on platform control panel in up direction and check voltage at TB6 Troubleshoot secondary boom function toggle switch TS21 on ground control panel OR repair open wht red 6 wire circuit from TS21 to TB6 OR consult Genie Industries Service Department Chart 18 Repair open in wht red 6 wire circuit from TB6 to boom function proportional valve coil item D OR repair open in ground wire circuit to valve coil item D Troubleshoot secondary boom function toggle switches TS21 and TS7 on ground and platform control panels OR repair open In wht red 6 wire circuit from TS21 to TB6 and from 57 to red wire on boom function speed controller OR consult Genie Industries Service Department If voltage to TB6 from TS21 and TS7 has been restored and secondary boom up function is still inoperative please continue troubleshooting from beginning of chart Part No 43037 Genie Z 34 22 IC Section 5 Troubleshooting Flow Charts CHART 18 With key switch in ground position and both Emergency Stop switches pulled out to the on position activate the function enable toggle switch TS19 if equipped and the secondary boom toggle switch TS21 on ground panel in up direction and check voltage on blu 10 wire on boom function directional valve coil i
161. en in blk wht wire from CR8 terminal 87 to glow plugs Repair open in red wire circuit from CB2 Check ground on good terminal 85 on CR8 bad Repair open in ground wire on terminal 85 on CR8 Repair open in circuit supplying 12V to glow plug switch Replace toggle switch OR replace diode Repair open in blk wht wire circuit from glow plug switch to TB34 Chart 6 Replace CR8 Part No 43037 Genie Z 34 22 Section 5 Troubleshooting Flow Charts Service Manual First Edition CHART 6 Hold ground control Repair open blk wht glow plug switch and wire circuit from from check voltage at TB34 to terminal 86 on CR8 Continued from the previous page terminal 86 CR8 Check ground wire circuit on terminal 85 on CR8 Repair open in ground wire circuit good Replace CR8 and hold glow plug does not work Consult Genie Industries ground control glow plug Service Department switch glow plug works Turn keyswitch to Start engine If engine platform and hold the won t start refer to platform control glow plug switch and check glow plug Note Do not depress the footswitch Engine Cranks Over but Will Not Start Kubota Diesel Models Chart 3 glow plug does not work Check voltage on center terminal on platform glow plug switch Repair open in power supply wire circuit Hold platorm glow plug switch and check v
162. ent 5 72 Genie Z 34 22 Part No 43037 Service Manual First Edition Section 5 Troubleshooting Flow Charts Jib Boom Down Function inoperative Be sure all other functions operate normally If jib boom down function operates normally from the ground controls but not from the platform controls troubleshoot the platform controller or diode See Repair Section If jib boom down function operates normally from the platform controls but not from the ground controls troubleshoot the ground control toggle switch OR diode OR resistor See Repair Section With key switch in ground position and both Emergency Stop switches pulled out to the on position activate the function enable toggle switch TS19 if equipped and thejib toggle switch TS26 on ground panel in down direction and check voltage on wht red 6 wire on boom function proportional valve coil item D 12V or more Continued on the next page With key switch in ground position and both Emergency Stop switches pulled out to the on position activate the function enable toggle switch TS19 if equipped and thejib toggle switch TS26 on ground panel in down direction and check voltage at TB6 With key switch in platform position both Emergency Stop switches pulled out to the on position and boom function speed controller turned to 9 activate footswitch and jib toggle switch 7512 on platform control
163. ent screw to obtain an air to fuel mixture ratio of 13 0 1 to 13 2 1 a low idle mixture adjustment screw C 11 Replace the Engine Air Filter Kubota specifications require that this procedure be performed every 1000 hours Perform this procedure more often if dusty conditions exist 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 Perform this procedure with the engine off 1 Diesel models Remove the retaining fastener from the air cleaner element end cap Remove the end cap Gasoline LPG models Release the latches from the air cleaner canister end cap Remove the end cap 2 Remove the filter element 3 Clean the inside of the canister and the end cap with a damp cloth 4 Install the new filter element 5 Diesel models Install the air cleaner element end cap retaining fastener Gasoline LPG models Install the air cleaner end cap and secure the latches Air filters Genie part numbers Kubota D 905 Engine 31745 Kubota WG 750 Engine 22107 4 38 Genie Z 34 22 IC Part No 43037 Service Manual First Edition Section 4 Scheduled Maintenance Procedures E TABLE C PROCEDURES 12 Check and Adjust the Ignition Timing Kubota Gasoline LPG Models Complete information to perform this procedure is available in the Kubota WG 750 Workshop Manua
164. eplace defective directional valve function inoperative Install a 0 to 5000 PSI Check for mechanical pressure gauge at the restrictions keeping quick disconnect platform rotate left coupling on the boom function from moving function manifold and OR the 030 orifice item activate the platform E could be plugged OR rotate left function repair hydraulic rotation motor OR consult Genie Industries Service less than 3200 PSI Department Repair hydraulic rotation motor OR platform rotate jib function manifold could have an internal fault Consult Genie Industries Service Department 5 66 Genie Z 34 22 Part No 43037 Service Manual First Edition Section 5 Troubleshooting Flow Charts Platform Rotate Right inoperative Be sure all other functions operate normally If platform rotate right function operates normally from the ground controls but not from the platform controls troubleshoot the platform controller or diode See Repair Section If platform rotate right function operates normally from the platform controls but not from the ground controls troubleshoot the ground control toggle switch OR diode OR resistor See Repair Section With key switch in ground position and both Emergency Stop switches pulled out to the on position activate the function enable toggle switch TS19 if equipped and theplatform rotate toggle switch TS25 on ground panel in
165. er Check the voltage at terminal 86 o CR6 12V Continued on the next page Adjust choke OR consult Genie Industries Service Department Repair open in red wht 23 wire circuit from TB23 to vacuum switch Turn machine off See bad Repair section for vacuum switch check ok Check vacuum line for bad restrictions ok See Kubota service manual to troubleshoot low manifold vacuum Repair open in red blk wire circuit from vacuum Switch to CR6 Chart 2A Replace vacuum switch Replace vacuum line Part No 43037 Genie Z 34 22 IC Section 5 Troubleshooting Flow Charts Service Manual First Edition CHART 2A Continued from the previous page With keyswitch on Repair open in red ground position and power wire circuit with Emergency Stop switch diode pulled out check voltage at center terminal on fuel select switch in ground control box With keyswitch on ground position and Emergency Stop switch pulled out check voltage on gasoline side blu wht wire of fuel select switch Replace toggle switch With keyswitch on Repair open in blu wht ground position and wire circuit from toggle Emergency Stop switch Switch to TB38 pulled out check voltage at terminal TB38 With keyswitch on Repair open in blu wht ground position and wire circuit from TB38 to Emergency Stop switch terminal 30 on CR6 pulled out check voltage at blu wht wire at
166. er turned to 9 activate footswitch and turntable rotate toggle switch TS6 on platform control panel in left direction and check voltage at TB6 Troubleshoot turntable rotate function toggle switch TS20 on ground control panel OR repair open in wht red 6 wire circuit from TS20 to 6 OR consult Genie Industries Service Department Chart 22 Repair open in wht red 6 wire circuit from TB6 to boom function proportional valve coil item D OR repair open in ground wire circuit to valve coil item D Troubleshoot turntable rotate function toggle switches TS20 and TS6 on ground and platform control panels OR repair open in wht red 6 wire circuit from 1520 to TB6 and from TS6 to red wire on boom function speed controller OR consult Genie Industries Service Department If voltage to TB6 from TS20 and TS6 has been restored and turntable rotate left function is still inoperative please continue troubleshooting from beginning of chart Part No 43037 Genie Z 34 22 IC Section 5 Troubleshooting Flow Charts Service Manual First Edition CHART 22 With key switch in ground position and both Emergency Stop switches pulled out to the on position activate the function enable toggle switch TS19 if equipped and theturntable rotate toggle switch TS20 on ground panel in left direction and check voltage on wht 4 wire on boom function directional valve coil item P Conti
167. eshooting from beginning of chart 5 40 Genie Z 34 22 IC Part No 43037 Service Manual First Edition Section 5 Troubleshooting Flow Charts g CHART 18 Disconnect wire to Oor secondary boom up m Replace secondary directional valve coil 5 boom up directional item Q Remove coil valve coil item Q and test resistance Continued from the previous page 4 to 8 ohms Exchange secondary boom up and down directional valves item Q P and activate secondary boom up function Replace defective directional valve function inoperative Install a 0 to 5000 PSI Check for mechanical pressure gauge at the restrictions keeping quick disconnect secondary boom from coupling on the boom moving OR repair function manifold and oylinder or cylinder activate the secondary counterbalance valve boom up function OR consult Genie Industries Service less than 3200 PSI Department Repair cylinder or cylinder counterbalance valve OR boom function manifold could have an internal fault Consult Genie Industries Service Department Part No 43037 Genie Z 34 22 5 41 Section 5 Troubleshooting Flow Charts Service Manual First Edition Chart 19 Secondary Boom Down Function inoperative Be sure all other functions operate normally If secondary boom down function operates normally from the ground controls but not from the platform controls troubleshoot the pl
168. ession arm lower mid pivot compression link lower secondary boom lower compression arm turntable pivot upper secondary boom ro o o 7 22 Genie Z 34 22 IC Part No 43037 Service Manual First Edition Section 7 Repair Procedures 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 may result in death or serious injury and significant component damage Dealer service is required Follow the disassembly steps to the point required to complete the repair Then re assemble the secondary boom by following the disassembly steps in reverse order 1 Lower the boom to the stowed position 2 Place a lifting device under the front of the platform 3 Remove the rear turntable cover Remove the cable cover from the side of the jib boom 5 Remove the wire loom from the cables at the platform control box 6 Locate the 4 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 Label and disconnect each wire of the 4 cables in the platform control box AWARNING Electrocution hazard Contact with electrically charged circuits may result in death or serious injury Remove all rings watc
169. f maintenance inspections that must be performed according to a schedule daily quarterly annual and two year To account for repeated procedures the Maintenance Tables and the Maintenance Inspection Report have been divided into four subsections A B C D Use the following chart to determine which group s of procedures are required to perform a scheduled inspection Inspection Table or Checklist Daily A Quarterly A B Annual A B C Two year A B C D Maintenance Tables The maintenance tables contained in this section provide summary information on the specific physical requirements for each inspection Complete step by step instructions for each scheduled maintenance procedure are provided in section 4 Scheduled Maintenance Procedures 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 43037 Genie Z 34 22 IC 3 1 Section 3 Scheduled Maintenance Inspections Service Manual First Edition Maintenance Tables Tools are New parts engine engine service required required required required suggested 1 Inspect the Operator s and Safety Manuals A 2 Inspect the Decals and Placards A 3 Inspect for Damage Loose or Missing Parts A 4 Check the Engine Oil Level A 5 Check the Engine Coolant Level
170. g Flow Charts Service Manual First Edition Chart 13 All Lift and Steer Functions inoperative Drive Functions Operational Be sure the hydraulic suction line shut off valve for the lift steer pump is in the open position Be sure all grounding wires for the function manifold valves are free of corrosion and have full continuity to ground Troubleshoot each function individually or consult Genie Industries Service Department Install a 0 to 5000 PSI pressure gauge on the function manifold Start engine move and hold the rpm switch in the high rpm position Hold the boom retract function and check the hydraulic pressure less than 3200 psi Adjust the function manifold relief valve item B all the way in clockwise counting the number of turns Hold the boom retract switch and recheck the pressure Hold the boom retract switch and readjust the relief pressure to 3200 psi less than 3200 psi Check steer functions steering inoperative steering operates Repair or replace differential sensing valve item C OR repair or replace flow regulator valve item W OR manifold has internal fault Consult Genie Industries Service Department Check the function pump See Repair section Replace the relief valve OR manifold has internal faults Consult Genie Industries Service Department Replace the pump Genie Z 34 22 Part No 43037 Service Manual
171. g hazard Keep hands AWARNING away from the block and all moving parts when lowering the secondary boom PRIMARY BOOM COMPONENTS 7 Remove the pin retainer from the primary boom lift cylinder rod end pin Then use a soft metal drift to remove the pin 8 Lower the rod end of the cylinder onto the blocks that were placed on the upper secondary boom 9 Remove the pin retainer from the upper compression arm pivot pin same side of machine as the primary boom lift cylinder barrel end pivot pin retainer 10 Place a rod through the compression arm pivot pin and twist to remove 11 Swing the compression arm up out of the way Secure it from moving 12 Tag disconnect and plug the primary boom lift cylinder hydraulic hoses AWARNING el 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 13 Support the primary boom lift cylinder with straps or ropes to restrict it from swinging freely 14 Remove the pin retainer from the pivot pin at the barrel end of the primary boom lift cylinder Do not remove the pivot pin Part No 43037 Genie Z 34 22 7 17 Section 7 Repair Procedures Service Manual First Edition PRIMARY BOOM COMPONENTS 15 Use the overhead crane to lift the primary boom 1 inch 2 5 cm This will relieve pressure on the barrel end pivot pin 16 Place a r
172. ground control and pull out the Emergency Stop button to the position 13 Rotate the platform full left and right and inspect the bleed valves for leaks Part No 43037 Genie Z 34 22 IC 7 9 Section 7 Repair Procedures Service Manual First Edition Jib Boom Components 3 1 Jib Boom How to Remove the Jib Boom Perform this procedure with the boom in the stowed position 1 Remove the platform See 2 1 How to Remove the Platform 2 Remove the platform mounting weldment and the platform rotator See 2 3 How to Remove the Platform Rotator 3 Tag disconnect and plug the jib boom lift cylinder hydraulic hoses 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 job boom manifold cover Remove the mounting fasteners from the jib boom manifold 6 Remove the cable cover from the side of the jib boom 7 Support the jib boom with an overhead crane 8 Remove the pin retainer from the jib boom pivot pin Use a soft metal drift to remove the pin then remove the jib boom from the primary boom Crushing hazard The jib boom will AWARNING 9 fall when the pin is removed if it is not properly supported 9 Remove the pin retainers from the jib boom lift cylinder rod end pivot pin Do not remove the pin 10 Remove both
173. h allow horsepower limit board System Is check if will boom s drive in drive controller or drive in the stowed stowed position over drive pump See chart Malfunctioni ng position with boom over non steer wheels 31 non steer wheels Repair or replace drive enable limit switch Do not hold the drive enable switch and check if machine will drive in the stowed position with boom over the steer wheels Repair or replace drive enable limit switch Will holding the drive enable switch allow boom to drive in stowed position over steer wheels Repair or replace drive enable toggle switch Part No 43037 Genie Z 34 22 IC 5 85 Section 5 Troubleshooting Flow Charts Service Manual First Edition Chart 39 Auxiliary Functions inoperative Be sure all other functions operate normally Be sure keyswitch is in the appropriate position and the Emergency Stop Buttons are pulled out to the on position Note Operating auxiliary power with the engine running should immediately kill the engine With engine not running lift switch cover hold pump auxiliary switch and ES listen for sound of auxiliary pump running pump doesn t run Hold the auxiliary power Switch and check the voltage at terminal TB27 Hold the auxiliary power switch and check the voltage at initiate terminal red wire on PR1 motor start solenoid Hold the auxiliary power Switch and check the vo
174. h the engine off 1 Loosen the vent plug located on the fuel filter water separator head Fuel filter water separator a head bolt b filter bowl c drain plug d ventplug e separator head TABLE B PROCEDURES 2 Place a container under the filter bowl Then 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 a thin layer of oil onto the bowl gasket and then install the new filter element Genie part no 22942 6 Tighten the drain plug and fill the bowl with clean diesel fuel 7 Install the bowl onto the filter head and then tighten the head bolt to 65 inch pounds 7 Nm 8 Tighten the vent plug 9 Clean up any diesel fuel that may have spilled during the installation procedure Bleed the fuel system Before bleeding the system fill the fuel tank 10 Loosen the vent plug located on the filter head 11 Tighten the vent plug when air stops coming through the vent 12 Loosen the air vent screw located on top of the fuel injection pump 13 Tighten the air vent screw when air stops coming through the air vent 14 Clean up any fuel that may have spilled 15 Start the engine from the ground controls and inspect the fuel filter water separator for leaks Explosion and fire hazard If a fuel leak is discovered keep any additional person
175. he drive limit switch from the base of the primary boom Do not disconnect the wiring 6 Remove the retaining bolt from the master cylinder rod end pivot pin then 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 Genie Z 34 22 IC Part No 43037 Service Manual First Edition Section 7 Repair Procedures 8 Disconnect and plug the extension cylinder hydraulic hoses Cap the fittings on the cylinder AWARNING we 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 9 Remove the retaining bolt from the extension cylinder pivot pin then use a soft metal drift to remove the pin 10 Carefully pull out and properly support the extension cylinder from the primary boom Crushing hazard The cylinder will ACAUTION fall if it is not properly supported when it is pulled out of the extension tube To make installation of the extension cylinder easier be sure that the cylinder rod is extended 3 to 4 feet 1 m PRIMARY BOOM COMPONENTS 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
176. he oil pressure to dissipate gradually Do not allow oil to squirt or spray 3 Chock the steer wheels 4 Loosen the wheel lug nuts Do not remove them 5 Center a lifting jack under the non steer axle Raise the machine and place blocks under the chassis for support 6 Remove the wheel lug nuts then the tire and wheel assembly 7 Place a second lifting jack under the torque hub for support 8 Remove the bolts that attach the torque hub to the chassis then remove the torque hub Crushing hazard The torque ACAUTION hub will fall if it is not properly supported when the mounting bolts are removed Torque specifications Lug nuts 125 ft lbs 169 5 Nm Drive torque hub mounting bolts 210 ft lbs 285 Nm Genie Z 34 22 IC Part No 43037 Service Manual First Edition Section 7 Repair Procedures M This page intentionally left blank Part No 43037 Genie Z 34 22 7 53 Section 7 Repair Procedures Service Manual First Edition 2WD Drive Manifold 17 1 2WD Drive Manifold Components The drive manifold is mounted inside the drive chassis at the non steer end Index Schematic No Description Item Function Torque 1 Shuttle valve 3 position 4 way 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 2 Relief valve 210 psi 14 5 bar
177. hematics Hydraulic Schematic 4WD Models before serial number 674 Service Manual a Hydraulic Schematic 4WD Models from serial number 674 to 1029 B Section 6 Schematics 4WD TRACTION STEERING D E F G H K B A CHARGE PRESSURE Uo r 3500 PSI at Mia 7 T AUXILIARY 3500 8 pump 05GPM x x WiC u T ot LIFT STEER Bo 1 320 PSI Ti 51 _ __ s 1 DRIVE PUMP 1 pe o Lt Ec HYDRAULIC TANK CHARGE PRESSURE Aat gt mama w 4 2 M4 o Sy q 150 175 PSI _ REAR XY o A RIGHT HO E FRONT 0 025 inch ts RIGHT BRAKE me 49 lm l B9 i L N M3 X pu 1i ES L E BRAKE 2 SPEED REAR 2 x LZ LEFT MANIFOLD 4605175 R81 1 4 6 27 Genie Z 34 22 IC Part No 43037 MANIFOLD Service Manual Section 6 Schematics a
178. hes and other jewelry SECONDARY BOOM COMPONENTS 9 Pull the cables out of the platform 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 platform rotator hydraulic hoses at the union located on the bottom side of the primary boom 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 14 Remove the drive speed limit switch mounted on the side of the pivot end of the primary boom Do not disconnect the wiring 15 Remove the limit switch cam mounting fastener from the primary boom pivot pin then remove the limit switch Do not disconnect the wiring Note the position of the cam before removing it 16 Attach a strap from an overhead crane to the pivot end of the primary boom 17 Carefully lift the secondary and primary boom assembly until the master and primary lift cylinder hydraulic hoses are accessible 18 Remove the cable covers from the top of the upper secondary boom 19 Tag disconnect and plug the primary boom lift cylinder and master cylinder hydraulic hoses AWARNING nid injury hazard Spraying ydraulic oil
179. ib Boom Components def ADBOT oaen 7 10 3 2 Jib Boom Litt Cylinder iip cte oA SE ooa NR 7 11 3 8 Jib Boom Platform Rotate Manifold Components before serial number 1030 7 12 3 4 Jib Boom Platform Rotate Manifold Components after serial number 1029 7 13 Primary Boom Components 44 Plastic Cable Track iinet titi Gu bees Adie 7 14 4 2 Bo0 c 7 14 4 3 Primary Boom Lift 7 17 4 4 Extension Cylinder oerte xa sherds 7 18 4 5 Platform Leveling Master Cylinder 7 19 Secondary Boom Components 5 1 Secondary 7 23 5 2 Secondary Boom Lift Cylinder 7 26 Part No 43037 Genie Z 34 22 IC Service Manual First Edition ET TABLE OF CONTENTS Section Seven Repair Procedures continued Kubota D 905 Engine 6 1 umingdjusttmert paiasso 7 27 SEMEL 7 27 6 3 Enone ter 7 27 6 4 7 27 6 5 Water Temperature and Pressure Gauges 7 28 Kubota WG 750 Engine Fed Choke Adj stments u u 7 29 2 Timing esca irre 7 29 7 3 Carburetor Adj stmielit 7 29 7 4
180. ic hoses from the pump 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 2 Remove the pump mounting bolts Carefully remove the pump 9 2 Lift Steer Pump How to Test the Lift Steer Pump 1 Disconnect and plug the high pressure hydraulic hose from the lift steer 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 Kubota Gasoline LPG models Remove the high tension lead from the center of the ignition coil Electrocution hazard Contact with ACAUTION electrically charged circuits may result in death or serious injury Remove all rings watches and other jewelry 4 Turn the key switch to ground control and pull the Emergency Stop button to the on position 5 Kubota Diesel models Hold the manual fuel shutoff valve clockwise to the cLosep position Both models Observe the pressure gauge while cranking the engine Immediately stop cranking if the pressure reaches or exceeds 3000 psi 206 bar Component damage hazard ACAUTION Hydraulic pressure in excess of 3000 psi 206 bar will cause severe
181. ics Se Electrical Schematic Diesel Models before serial number 869 Service Manual ES34D1E WHTIBLKAS EH J Far hd TURNTABLE ROTATE RIGHT swine wires E TURNTABLE ROTATE LEFT Vp LEFT wena gi i A 1 1 ial MR Jl 5 8 1 be L gs 5 iB 168 BLKRED 1 B if E bd I 8 HIGH RPM CUTOUT COIL RELAY l P li 1 ENGINE SPEED FUNCTION ENABLE 8 q ronnen eeen ae He BLUWHT 1 Low PLUG RELAY ENGINE GLOW PLUG 8 B RED WHTH23 E H FLASHING BEACONS ENGINE GLOW PLUG 58 29 us ENGINE WNT RED 26 E H START x WATER TEMP SENDER z B 5 g d ENGINE i WHTIBLK 25 E H START H OIL PRESSURE SENDER t m 58 5 Gs Ls PS o M i t H 5 1 2 21 STARTER MOTOR p L 1 1 FUEL SOLENOID T I zs 5 B I 1 E 1 RED AUXILIARY AUXILIARY POWER RELAY POWER
182. in org blk 41 wire circuit from alternator to TB41 to terminal 2 on ign start module Disconnect wht 24 wire from oil pressure sender and check continuity to ground on signal post of sender while cranking the engine Is continuity maintained no Repair short to ground wht 24 wire from sende to TB24 to terminal 10 on ign start module Disconnect red wire from terminal 4 ign start module and check voltage at terminal 4 Repair short in red wire circuit from TB27 12V CHART 3 Repair or replace alternator OR contact Genie Industries Service Department Check oil level OR replace oil pressure sending unit OR refer to Kubota service manual for troubleshooting low oi pressure Replace ign start OR consult Genie Industries Service Department Part No 43037 Genie Z 34 22 IC Section 5 Troubleshooting Flow Charts Service Manual First Edition Chart 4 Engine Will Not Disconnect PG supply ine from tank an Start On LPG bleed pressure from But Will Start line On Gasoline Kubota With keyswitch on Replace fuel select Gasoline LPG ground position and switch Emergency Stop switch Models pulled out check voltage at LPG side blu Be sure the fuel select red wire of fuel select switch is switched to switch LPG Be sure to check the With keyswitch on Repair open in blu red LPG fuel level ground position and wire circuit fro
183. ion Chart 10 Engine High Idle Inoperative Kubota Diesel Models Be sure mechanical linkage is not binding or defective Be sure 2 speed solenoid grounding wires are free of corrosion and have full continuity to ground Start engine switch rom select switch to high idle rabbit symbol and solenoid pulls in check if 2 solenoid pulls in solenoid does not pull in Check voltage at blk red wire on rpm select switch 12V Check voltage at TB35 a 12V Check voltage at 0V terminal 30 on CR3 12V Check voltage to oV terminal 86 on CR3 12V Check ground wire to bad terminal 85 on CR3 good Check voltage to ov terminal 87 on CR3 12V Check voltage at initiate terminal 86 on CR4 12V Continued on the next page Check high idle adjustment see Maintenance section or see Kubota workshop manual to troubleshoot fuel injection system Check voltage on red wire at center terminal of rpm select switch Repair open in circuit supplying 12V to center terminal of switch 12V Replace toggle switch Replace diode OR repair open in blk red wire circuit from toggle switch to TB35 Repair open in blk red wire circuit from TB35 to terminal 30 on CR3 Repair open in wht wire circuit from terminal 87 on CR2 to terminal 86 on CR3 Repair open in ground wire to terminal 85 on CR3 Replace CR3 relay Repair open in blk red wire circuit from
184. ion TABLE A PROCEDURES A 5 Check the Engine Coolant Level Maintaining the engine coolant at the proper level is essential to engine service life Improper coolant level will affect the engine s cooling capability and damage engine components Daily checks will allow the inspector to identify changes in coolant level that might indicate cooling system problems 1 Check the fluid level in the coolant recovery tank Add fluid as needed Result The fluid level should be in the NORMAL range A 6 Check for Fuel Leaks Failure to detect and repair fuel leaks will result in an unsafe condition An explosion or fuel fire may cause death or serious injury 7 Explosion and fire hazard Engine fuels are combustible Inspect the machine in an open well ventilated area away from heaters sparks flames and lighted tobacco Always have an approved fire extinguisher within easy reach 1 Open the shutoff valve on the liquid petroleum gas LPG tank by turning it counterclockwise 2 Perform a visual inspection around the areas listed below An LPG detector may be necessary to locate LPG leaks Kubota Gas models LPG tank hoses and fittings solenoid shutoff valve LPG regulator and carburetor gasoline tank shutoff valve solenoid shutoff valve hoses and fittings fuel pump and carburetor Kubota Diesel models fuel tank shutoff valve hoses and fittings fuel pump fuel filter water separator fuel inject
185. ion toggle switch TS10 on platform control panel in down direction and check voltage at TB15 Troubleshoot platform level function toggle switch TS24 on ground control panel OR replace diode on TS24 OR repair open in org blk 15 wire circuit from TS24 to TB15 OR consult Genie Industries Service Department Repair open in org blk 15 wire circuit from TB15 to boom function directional valve coil item N OR repair open in ground wire circuit to manifold item N Troubleshoot platform level function toggle switches TS24 and TS10 on ground and platform control panels OR replace diodes on 1524 and TS10 OR repair open in org blk 15 wire circuit from TS24 and TS10 to TB15 OR consult Genie Industries Service Department If voltage to TB15 from 7824 TS10 has been restored and platform level down function is still inoperative please continue troubleshooting from beginning of chart Genie Z 34 22 Part No 43037 Service Manual First Edition Section 5 Troubleshooting Flow Charts CHART 26 Continued from the Disconnect wire to infinite Hovis pane platform level down ohms Replace platform level page directional valve coil down directional valve item N Remove coil coil item N and test resistance 4 to 8 ohms Exchange platform level up and down directional valves item M and Mie activate platform level down function function inoperati
186. ion 5 Troubleshooting Flow Charts Service Manual First Edition TROUBLESHOOTING FLOW CHARTS About This Section When a malfunction is discovered the flow charts in this section will help a service professional pinpoint the cause of the problem To use this section basic hand tools and certain pieces of test equipment are required voltmeter ohmmeter pressure gauges The location of terminals mentioned in this section can be found on the appropriate electrical or hydraulic schematics provided in Section 6 Schematics Since various degrees of a particular function loss may occur selecting the appropriate flow chart may be troublesome When a function will not operate with the same speed or power as a machine in good working condition refer to the flow chart which most closely describes the problem General Repair Process Malfunction discovered Return to service Identify Troubleshoot symptoms problem still exists Perform repair problem solved 5 2 Genie Z 34 22 Part No 43037 Service Manual First Edition Section 5 Troubleshooting Flow Charts Engine Will Not Crank Over Kubota Gas LPG Models Be sure key switch is in the appropriate position Be sure the Emergency Stop buttons are pulled up to the on position Be sure the circuit breaker and fuses are not tripped or blown less than Check battery voltage 12V
187. ion 7 Repair Procedures M This page intentionally left blank Part No 43037 Genie Z 34 22 7 37 Section 7 Repair Procedures Service Manual First Edition Function Manifold 10 1 Function Manifold Components The function manifold is mounted to the turntable under the ground controls Index Schematic No Description Item Function Torque 1 Counterbalance valve ues Platform level up 35 40 ft lbs 47 54 Nm 2 Counterbalance valve CT Platform level down 35 40 ft Ibs 47 54 Nm 3 Relief valve 1750 psi 121 bar before serial number 674 Hs Turntable rotate 25 30 ft lbs 34 41 Nm Counterbalance valve 1500 psi 103 bar after serial number 673 Elus Turntable rotate left 35 40 ft lbs 47 54 Nm 4 Relief valve 1750 psi 121 bar before serial number 674 ateen Turntable rotate right 25 30 ft lbs 34 41 Counterbalance valve 1500 psi 103 bar after serial number 673 Lum Turntable rotate right 35 40 ft lbs 47 54 Nm 5 Relief valve 1600 psi 110 bar diio Secondary boom down 25 30 ft lbs 34 41 Nm 6 Relief valve 1400 psi 97 bar I aee Primary boom down
188. ion pump and fuel injectors 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 4 4 Genie Z 34 22 IC Part No 43037 Service Manual First Edition Section 4 Scheduled Maintenance Procedures A 7 Check the Hydraulic Oil Level Maintaining the hydraulic oil at the proper level is essential to machine operation Improper hydraulic oil levels can damage hydraulic components Daily checks allow the inspector to identify changes in oil level that might indicate the presence of hydraulic system problems 1 Be sure that the boom is in the stowed position then visually inspect the sight gauge located on the side of the hydraulic tank Result The hydraulic oil level should be within the top 2 inches 5 cm of the sight gauge Hydraulic Oil Specifications Hydraulic oil type Dexron equivalent Hydraulic tank capacity 18 gallons 68 1 liters Hydraulic system 2WD Models 21 gallons including tank 79 5 liters Hydraulic system 4WD Models 22 gallons including tank 83 3 liters TABLE A PROCEDURES A 8 Check for Hydraulic Leaks Detecting hydraulic fluid leaks is essential to operational safety and good machine performance Undiscovered leaks can develop into hazardous situations impair machine functions and damage machine components 1 Inspect for hydraulic oil puddles dr
189. ipping or residue on or around the following areas Hydraulic reservoir filter fittings hoses and turntable surface Engine compartment hydraulic power unit pumps suction filter fittings hoses and turntable surface All hydraulic cylinders All hydraulic manifolds Primary secondary and jib booms The underside of the turntable The underside of the drive chassis Ground area under the machine Part No 43037 Genie Z 34 22 Section 4 Scheduled Maintenance Procedures Service Manual First Edition TABLE A PROCEDURES A 9 Check the Tire Pressure Bodily injury hazard An over AWARNING inflated tire can explode and may cause death or serious injury This procedure does not need to be performed on machines equipped with the foam filled tire option To safeguard maximum stability achieve optimum machine handling and minimize tire wear it is essential to maintain proper pressure in all air filled tires 1 Check each tire with an air pressure gauge and add air as needed Tire Specifications 2WD Models 4WD Models Industrial tire 9 14 5 LT 100 psi 6 89 bar Rough terrain tire 10 16 5 NHS 10 16 5 NHS 45 psi 3 1 bar 45 psi 3 1 bar A 10 Test the Platform and Ground Controls Testing the machine functions and the Emergency Stop buttons for malfunctions is essential for safe machine operation An unsafe working condition exists if any function fails to operate properly
190. ir Procedures Service Manual First Edition Non steer Axle Components 16 1 Drive Motor Component damage hazard ACAUTION Repairs to the drive motor should only be performed by an authorized Sundstrand Sauer dealer How to Remove a Drive Motor A drive motor can only be removed from the inside of the chassis AWARNING Component damage hazard The work area and surfaces where this procedure will be performed must be clean and free of debris that could get into the hydraulic system and cause severe component damage Dealer service is recommended 1 Tag disconnect and cap the hydraulic hoses from the drive motor and plug them 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 drive motor mounting bolts 3 Guide the drive motor shaft out of the brake and then remove the drive motor 16 2 Torque Hub How to Remove a Drive Torque Hub The drive motor must be removed in order to access the torque hub mounting bolts 1 Remove the drive motor See 16 1 How to Remove a Drive Motor 2 Disconnect the hydraulic hose from the brake and plug it Then remove the hydraulic fitting and the bleed valve AWARNING Bodily injury hazard Spraying hydraulic oil can penetrate and burn skin Loosen hydraulic connections very slowly to allow t
191. ised spline away from the flywheel pump a b pump shaft pump coupler d flex plate e flywheel 2 Install the coupler onto the pump shaft with the set screw towards the pump Leave a 1 32 inch 0 8 mm gap between the coupler and pump end plate 3 Apply Loctite removable thread sealant to the coupler set screw Torque the set screw to 36 ft lbs 49 Nm Component damage hazard Do ACAUTION not force the drive pump during installation or the flex plate teeth may become damaged Part No 43037 Genie Z 34 22 IC Section 7 Repair Procedures Service Manual First Edition KUBOTA D 905 ENGINE 6 5 Water Temperature and Oil Pressure Gauges The water temperature gauge is an electrical gauge The sending unit has limit contacts that are factory set The contacts will close at 230 F 109 C When the contacts close the engine will shut off to prevent damage and will not start until the temperature drops below the contact point Temperature will be indicated when the key is on and the Emergency Stop Button is pulled out to the ON position Component damage hazard ACAUTION Do not crank the engine with the over temperature light on The oil pressure gauge is an electrical gauge The sending unit has limit contacts that are factory set The contacts will close at 8 psi 0 55 bar When the contacts close the engine will shut off to prevent damage Oil pressure will be indicated when the engi
192. ive speed maximum raised 40 feet 40 seconds 12 2 m 40 seconds TABLE A PROCEDURES Drive Enable Limit Switch 1 With the engine off and the boom in the stowed position visually inspect the drive enable limit switch for the following Broken or missing rollers or arms Missing fasteners Loose wiring 2 Manually activate the drive enable limit switch turntable rotation bearing b drive enable limit switch C drive chassis Result The drive enable limit switch roller should move freely and spring return to center A distinct click should be felt and heard 3 Start the engine from the platform controls 4 Rotate the turntable to the left until the primary boom is past the left non steer wheel Result The drive enable indicator light should be Drive function should not operate until the drive enable switch is activated 5 Rotate the turntable to the right until the primary boom is past the right non steer wheel Result The drive enable indicator light should be Drive function should not operate until the drive enable switch is activated Part No 43037 Genie Z 34 22 IC 4 9 Section 4 Scheduled Maintenance Procedures Service Manual First Edition TABLE A PROCEDURES A 14 Perform 30 Day Service The 30 day maintenance procedure is a onetime sequence of procedures to be performed after the first 30 da
193. jury hazard Beware of ACAUTION hot engine parts and coolant Contact with hot engine parts and or coolant will cause severe burns Perform this procedure with the engine off and cooled 1 Put on protective clothing and eye wear 2 Disconnect the coolant return hose at the radiator and drain the coolant return tank 3 Remove the radiator cap from the radiator 4 Open the petcock on the radiator and allow all the coolant to drain into a suitable container 5 After all the coolant has drained close the petcock Connect the coolant return hose to the radiator 6 Open the petcock on the engine block and allow the coolant to drain into a suitable container After the fluid is drained close the petcock 7 Replace all coolant hoses and clamps 8 Pour the proper coolant mixture anti freeze and water for your climate into the radiator until it is full 9 Clean up any coolant spilled during this procedure 10 Start the engine from the ground controls run it for 30 seconds and then turn it off TABLE D PROCEDURES 11 Inspect for leaks and then check the fluid level in the coolant recovery tank Add water if needed Coolant capacity Kubota WG 750 3 1 quarts 2 9 liters Kubota D 905 3 3 quarts 3 1 liters 12 Start the engine from the ground controls and run it until reaching normal operating temperature 13 Allow engine to cool and check the fluid level in the coolant recovery tank Add water if needed
194. k if 2 speed binds solenoid moves in and out freely Check linkage or replace solenoid moves freely Check adjustment of linkage and fuel injection system low idle See Maintenance section See Kubota workshop manual to troubleshoot fuel injection system OR consult Genie Industries Service Department Genie Z 34 22 Part No 43037 Service Manual First Edition Section 5 Troubleshooting Flow Charts Chart 12 All Functions inoperative Engine Starts and Runs Check hydraulic Fill with Dexron fluid level hydraulic uid Check pump suction line Open valves If engine shutoff valves Valve closed has been run with handles should be valves closed it may parallel with hose have damaged one or both pumps Disconnect center coil Troubleshoot wire from distributor cap inoperative boom and isolate from functions and grounding Kubota inoperative drive Diesel models functions separately disconnect the blk R1 wire from the red wire of the fuel solenoid and disconnect the wht 21 wire from the wht wire of the fuel solenoid Remove function pump from main pump but leave all hoses connected Hold start switch and crank engine over while observing female spline drive at rear of drive pump spline does not turn Engine to pump flex plate coupling Is defective See Repair section Part No 43037 Genie Z 34 22 5 29 Section 5 Troubleshootin
195. l Kubota number 97897 00643 Genie part number 52492 C 13 Check the Engine Valve Clearance Kubota Gasoline LPG Models Complete information to perform this procedure is available in the Kubota WG 750 Workshop Manual Kubota number 97897 00643 Genie part number 52492 C 14 Bleed the Platform Rotator See Repair procedure 2 3 How to Bleed the Platform Rotator Part No 43037 Genie Z 34 22 4 39 Section 4 Scheduled Maintenance Procedures Service Manual First Edition Table D Procedures D 1 Test or Replace the Hydraulic Oil Replacement or testing of the hydraulic oil is essential 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 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 Perform this procedure with the boom in the stowed position 1 Remove the plug from the drain hose on the hydraulic tank 2 Completely drain the tank into a suitable container See capacity specifications listed below 3 Remo
196. l valve item D OR consult Genie Industries Service Department Repair open in grn blk 18 wire circuit from TB18 to boom function directional valve coil item D OR repair open in ground wire circuit to manifold item D Troubleshoot platform rotate function toggle switches TS25 and 7811 on ground and platform control panels OR replace diodes on 7825 and 1511 OR repair open in yellow wire circuit from TS25 and TS11 to boom function directional valve item D OR consult Genie Industries Service Department If voltage to boom function directional valve coil item D from TS25 and TS11 has been restored and platform rotate right function is still inoperative please continue troubleshooting from beginning of chart Genie Z 34 22 Part No 43037 Service Manual First Edition Section 5 Troubleshooting Flow Charts CHART 28 Disconnect wire to 0 or Continued from the platform rotate right infinite previous page directional valve coil ohms Replace platform rotate right directional valve item D Remove coil il item D and test resistance coil ttem D 4108 ohms Exchange platform rotate left and right function directional valves item operates Replace defective D and activate directional valve platform rotate right function function inoperative Install a 0 to 5000 PSI Check for mechanical pressure gauge at the restrictions keeping
197. lace the entire assembly onto a structure capable of supporting it 28 Remove the pin retainers from the upper compression arm pivot pins Do not remove the pins 29 Position the lifting strap from an overhead crane at the center of the control box side upper compression arm then remove it from the machine Repeat this step for the engine side upper compression arm AWARNING Crushing hazard If the overhead crane is not properly attached the upper compression arm may become unbalanced and fall when it is removed from the machine 30 Remove the pin retainer from the rod end of the secondary boom lift cylinder Use a soft metal drift to remove the pin Secure the cylinder from moving 31 Remove the pin retainer from the lower pivot pin on the compression link Use a soft metal drift to remove the pin 32 Attach the strap from an overhead crane to the upper secondary boom 33 Remove the pin retainer from the upper secondary boom to lower mid pivot pivot pin Use a soft metal drift to remove the pin 34 Remove the upper secondary boom with compression link from the machine AWARNING Crushing hazard If the overhead crane is not properly attached the upper secondary boom with compression link may become unbalanced and fall when it is removed from the machine 35 Remove the drive speed limit switch mounted on the inside of the lower mid pivot Do not disconnect the wiring 36 Remove the cable covers from the top of the
198. latform Rotator 1 Connect a clear hose to the top bleed valve Place the other end of the hose in a container to collect any discharge a clear hose b top bleed valve bottom bleed valve d container 2 Open the top bleed valve but do not remove it 3 Turn the key switch to ground control and pull out the Emergency Stop button to the position 4 Hold the platform rotate switch to the right for approximately 5 seconds then release it Repeat three times Crushing hazard Keep hands ACAUTION clear of the platform pivot weldment during rotation 5 Hold the platform rotate switch to the left for approximately 5 seconds then release it 6 Fully rotate the platform to the left and continue holding the platform rotate switch until air stops coming out of the bleed valve Immediately release the platform rotate switch and close the bleed valve PLATFORM COMPONENTS 7 Rotate the platform to the right until it is centered 8 Connectthe clear hose to the bottom bleed valve and open the valve 9 Rotate the platform to the right and continue holding the platform rotate switch until air stops coming out of the bleed valve Crushing hazard Keep hands ACAUTION clear of the platform pivot weldment during rotation 10 Close the bleed valve and remove the hose 11 Turn the key switch to the orr position and clean up any hydraulic oil that may have spilled 12 Turn the key switch to
199. le Is continuity maintained Check voltage at terminal 4 on ign start module Replace start lockout module OR consult Genie Industries Service Department Crank engine and check gy Crank engine and check voltage at org blk 41 wire on alternator 6 to 7V Repair open in org blk 41 wire circuit from alternator to TB41 to terminal 2 on ign start module Disconnect wht 24 wire from oil pressure sender and check continuity to ground on signal post of sender while cranking the engine Is continuity maintained Repair short to ground in wht 24 wire from sender to TB24 to ign start module terminal 10 Repair short to power in red wire circuit trom TB27 Check alternator wiring OR repair or replace alternator OR contact Genie Industries Service Department Check oil level OR replace oil pressure sending unit OR refer to Kubota service manual for troubleshooting low oil pressure Genie Z 34 22 Part No 43037 Service Manual First Edition Section 5 Troubleshooting Flow Charts Engine Cranks Over But Will Hold start switch and check battery voltage while engine is cranking Not Start Kubota Diesel more than 11V Models Check if engine coolant Be sure to check the over temperature sending signal post has fuel level continuity to ground Be sure to check engine oil level and engine coolant level fill as needed Be sure the diesel sh
200. led out to the on position and boom function speed controller turned to 9 activate footswitch and secondary boom function toggle switch TS7 on platform control panel in down direction and check voltage TB11 Troubleshoot secondary boom function toggle switch TS21 on ground control panel OR replace diode TS21 OR repair open in blu blk 11 wire circuit from TS21 to TB11 OR consult Genie Industries Service Department CHART 19 Repair open in blu blk 11 wire circuit from TB11 to boom function directional valve coil item R OR repair open in ground wire circuit to manifold item Troubleshoot secondary boom function toggle switches TS21 and TS7 on ground and platform control panels OR replace diodes on TS21 and TS7 OR repair open in blu blk 11 wire circuit from TS21 and TS7 to TB11 OR consult Genie Industries Service Department If voltage to TB11 from TS21 and TS7 has been restored and secondary boom down function is still inoperative please continue troubleshooting from beginning of chart Part No 43037 Genie Z 34 22 IC Section 5 Troubleshooting Flow Charts Service Manual First Edition ee CHART 19 Disconnect wire to Oor secondary boom down infinite directional valve coil ohms item R Remove coil and test resistance Continued from the previous page Replace secondary boom down directional valve coil item R 4 to 8 ohms
201. line LPG Models uu uyu tae diae 4 35 C 9 Replace the Spark Plugs Kubota Gasoline LPG Models 4 36 C 10 Check and Adjust the Air LPG Mixture Kubota Gasoline LPG Models 4 37 C 11 Replace the Engine Air Filter 4 4 38 C 12 Check and Adjust the Ignition Timing Kubota Gasoline LPG Models 4 39 C 13 Check and Adjust the Engine Valve Clearance Kubota Gasoline LPG Models 4 39 C 14 Bleed the Platform Rotator 4 39 D 1 Testor Replace the Hydraulic Oil 4 40 D 2 Change or Recondition the Engine Coolant 4 41 D 3 Change the Fuel Lines eritis 4 42 43037 Genie Z 34 22 IC vii Service Manual First Edition EE TABLE OF CONTENTS Section Five Troubleshooting Flow Charts o 5 1 1 Engine Will Not Crank Over Kubota Gasoline LPG Models 5 3 2 Engine Cranks Over But Will Not Start Kubota Gasoline LPG Models 5 5 2A Engine Cranks Over But Will Not Start OR Engine Runs While Cranking Then Dies Kubota Gasoline LPG 5 7 2B Engine Runs While Cranking Then Dies Kubota Gasoline LPG Models 5 10 Engine Cranks Over But Will Not Start Ku
202. ll close at 8 psi 0 55 bar When the contacts close the engine will shut off to prevent damage Oil pressure will be indicated when the engine is running Component damage hazard ACAUTION Do not crank the engine with the low oil pressure light on 7 30 Genie Z 34 22 IC Part No 43037 Service Manual First Edition Section 7 Repair Procedures oo KUBOTA WG 750 ENGINE 7 7 Vacuum Switch How to Test the Vacuum Switch ohmmeter common terminal SOL vacuum switch normally open terminal ING 1 Connect the leads from ohmmeter continuity tester to the common and normally open terminals Result There should be no continuity infinite Q 2 Apply mild suction to the vacuum port Result The switch should close and show full continuity zero Q Component damage hazard Do ACAUTION not short vacuum switch terminals to ground Part No 43037 Genie Z 34 22 7 31 Section 7 Repair Procedures Service Manual First Edition Ground Controls 8 1 Control Relays Relays used for dual function switching are double pole double throw DPDT relays How to Test a Single Pole Double Throw Relay AWARNING Electrocution hazard Contact with electrically charged circuits may cause death or serious injury Remove all rings watches and other jewelry This procedure covers fundamental relay testing and does not specifically apply to all varieties of
203. ll of the safety and instructional decals and placards 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 Refer to the Decals section in the appropriate Genie Z 34 22 IC Operator s Manual and use the decal list and illustrations to determine that all decals and placards are in place 2 Inspect all decals for legibility and damage Replace any damaged or illegible decal immediately Contact your authorized Genie distributor or Genie Industries if replacement decals are needed 4 2 Genie Z 34 22 IC Part No 43037 Service Manual First Edition Section 4 Scheduled Maintenance Procedures A 3 Inspect for Damage Loose or Missing Parts Daily machine condition inspections are essential to safe machine operation and good machine performance Failure to locate and repair damage and discover loose or missing parts may result in an unsafe operating condition 1 Inspect the entire machine for damage and improperly installed or missing parts including Electrical components wiring and electrical cables Auxiliary power unit hoses fittings cylinders and manifolds Fuel and hydraulic tanks Drive motors Turnta
204. ll other functions operate normally If turntable rotate right function operates normally from the ground controls but not from the platform controls troubleshoot the platform controller or diode See Repair Section If turntable rotate right function operates normally from the platform controls but not from the ground controls troubleshoot the ground control toggle switch OR diode OR resistor See Repair Section With key switch in ground position and both Emergency Stop switches pulled out to the on position activate the function enable toggle switch TS19 if equipped and the turntable rotate toggle switch TS20 on ground panel in right direction and check voltage on wht red 6 wire on boom function proportional valve coil item D Continued on the next page 12V or more With key switch in ground position and both Emergency Stop switches pulled out to the on position activate the function enable toggle switch TS19 if equipped and the turntable rotate toggle switch TS20 on ground panel in right direction and check voltage at TB6 With key switch in platform position both Emergency Stop switches pulled out to the on position and boom function speed controller turned to 9 activate footswitch and turntable rotate toggle switch TS6 on platform control panel in right direction and check voltage at TB6 Troubleshoot turntable rotate function toggle switch TS20
205. ls and hol the platform choke switc and check choke Note Do not press down the footswitch Adjust choke if needed See Repair Section Continued from the previous page choke does not work Check voltage on center terminal on platform choke switch Repair open in power supply wire circuit Hold platform choke switch and check voltage on output at the diode Replace toggle switch OR replace diode Consult Genie Industries Service Department 5 18 Genie Z 34 22 Part No 43037 Service Manual First Edition Section 5 Troubleshooting Flow Charts Engine Glow Plugs inoperative Kubota Diesel Models Be sure the battery is fully charged Hold glow plug switch 12V and check voltage at blk wht R8 wire on glow plugs Hold glow plug switch and check voltage at terminal 87 on CR8 with blk wht wire attached Check voltage at OV terminal 30 on 12V Hold glow plug switch 12V and check voltage at terminal 86 on CR8 oV Turn keyswitch to ground control position and check voltage on center terminal of glow plug switch 12V Hold ground control glow plug switch and check voltage at blk wht 41 wire on toggle switch 12V Hold ground control glow plug switch and check voltage at TB34 Continued on the next page Refer to Kubota Service Manual on trouble shooting glow plugs Repair op
206. ltage across terminals TB30 and TB31 Press down foot switch hold drive controller in full forward position and check voltage across the two wires at EDC quick disconnect Replace drive pump EDC OR consult Genie Industries Service Department Service Manual First Edition Repair or replace drive controller Repair open in either wht or wht blk wire circuit from drive controller to TB30 and TB31 respectively Repair open in wht blk wire circuit from TB31 to EDC quick disconnect OR repair open in wht wire circuit from TB30 to EDC quick disconnect Genie Z 34 22 Part No 43037 Service Manual First Edition Section 5 Troubleshooting Flow Charts Drive Forward or Reverse Function inoperative Be sure all other functions operate normally including drive in opposite direction of malfunction Be sure engine is in high rpm rabbit symbol Chart 34 Disconnect the EDC wire connector from the drive pump start engine move the drive controller to full forward position and note the voltage across terminals TB30 and TB31 Reverse the volt meter leads and move the drive controller to full reverse position and note the voltage voltage readings different Repair or replace the drive controller voltage readings the same Defective Sundstrand drive pump contact Sundstrand authorized repair facility Adjust the drive pump null neutral See Sundstrand Series
207. ltage at positive power cable on auxiliary power unit 12V Check auxiliary power unit grounding cable OR repair or replace electric motor Install a 0 to 5000 pressure gauge into the pressure port located on the function manifold and bump the auxiliary power switch 2000 psi Check battery condition There is possibly not enough battery capacity to operate both auxiliary pump and function valves Replace defective auxiliary power toggle switch Repair open in red wire circuit from TB27 to PRI Replace PR1 relay less than 2000 psi Replace pump Genie Z 34 22 Part No 43037 Service Manual First Edition Section 6 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 Genie Z 34 22 IC Operator s Manual Be sure that all necessary tools and test equipment are available and ready for use Schematics About This Section There are two groups of schematics in this section An illustration legend precedes each group of drawings Electrical Schematics AWARNING Electrocution hazard
208. ly pipe thread sealant to the plugs then install the plugs 6 Repeatthis procedure for each torque hub 17 fluid ounces 0 5 liters Cil capacity per hub TABLE C PROCEDURES C 6 Replace the Hydraulic Filters 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 The return hydraulic filter is mounted on the hydraulic tank 1 Clean the area around the oil filter then remove the filter with an oil filter wrench 2 Apply a thin layer of oil to the new oil filter gasket 3 Install the new filter and tighten it securely by hand Clean up any oil that may have spilled during the replacement procedure Return oil filter Genie part number 44207 Type SAE 90 multipurpose hypoid gear oil API service classification GL5 Part No 43037 Genie Z 34 22 IC Section 4 Scheduled Maintenance Procedures Service Manual First Edition TABLE C PROCEDURES Hydraulic Suction Filter Burn hazard Beware of hot oil ACAUTION Contact with hot oil may cause severe burns The suction hydraulic filter is mounted in the engine compartment 1 Close the shut off valv
209. ly to allow the oil pressure to dissipate gradually Do not allow oil to squirt or spray 3 Remove the pin retainers 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 Then lower the leveling link to the ground Tap the pin the other direction and lower the opposite leveling link Do not remove the pin Part No 43037 Genie Z 34 22 IC 7 11 Section 7 Repair Procedures Service Manual First Edition m JIB BOOM COMPONENTS 3 3 Jib Boom Platform Rotate Manifold Components before serial number 1030 The jib boom platform rotate manifold is mounted to the jib boom Index Schematic No Description Item Function Torque 1 2 position way spool valve A 8 10 ft lbs 11 14 Nm 2 2 position 3 way spool valve ID uas Platform rotate right 8 10 ft lbs 11 14 Nm 3 Orifice 0 030 in 0 76 mm E ui Platform rotate circuit 4 2 position way spool valve uus Platform rotate left 8 10 ft Ibs 11 14 Nm 5 2 position way spool valve Boss JID GOWN 8 10 ft lbs 11 14 Nm 0 How to Check the Resistance of a Valve Coil 1 Turn the key switch to the position and disconnect the wires from the valve coil to Plug Torque Specifications be
210. m fuel Emergency Stop switch select switch to TB39 Perform these tests with pulled out check the keyswitch in the voltage at TB39 ground position 12V If engine starts on gasoline from the With keyswitch on Repair open in blu red ground controls but not ground position and wire circuit from TB39 to Emergency Stop switch terminal 30 on CRT from the platform pulled out check controls troubleshoot voltage at terminal 30 the platform fuel select on CR7 Switch or the control cables Crank engine for 15 seconds and check Repair open in red blk wire circuit from vacuum voltage at terminal 486 switch to CR7 on CR7 12V Check ground wire to bad Repair open in ground terminal 85 on CR7 to terminal 85 on CR7 good Continued on the next page 5 14 Genie Z 34 22 Part No 43037 Service Manual First Edition Section 5 Troubleshooting Flow Charts previous page Continued from the Hold start switch and Replace CR7 relay check voltage at terminal 87 on Hold start switch and Repair open in blu red check voltage at blu red ov wire circuit from CR7 wire on LPG solenoid terminal 87 to LPG solenoid 12V Oor infinite ohms Check resistance of LPG solenoid Replace LPG solenoid 9 to 10 ohms Reconnect LPG tank and starter then see Maintenance section for LPG adjustments OR consult Genie Industries Service Department
211. mber 674 M L K J l H G F E D C B A PLATFORM LEVEL SLAVE CYLINDER 1 PRIMARY BOOM EXTENSION JIB BOOM 0 032 inch 0 025 inch 2 ow Ao Pw TURNTABLE ROTATE PLATFORM ROTATE 3000 PSI 5 4 ji 5 9 CU IN at Esel I a 3 MASTER x E MAH o M HD 1 HM SD H Hp S1 L op S al Sex l Lt N LL 52 3000 PSI 3000 PSI 2500 PSI 2500 PSI 2500 PSI B 1 54 3 1 3 1 3 1 3 1 4 CREE POEM LS PEE S a PR RED C Ds _ 1 fT DX he 5 P1 1 4 3200 PSI I G Em H 6 le o MI OF Or at 1750 PSI 1600 PSI 1400 PSI 1800 PSI 3000 PSI pos 1 J J2 PR1 PR2 1750 PSI
212. mergency Stop switches pulled out to the on position activate the function enable toggle switch TS19 if equipped and the ext ret boom toggle switch TS23 on ground panel in extend direction and check voltage on wht red 6 wire on boom function proportional valve coil item D Continued on the next page 12V or more With key switch in ground position and both Emergency Stop switches pulled out to the on position activate the function enable toggle switch TS19 if equipped and the ext ret boom toggle switch TS23 on ground panel in extend direction and check voltage at TB6 With key switch in platform position both Emergency Stop switches pulled out to the on position and boom function speed controller turned to 9 activate footswitch and boom toggle switch TS9 on platform control panel in extend direction and check voltage at TB6 Troubleshoot ext ret boom function toggle switch TS23 on ground control panel OR repair open in wht red 6 wire circuit from TS23 to TB6 OR consult Genie Industries Service Department Chart 20 Repair open in wht red 6 wire circuit from TB6 to boom function proportional valve coil item D OR open in ground wire circuit to valve coil item D Troubleshoot ext ret boom function toggle switches TS23 and TS9 on ground and platform control panels OR repair open in wht red 6 wire circuit from 1523 to TB6 and from TS9 to red
213. n platform control panel in up direction and check voltage TB1 Troubleshoot primary boom function toggle switch TS22 on ground control panel OR replace diode 522 OR repair open in red 1 wire circuit from TS22 to TB1 OR consult Genie Industries Service Department Repair open in red 1 wire circuit from TB1 to boom function directional valve coil item S OR repair open in ground circuit to manifold Troubleshoot primary boom function toggle switches TS22 and TS8 on ground platform control panels OR replace diodes on 7822 and TS8 OR repair open in red 1 wire circuit from TS22 and TS8 to TB1 OR consult Genie Industries Service Department If voltage to TB1 from 7922 and TS8 has been restored and primary boom up function is still inoperative please continue troubleshooting from beginning of chart 5 34 Genie Z 34 22 Part No 43037 Service Manual First Edition Section 5 Troubleshooting Flow Charts g rm Sr CHART 16 Disconnect wire to primary boom up infinite directional valve coil ohms Replace primary boom iter 5 Remove coil up directional valve coil and test resistance item 5 Continued from the previous page 4 to 8 ohms Exchange primary boom up and down directional function valves item S 4 T and activate primary boom up function Replace defective directional valve function inoperative Install
214. nction toggle switches TS23 and TS9 on ground and platform control panels OR replace diodes on TS23 and TS9 OR repair open in blk wht 8 wire circuit from TS23 and TS9 to 8 OR consult Genie Industries Service Department If voltage to TB8 from TS23 and TS9 has been restored and boom retract function is still inoperative please continue troubleshooting from beginning of chart Part No 43037 Genie Z 34 22 IC Section 5 Troubleshooting Flow Charts Service Manual First Edition CHART 21 Oor infinite ohms Disconnect wire to boom retract directional valve Replace retract boom up coil item V Remove directional valve coil coil and test resistance item V Continued from the previous page 4 to 8 ohms Exchange primary boom function extend and retract operates directional valves item U V and activate primary boom retract function Replace defective directional valve function inoperative Install a 0 to 5000 PSI Check for mechanical pressure gauge at the restrictions keeping quick disconnect extension boom from coupling on the boom moving OR repair function manifold and cylinder or cylinder activate the retract counterbalance valve boom function OR consult Genie Industries Service less than 3200 PSI Department Repair cylinder or cylinder counterbalance valve OR boom function manifold could have an internal fault Consult Ge
215. nd and platform control panels OR repair open in wht red 6 wire circuit from TS24 to TB6 and from TS10 to red wire on boom function speed controller OR consult Genie Industries Service Department If voltage to TB6 from 1524 TS10 has been restored and platform level down function is still inoperative please continue troubleshooting from beginning of chart Part No 43037 Genie Z 34 22 IC Section 5 Troubleshooting Flow Charts s r 26 Continued from the previous page With key switch in ground position and both Emergency Stop switches pulled out to the on position activate the function enable toggle switch TS19 if equipped and theplatform level toggle switch TS24 on ground panel in down direction and check voltage on org blk 15 wire on boom function directional valve coil item N 12V or more Continued on the next page Service Manual First Edition With key switch in ground position and both Emergency Stop switches pulled out to the on position activate the function enable toggle switch TS19 if equipped and theplatform level toggle switch TS24 on ground panel in down direction and check voltage at 15 With key switch in platform position both Emergency Stop switches pulled out to the on position and boom function speed controller turned to 9 activate footswitch and platform level funct
216. nd control toggle switch OR diode OR resistor See Repair Section With key switch in ground position and both Emergency Stop switches pulled out to the on position activate the function enable toggle switch TS19 if equipped and theplatform level toggle switch TS24 on ground panel in down direction and check voltage on wht red 6 wire on boom function proportional valve coil item D Continued on the next page 12V or more With key switch in ground position and both Emergency Stop switches pulled out to the on position activate the function enable toggle switch TS19 if equipped and theplatform level toggle switch TS24 on ground panel in down direction and check voltage at TB6 With key switch in platform position both Emergency Stop switches pulled out to the on position and boom function speed controller turned to 9 activate footswitch and platform level toggle switch TS10 on platform control panel in down direction and check voltage at TB6 Troubleshoot platform level function toggle switch TS24 on ground control panel OR repair open wht red 6 wire circuit from TS24 to TB6 OR consult Genie Industries Service Department Chart 26 Repair open in wht red 6 wire circuit from TB6 to boom function proportional valve coil item D OR open in ground wire circuit to valve coil item D Troubleshoot platform level function toggle switches TS24 and TS10 on grou
217. ne is running Component damage hazard ACAUTION Do not crank the engine with the low oil pressure light on 7 28 Genie Z 34 22 IC Part No 43037 Service Manual First Edition Section 7 Repair Procedures Kubota WG 750 Engine 7 1 Choke Adjustments The manual choke is solenoid operated and is only operational in the gasoline mode This choke will not operate in propane mode Choke adjustments are affected by climate Richer adjustment will be necessary in colder climates leaner adjustment in warmer climates 7 2 Timing Adjustment Complete information to perform this procedure is available in the Kubota WG 750 Workshop Manual Kubota number 97897 00643 Genie part number 52492 7 3 Carburetor Adjustment Complete information to perform this procedure is available in the Kubota WG 750 Workshop Manual Kubota number 97897 00643 Genie part number 52492 7 4 RPM Adjustment See the scheduled maintenance procedure B 10 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 Flex Plate Removal 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 3 Remove the flex plate mounting fasteners
218. nel from entering the area and do not operate the machine Repair the leak immediately Part No 43037 Genie Z 34 22 IC Section 4 Scheduled Maintenance Procedures Service Manual First Edition Table C Procedures C 1 Check the Primary Boom Wear Pads 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 Emergency Stop button to the on position 2 Extend the primary boom 10 inches 25 cm 3 Measure each wear pad Replace the wear pad if it is less than 0 41 inches 1 cm thick If the wear pad is more than 0 41 inches 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 Always maintain squareness between the primary boom outer and inner tubes C 2 Check the Turntable Rotation Bearing Bolts Maintaining proper torque on the turntable bearing bolts is essential to safe machine operation Improper bolt torque could result in an unsafe operating condition and component damage 1 Raise the secondary boom and place
219. nents 14 1 Yoke and Hub 14 2 Steering Cylinder 14 3 Tie ROU Brake 2 Speed Manifold 15 1 Brake and 2 Speed Manifold Components Non steering Axle Components 16 1 DriVe MOTOR iui rnc iei 16 2 Torque Hubs nasaq apanka 2WD Drive Manifold 17 1 2WD Drive Manifold Components 17 2 Valve Adjustment 4WD Drive Manifold 18 1 4WD Drive Manifold Components 18 2 Valve Adjustments TABLE OF CONTENTS Part No 43037 Genie Z 34 22 IC Xiii Service Manual First Edition This page intentionally left blank Genie Z 34 22 Part No 43037 Service Manual First Edition Section 2 Specifications Specifications Machine Specifications Tires and wheels Rough terrain Industrial Stowed dimensions Tire size 10 16 5 NHS 9 14 5 LT Tire ply rating Tread 6 Length 18 ft 6 in 5 6m Sidewall 6 Width 5 ft 8 in 1 7m Tire contact area 77 8 sq in 43 5 sq in Height maximum 6 ft 7 in 2m 502 cm 280 sq Machine Weight See Serial Plate Overall tire diameter 30 5 in 28 in Machine weights vary with option configurations 77 5 37 cm Ground clearance Wheel diameter 16 5 in 14 5 in 2WD models 5 75 in 14 6 cm 42 cm
220. nie Industries Service Department 5 50 Genie Z 34 22 IC Part No 43037 Service Manual First Edition Section 5 Troubleshooting Flow Charts Turntable Rotate Left Function inoperative Be sure all other functions operate normally If turntable rotate left function operates normally from the ground controls but not from the platform controls troubleshoot the platform controller or diode See Repair Section If turntable rotate left function operates normally from the platform controls but not from the ground controls troubleshoot the ground control toggle switch OR diode OR resistor See Repair Section With key switch in ground position and both Emergency Stop switches pulled out to the on position activate the function enable toggle switch TS19 if equipped and the turntable rotate toggle switch TS20 on ground panel in left direction and check voltage on wht red 6 wire on boom function proportional valve coil item D Continued on the next page 12V or more With key switch in ground position and both Emergency Stop switches pulled out to the on position activate the function enable toggle switch TS19 if equipped and the turntable rotate toggle switch TS20 on ground panel in left direction and check voltage at TB6 With key switch in platform position both Emergency Stop switches pulled out to the on position and boom function speed controll
221. nspector 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 Inspection A Quarterly Inspection A B Annual Inspection A B C 2 Year Inspection A B C D Place a check in the appropriate box after each inspection procedure is completed Use the maintenance tables in this section and the step by step procedures in section 4 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 box Legend Y yes acceptable N no remove from service R repaired Comments Checklist A YN R B 12 Emergency Stop Refer to Table A A 1 Operator s and Safety manuals B 13 Ground control override B 14 Platform leveling A 2 Decals and placards B 15 Service horn A 3 Damage loose or missing parts A 4 Check engine oil level A 5 Check engine coolant A 6 Check for fuel leaks A 7 Hydraulic oil level A 8 Hydraulic leaks A 9 Check the tire pressure A 10 Platform and ground controls A 11 Auxiliary power A 12 Tilt sensor A 13 Limit switches A 14 30 Day Service Perform every 50 hours A 15 Clean the air filter Perform every 100 hours A 16 Drain the fuel filter water separator Diesel models
222. nued from the previous page Continued on the next page 12V or more With key switch in ground position and both Emergency Stop switches pulled out to the on position activate the function enable toggle switch TS19 if equipped and the turntable rotate toggle switch TS20 on ground panel in left direction and check voltage at TB4 With key switch in platform position both Emergency Stop switches pulled out to the on position and boom function speed controller turned to 9 activate footswitch and turntable rotate function toggle switch TS6 on pan control panel in eft direction and check voltage at TB4 Troubleshoot turntable rotate function toggle switch TS20 on ground control panel OR replace diode on TS20 OR repair open in wht 4 wire circuit from TS20 to TB4 OR consult Genie Industries Service Department Repair open in wht 4 wire circuit from TB10 to boom function directional valve coil item P OR repair open in ground wire circuit to manifold item Troubleshoot turntable rotate function toggle switches TS20 and TS6 on ground and platform control panels OR replace diodes on TS20 and TS6 OR repair open in wht 4 wire circuit from TS20 and TS6 to TB4 OR consult Genie Industries Service Department If voltage to TB4 from 7520 and TS6 has been restored and turntable rotate left function is still inoperative please continue troubleshooting from beginning of chart 5
223. o Bleed the Slave Cylinder 1 Raise the jib boom to a horizontal position 2 Move the platform level switch up and down through two platform leveling cycles to remove any air that might be in the system 2 3 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 1 Remove the platform See 2 1 How to Remove the Platform 2 Tag disconnect and plug the hydraulic hoses from the platform rotator 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 3 Support the platform mounting weldment but do not apply any lifting pressure 4 Remove the six mounting bolts from the platform mounting weldment then remove the center bolt and slide the platform mounting weldment off of the platform rotator 5 Support the platform rotator Do not apply any lifting pressure 6 Remove the pin retainers from the jib boom and leveling links to platform rotator pivot pins Do not remove the pins 7 Support the jib boom and leveling links 8 Use a soft metal drift to drive both pins out then remove the platform rotator from the machine 7 8 Genie Z 34 22 IC Part No 43037 Service Manual First Edition Section 7 Repair Procedures How to Bleed the P
224. o continuity terminal to 4 5 amp 6 no continuity terminal 4 to 5 amp 6 no continuity terminal 5 to 6 Center position continuity There are no terminal combinations that will produce continuity infinite Right position terminal 1 to 2 continuity zero Q terminal 1 to 3 4 5 amp 6 no continuity infinite terminal 2 to 3 4 5 amp 6 no continuity terminal 3 to 4 5 amp 6 no continuity terminal 4 to 5 continuity terminal 4 to 6 no continuity terminal 5 to 6 no continuity 7 6 Genie Z 34 22 IC Part No 43037 Service Manual First Edition Section 7 Repair Procedures Platform Components 2 1 Platform How to Remove the Platform 1 Separate the foot switch wiring quick disconnect plug from the platform toeboard 2 Remove the platform control box mounting fasteners then lower the control box If your machine is equipped with an air line to platform option the air line must be disconnected from the platform before removal 3 Place blocks under the platform railing for support Then carefully lower the platform onto the blocks 4 Remove the platform mounting fasteners and remove the platform Do not overtighten the platform mounting fasteners during installation 2 2 Platform Leveling Slave Cylinder The slave cylinder and the rotator pivot are the two primary supports for the platform
225. od through the barrel end pivot pin and twist to remove the pin Crushing hazard When the barrel ACAUTION end pivot pin is removed the primary boom lift cylinder will swing down if it is not properly supported 17 Attach an overhead crane or similar lifting device to the rod end of the primary boom lift cylinder Carefully loosen the straps and allow the primary boom lift cylinder to slowly swing down 18 Carefully remove the cylinder from the machine 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 P 4dily injury hazard This procedure requires specific repair skills lifting equipment and a suitable workshop Attempting this procedure without these skills and tools may result in death or serious injury and significant component damage Dealer service is strongly recommended 1 Raise the primary boom to the horizontal position Then extend the boom 3 to 4 feet 7 6 to 10 m until the extension cylinder rod end pivot pins are accessible 2 Remove the snap rings from the extension cylinder rod end pivot pins Then use a soft metal drift to remove the pins 3 Remove the rear turntable cover 4 Raise the secondary boom until the master cylinder rod end pivot pin is accessible 5 Remove t
226. of the jib boom leveling links from the primary boom 11 Support the jib boom lift cylinder with an overhead crane 12 Use a soft metal drift to remove the jib boom lift cylinder rod end pivot pin then remove the jib boom lift cylinder from the primary boom Crushing hazard The jib boom AWARNING lift cylinder will fall when the pin is removed if it is not properly supported 7 10 Genie Z 34 22 IC Part No 43037 Service Manual First Edition Section 7 Repair Procedures MMM R JIB BOOM COMPONENTS 3 2 5 Support the jib boom lift cylinder with an n head Jib Lift Cylinder BSC Remove the pin retainer from the jib boom lift How to Remove the Jib Boom cylinder barrel end pivot pin Use a soft metal drift to remove the barrel end pin Lift Cylinder 7 Use a soft metal drift to remove the jib boom lift Perform this procedure with the cylinder rod end pin Remove the cylinder from boom in the stowed position the machine 1 Raise the jib boom slightly and place blocks AWARNING Crushing hazard The jib boom lift under the platform mounting weldment Then cylinder will fall when it is removed lower the jib boom until the platform is resting if it is not properly supported on the blocks 2 Disconnect and plug the jib boom lift cylinder hydraulic hoses Bodily injury hazard Spraying ACAUTION hydraulic oil can penetrate and burn skin Loosen hydraulic connections very slow
227. oller OR consult Genie Industries Service Department If voltage to TB6 from 525 and 511 has been restored and platform rotate left function is still inoperative please continue troubleshooting from beginning of chart Genie Z 34 22 Part No 43037 Service Manual First Edition Continued from the previous page With key switch in ground position and both Emergency Stop switches pulled out to the on position activate the function enable toggle switch TS19 if equipped and theplatform rotate toggle switch TS25 on ground panel in left direction and check voltage on org wire on boom function directional valve coil item 12V or more Continued on the next page Section 5 Troubleshooting Flow Charts s E With key switch in ground position and both Emergency Stop switches pulled out to the on position activate the function enable toggle switch TS19 if equipped and theplatform rotate toggle switch TS25 on ground panel in left direction and check voltage at TB17 With key switch in platform position both Emergency Stop switches pulled out to the on position and boom function speed controller turned to 9 activate footswitch and platform rotate function toggle switch TS11 on control panel in eft direction and check voltage on org wire on boom function directional valve coil item C Troubleshoot platform rotate
228. oltage on output diode with blk wht wire attached Replace toggle switch OR replace diode 12V Hold platform glow plug Repair open in blk wht Switch and check from cable 1 wire circuit from platform voltage at TB34 glow plug switch to TB34 12V Consult Genie Industries Service Department 5 20 Genie Z 34 22 IC Part No 43037 Service Manual First Edition Section 5 Troubleshooting Flow Charts Engine Will Not Start On Gasoline But Will Start On LPG Kubota Gasoline LPG Models Be sure the fuel select switch is switched to gasoline Be sure to check gasoline fuel level Be sure that engine choke is operating properly Perform these tests with the keyswitch in the ground position If the engine starts on LPG from the ground controls but not from the platform controls troubleshoot the platform fuel select switch or the control cables With keyswitch on ground position and Emergency Stop switch pulled out check voltage at gasoline side blu wht wire of fuel select switch With keyswitch on ground position and Emergency Stop switch pulled out check voltage at TB38 With keyswitch on ground position and Emergency Stop switch pulled out check voltage at terminal 30 on CR6 12V Crank engine for 15 seconds and check voltage at terminal 86 on CR6 while cranking 12V Check ground wire to bad terminal 85 on CR6 good Hold st
229. om 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 Remove and label the location of the wear pads from the top side of the boom tube at the platform end of the boom Pay careful attention to the location and amount of shims used with each wear pad 5 Carefully rotate the base end of the extension cylinder until the pin mounting bore is in a vertical position 6 Support the extension tube with an overhead crane at the platform end of the boom Crushing hazard The boom tubes ACAUTION x will fall when they are removed from the boom if they are not properly supported 7 Support and slide the number 2 extension tube out of the number 1 primary boom tube Place the number 2 boom tube on blocks for support During removal the overhead crane strap will need to be carefully adjusted for proper balancing 8 Remove the retaining rings from the extension cylinder rod end pivot pin at the platform end of the number 2 extension tube Use a soft metal drift to remove the pin 9 Support and slide the extension cylinder out of the base end of the number 2 boom tube Place the extension cylinder on blocks for support During removal the overhead crane strap will need to be caref
230. om Down Function Inoperative 5 42 viii Genie Z 34 22 IC Part No 43037 Service Manual First Edition mu Section Five TABLE OF CONTENTS Troubleshooting Flow Charts continued 20 Primary Boom Extend Function Inoperative 5 45 21 Primary Boom Retract Function Inoperative 5 48 22 Turntable Rotate Left Function Inoperative 5 51 23 Turntable Rotate Right Function Inoperative 5 54 24 All Platform Leveling Functions Inoperative 5 57 25 Platform Level Up Function Inoperative 5 58 26 Platform Level Down Function Inoperative 5 61 27 Platform Rotate Left Function Inoperative 5 64 28 Platform Rotate Right Function 5 67 29 Boom Up Function Inoperative 5 70 30 Jib Boom Down Function Inoperative eese 5 73 31 Steer Left Function Inoperative 5 76 32 Steer Right Function Inoperative 5 77 33 Drive Functions Inoperative All Other Functions Operate Normally 5 78 34 Drive Forward or Reverse Function Inoperative
231. om function proportional valve coil item D OR repair open in ground wire circuit to valve coil item D Troubleshoot secondary boom function toggle switches TS21 and TS7 on ground and platform control panels OR repair open In wht red 6 wire circuit from TS21 to TB6 and from 57 to red wire on boom function speed controller OR consult Genie Industries Service Department If voltage to TB6 from TS21 and TS7 has been restored and secondary boom down function is still inoperative please continue troubleshooting from beginning of chart Genie Z 34 22 IC Part No 43037 Service Manual First Edition Continued from the previous page With key switch in ground position and both Emergency Stop switches pulled out to the on position activate the function enable toggle switch TS19 if equipped and the secondary boom toggle switch TS21 on ground panel in down direction and check voltage on blu blk 11 wire on boom function directional valve coil item R 12V or more Continued on the next page Section 5 Troubleshooting Flow Charts s With key switch in ground position and both Emergency Stop switches pulled out to the on position activate the function enable toggle switch TS19 if equipped and the secondary boom toggle switch TS21 on ground panel in down direction and check voltage at TB11 With key switch in platform position both Emergency Stop switches pul
232. operation is essential to good engine performance ADANG T 1 Explosion and fire hazard Engine o fuels are combustible Perform this procedure an open well ventilated area away from heaters sparks flames and lighted tobacco Always have an approved fire extinguisher within easy reach The engine rpm needs to be preset for gasoline fuel operation before adjusting the LPG idle mixture Refer to B 10 Check and Adjust the Engine RPM The engine should be warmed to normal operating temperature before performing this procedure 1 Move the fuel select switch to LPG fuel and start the engine from the ground controls TABLE C PROCEDURES Loosen the high idle mixture adjustment lock nut high idle mixture adjustment screw 3 Load the system by pressing the primary boom retract switch with the primary boom fully retracted then move the engine idle control switch to high idle rabbit symbol 4 Adjust the high idle adjustment screw to obtain an air to fuel mixture ratio of 13 0 1 to 13 2 1 using an exhaust gas analyzer If an exhaust gas analyzer is not available adjust to obtain peak or optimum rpm Hold the adjustment screw and tighten the lock nut Part No 43037 Genie Z 34 22 4 37 Section 4 Scheduled Maintenance Procedures Service Manual First Edition TABLE C PROCEDURES 6 Move the engine idle control switch to low idle turtle symbol and adjust the low idle mixture adjustm
233. ound controls will override the platform controls including the Emergency Stop button 1 Turn the key switch to ground control and pull out the Emergency Stop button to the position 2 Push in the Emergency Stop button to the orF position Result No functions should operate the machine should stop 3 Turn the key switch to platform control and pull out the Emergency Stop button to the position at both the ground and platform controls 4 Push down the Emergency Stop button to the OFF position Result No machine functions should operate The ground Emergency Stop button will stop all machine operation even if the key switch is switched to platform control Genie Z 34 22 IC Part No 43037 Service Manual First Edition Section 4 Scheduled Maintenance Procedures B 13 Test the Ground Control Override 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 Emergency Stop button on the platform controls is in the on or position This function is particularly useful if the operator at the platform controls cannot return the boom to the stowed position 1 Push the platform Emergency Stop button to the position 2 Turn the key switch to ground control and pull out the Emergency Stop button to the on po
234. own directional valves item M and activate platform level up function Replace defective directional valve function inoperative Exchange platform level up and down counterbalance valves item F G and activate platform level up function Replace defective counterbalance valve function inoperative Install a 0 to 5000 PSI Check for mechanical pressure gauge at the restrictions keeping quick disconnect platform level up coupling on the boom function from moving function manifold and OR replace slave activate the platform cylinder OR replace level up function slave cylinder counterbalance valves OR consult Genie Industries Service Department less than 3200 PSI Test master cylinder refer to Chart 22 OR repair or replace slave cylinder or slave cylinder counterbalance valves OR boom function manifold could have an internal fault Consult Genie Industries Service Department Genie Z 34 22 Part No 43037 Service Manual First Edition Section 5 Troubleshooting Flow Charts Platform Level Down Function inoperative Be sure all other functions operate normally If platform level down function operates normally from the ground controls but not from the platform controls troubleshoot the platform controller or diode See Repair Section If platform level down function operates normally from the platform controls but not from the ground controls troubleshoot the grou
235. panel in down direction and check voltage at TB6 Troubleshoot jib function toggle switch TS26 on ground control panel OR repair open in wht red 6 wire circuit from TS26 to TB6 OR consult Genie Industries Service Department Chart 30 Repair open in wht red 6 wire circuit from TB6 to boom function proportional valve coil item D OR open in ground wire circuit to valve coil item D Troubleshoot jib function toggle switches 7526 and TS12 on ground and platform control panels OR repair open in wht red 6 wire circuit from TS26 to TB6 and from TS12 to red wire on boom function speed controller OR consult Genie Industries Service Department If voltage to TB6 from TS26 and TS12 has been restored and jib down function is still inoperative please continue troubleshooting from beginning of chart Part No 43037 Genie Z 34 22 IC Section 5 Troubleshooting Flow Charts ea CHART 30 Continued from the previous page With key switch in ground position and both Emergency Stop switches pulled out to the on position activate the function enable toggle switch TS19 if equipped and thejib toggle switch TS26 on ground panel in down direction and check voltage on wht wire on boom function directional valve coil item B 12V or more Continued on the next page Service Manual First Edition With key switch in ground position and both Emergency Stop switches pulled o
236. perative Chart 24 Remove both hydraulic hoses from the manifold ports C1 amp C2 and install adjustable orifice valves Then reconnect the hydraulic hoses with valves to manifold Bleed the system see Repair Procedures Close the adjustable orifice valves Operate primary boom up function and check if platform levels Replace the counterbalance valves on function manifold items F amp G Check for mechanical restrictions OR replace the slave cylinder counterbalance valves Plumb a pressure gauge 2000 into the barrel end PSI hydraulic hose hose connected to port C1 using a tee fitting Operate primary boom up function and read the pressure less than 2000 PSI Deadhead the pressure gauge into the barrel end hydraulic hose from the master cylinder and raise the primary boom one inch at a time Continually monitor the pou gauge during oom up Do not allow the pressure to exceed 2500 PSI less than 2000 PSI Repair or replace the master oylinder 2000 PSI or more Repair or replace the slave cylinder Part No 43037 Genie Z 34 22 IC Section 5 Troubleshooting Flow Charts Service Manual First Edition Chart 25 Platform Level Up Function inoperative Be sure all other functions operate normally If platform level up function operates normally from the ground controls but not from the platform controls troubleshoot the platform controller or diode
237. pling on the boom moving OR repair function manifold and oylinder or cylinder activate the extend counterbalance valve boom function OR consult Genie Industries Service less than 1800 PSI Department Reset extend relief item L pressure OR replace secondary down relief valve item L OR repair cylinder or cylinder counterbalance valve OR boom function manifold could have an internal fault Consult Genie Industries Service Department Part No 43037 Genie Z 34 22 IC 5 47 Section 5 Troubleshooting Flow Charts Service Manual First Edition Chart 21 Primary Boom Retract Function inoperative Be sure all other functions operate normally If primary boom retract function operates normally from the ground controls but not from the platform controls troubleshoot the platform controller or diode See Repair Section If primary boom retract function operates normally from the platform controls but not from the ground controls troubleshoot the ground control toggle switch OR diode OR resistor See Repair Section With key switch in ground position and both Emergency Stop switches pulled out to the on position activate the function enable toggle switch TS19 if equipped and the ext ret boom toggle switch TS23 on ground panel in retract direction and check voltage on wht red 6 wire on boom function proportional valve coil item D Continued on the next page 12V or mo
238. primary boom function toggle switches TS22 and TS8 on ground and platform control panels OR repair open In wht red 6 wire circuit from TS22 to TB6 and from 58 to red wire on boom function speed controller OR consult Genie Industries Service Department If voltage to TB6 from TS22 and TS8 has been restored and primary boom up function is still inoperative please continue troubleshooting from beginning of chart Part No 43037 Genie Z 34 22 IC Section 5 Troubleshooting Flow Charts CHART 16 With key switch in ground position and both Emergency Stop switches pulled out to the on position activate the function enable toggle switch TS19 if equipped and the primary boom toggle switch TS22 on ground panel in up direction and check voltage on red 1 wire on boom function directional valve coil item 5 Continued from the previous page 12V or more Continued on the next page Service Manual First Edition l With keyswitch in ground position and both Emergency Stop switches pulled out to the on position activate the function enable toggle switch TS19 if equipped and the primary boom toggle switch TS22 on ground panel in up direction and check voltage at TB1 With key switch in platform position both Emergency Stop switches pulled out into on position and boom function speed controller turned to 9 activate footswitch and primary boom toggle switch TS8 o
239. r A 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 that fasteners intended for one N 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 other fluids Use an approved container Please be environmentally safe iv Genie Z 34 22 IC Part No 43037 Service Manual First Edition Introduction Section One Section Two Section Three Section Four Table of Contents Important INTOMMATION Safety Rules General Safety Rules eene nennen nne iii Specifications Machine SpecifiCatiOns i5 duci epe epu tas ata 2 1 Performance 2 2 Flydraulie Specifieati niSu UL 2 2 Bolt Torque Specifications 2 4 Kubota WG 750 Engine Specifications 2 2 5 Kubota D 905 Engine Specifications 2 7 Scheduled Maintenance Inspections ELLE 3 1 TADE u u 3 2 ES 3 3 Table 3 5 3 6 Maintenance
240. r 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 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 Lower the boom into the stowed position 6 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 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 Drive speed stowed position maximum High range 2WD 40 ft 6 1 sec 12 2m 6 1 sec High range 4WD 40 ft 6 8 sec 12 2m 6 8 sec B 22 Test the Drive Speed Raised or Extended Position Proper drive function movement is essential to safe machine operation The drive function should respond quickly and smoothly to operator control Drive performance should al
241. re With key switch in ground position and both Emergency Stop switches pulled out to the on position activate the function enable toggle switch TS19 if equipped and the ext ret boom toggle switch TS23 on ground panel in retract direction and check voltage at TB6 With key switch in platform position both Emergency Stop switches pulled out to the on position and boom function speed controller turned to 9 activate footswitch and ext ret boom function toggle switch TS9 on platform control panel in retract direction and check voltage at TB6 Troubleshoot ext ret boom function toggle switch TS23 on ground control panel OR repair open in wht red 6 wire circuit from TS23 to TB6 OR consult Genie Industries Service Department Repair open in wht red 6 wire circuit from TB6 to boom function proportional valve coil item D OR repair open in ground wire circuit to valve coil item D Troubleshoot ext ret boom function toggle switches TS23 and TS9 on ground and platform control panels OR repair open in wht red 6 wire circuit from 1523 to TB6 and from TS9 to red wire on boom function speed controller OR consult Genie Industries Service Department If voltage to TB6 from TS23 TS9 has been restored and retract function is still inoperative please continue troubleshooting from beginning of chart Genie Z 34 22 Part No 43037 Service Manual First Edition
242. repair open in wht wire circuit from foot switch to terminal 1 of the horsepower limiter Does engine start from the platform controls Repair open in wht wire circuit from terminal 1 to function toggle switches Check for open in red wire circuit from key switch to TB22 OR replace the key switch platform contacts Check voltage at TB22 Check voltage at blk 2 wire on platform emergency stop button Repair open in blk 2 wire circuit from TB22 to emergency stop button Check voltage at blk wire on opposite end of on emergency stop utton Replace contact on emergency stop button Check voltage at wht 2 wire connected to diode on platform emergency stop button Replace contact on emergency stop button OR replace diode Repair open in blk wire circuit from platform emergency stop switch to foot switch OR replace foot switch OR repair open in grn wire circuit from foot switch to start toggle switch OR consult Genie Industries Service Department Genie Z 34 22 IC Part No 43037 Service Manual First Edition Section 5 Troubleshooting Flow Charts Primary Boom Up Function inoperative Be sure all other functions operate normally If boom up function operates normally from the ground controls but not from the platform controls troubleshoot the platform controller or diode See Repair Section If boom up function operates normally from the platform controls
243. rgency Stop button to the ON position at both the ground and platform controls 2 Push down the service horn button at the platform controls Result The service horn should sound B 16 Test the Foot Switch A properly functioning foot switch is essential to safe machine operation Machine functions should activate and operate smoothly as long as the foot switch is pressed down and promptly stop when the foot switch is released An improperly functioning foot switch can cause an unsafe working condition The engine should not start with the footswitch pressed down 1 Start the engine from the platform controls 2 Without pressing down the foot switch check the machine functions Result The machine functions should not operate 3 Press down the foot switch and operate the machine functions Result The machine functions should operate Genie Z 34 22 IC Part No 43037 Service Manual First Edition Section 4 Scheduled Maintenance Procedures B 17 Test the Engine Idle Select A properly operating engine idle select switch is essential to good engine 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 idl
244. ries Service Department Part No 43037 Genie Z 34 22 IC 5 77 Section 5 Troubleshooting Flow Charts Service Manual First Edition Chart 33 All Drive Functions Inoperative All Other Functions Operate Normally Be sure the hydraulic suction line valve is in the open position Be sure the machine is not in the free wheel configuration Start engine from ground controls and standing clear of the Repair or replace the drive pump OR consult Genie Industries Service Department machine does not move tires momentarily move control override ever in each direction machine moves Move to platform press down foot switch hold drive enable Place a jumper wire between TB30 and TB12 and test drive Repair open in wht wire circuit from TS14 to TB30 machine no drive drives Switch to either side and try to drive without holding drive enable switch machine drives Replace drive enable limit switch OR repair open in wire circuits no drive from terminal TB30 to limit switch and from limit switch to TB12 0 or Disconnect drive pump De electronic displacement ohms controller EDC wires Replace EDC Check resistance across both wires on EDC side of quick disconnect 20 to 24 ohms Correct insufficient voltage supply alternator or battery Press down foot switch and check voltage at less than 12V horsepower limiter board terminal
245. right direction and check voltage on wht red 6 wire on boom function proportional valve coil item D 12V or more Continued on the next page With key switch in ground position and both Emergency Stop switches pulled out to the on position activate the function enable toggle switch TS19 if equipped and theplatform rotate toggle switch TS25 on ground panel in right direction and check voltage at TB6 With key switch in platform position both Emergency Stop switches pulled out to the on position and boom function speed controller turned to 9 activate footswitch and platform rotate toggle Switch TS11 on platform control panel in right direction and check voltage at TB6 Troubleshoot platform rotate function toggle switch TS25 on ground control panel OR repair open wht red 6 wire circuit from TS25 to TB6 OR consult Genie Industries Service Department Chart 28 Repair open in wht red 6 wire circuit from TB6 to boom function proportional valve coil item D OR open in ground wire circuit to valve coil item D Troubleshoot platform rotate function toggle switches TS25 and TS11 on ground and platform control panels OR repair open in wht red 6 wire circuit from TS25 to TB6 and from 511 to red wire on boom rotary speed controller OR consult Genie Industries Service Department If voltage to TB6 from 525 and TS11 has been restored and platform rotate right function is
246. rminal 86 of CR2 Check voltage at terminal 7 on ign start module Replace ign start module OR consult Genie Industries Service Department no good Check ground to terminal 85 on CR2 Repair open in ground wire to CR2 20 If weak spark still exists contact Genie Industries Service Department OR consult Kubota engine service manual for troubleshooting engine with weak spark Repair open in blk wire from terminal 86 on CR2 to terminal 9 on ign start module Repair open in power supply wires to terminal 7 on ign start module 5 6 Genie Z 34 22 IC Part No 43037 Service Manual First Edition Section 5 Troubleshooting Flow Charts Engine Cranks Over But Will Not Start OR Engine Runs While Cranking Then Dies Kubota Gas LPG Models Continuation of good spark fault path Perform the following tests in the gasoline mode only Check choke for proper adjustment or internal damage good With keyswitch turned to ground position and Emergency Stop switch pulled out check voltage at red wht 23 wire on vacuum switch Remove the blk wire with diode from terminal 86 OV on CR3 crank the engine over for 15 seconds and check voltage at red blk wire on vacuum switch reconnect blk wire after test 12V With keyswitch on and both Emergency Stop buttons pulled out disconnect wires from vacuum switch and connect the wires togeth
247. rol panel OR replace diode on TS23 OR repair open in blk 7 wire circuit from TS23 to TB7 OR consult Genie Industries Service Department Repair open in blk 7 wire circuit from TB7 to boom function directional valve coil item U OR repair open in ground wire circuit to manifold item U Troubleshoot ext ret boom function toggle switches TS23 and 159 on ground and platform control panels OR replace diodes on TS23 and TS9 OR repair open in blk 7 wire circuit from TS23 and TS9 to TB7 OR consult Genie Industries Service Department If voltage to TB7 from TS23 TS9 has been restored and boom extend function is still inoperative please continue troubleshooting from beginning of chart 5 46 Genie Z 34 22 IC Part No 43037 Service Manual First Edition Section 5 Troubleshooting Flow Charts gr CHART 20 Disconnect wire to boom 0 or Continued from the extend directional valve infinite previous Page coil item 0 Remove ohms a reac extend directional valve coil and test resistance coil item U 4 to 8 ohms Exchange primary boom extend and retract function directional valves item operates Replace defective U V and activate directional valve primary boom extend function function inoperative Install a 0 to 3000 PSI Check for mechanical pressure gauge at the restrictions keeping quick disconnect extension boom from cou
248. roller turned to 9 activate footswitch and platform level function toggle switch TS10 on platform control panel in up direction and check voltage at TB14 Troubleshoot platform level function toggle switch TS24 on ground control panel OR replace diode on TS24 OR repair open in org 14 wire circuit from TS24 to TB14 OR consult Genie Industries Service Department ground position and both soy or CHART 25 Repair open in org 14 wire circuit from TB14 to boom function directional valve coil item M OR repair open in ground wire circuit to manifold item M Troubleshoot platform level function toggle switches TS24 and TS10 on ground and platform control panels OR replace diodes on 1524 TS10 OR repair open in org 14 wire circuit from TS24 and TS10 to TB14 OR consult Genie Industries Service Department If voltage to 14 from TS24 TS10 has been restored and platform level up function is still inoperative please continue troubleshooting from beginning of chart Part No 43037 Genie Z 34 22 Section 5 Troubleshooting Flow Charts Service Manual First Edition CHART 25 Continued from the previous page Disconnect wire to oo platform level up infinite directional valve coil ohms Replace platform level item M Remove coil up directional valve coil and test resistance item 4 to 8 ohms Exchange platform level up and d
249. s X Kubota Diesel Models B 10 Check and adjust the Engine RPM Part No 43037 Genie Z 34 22 IC Section 3 Scheduled Maintenance Inspections Service Manual First Edition MAINTENANCE TABLES Table B continued Warm Cold Dener ools are New parts engine engine service required required required required suggested B 11 Test the Key Switch B 12 Test the Emergency Stop Buttons B 13 Test the Ground Control Override B 14 Test the Platform Self leveling B 15 Test the Service Horn B 16 Test the Foot Switch B 17 Test the Engine Idle Select B 18 Test the Fuel Select Operation Kubota Gasoline LPG Models B 19 Test the Drive Enable System B 20 Test the Drive Brakes B 21 Test the Drive Speed Stowed Position B 22 Test the Drive Speed Raised or Extended D Position B 23 Test the Alarm Package Optional Equipment Perform Hydraulic Oil Analysis See D 1 Test Replace the Hydraulic Oil Every 400 hours perform the following engine maintenance procedure B 25 Replace the Diesel Fuel Filter Water X Separator Element Kubota Diesel Models E Genie Z 34 22 IC Part No 43037 Service Manual First Edition Section 3 Scheduled Maintenance Inspections MAINTENANCE TABLES W Cold Deal Table C Tools are New parts 2 required required required required suggested C 1 Check
250. s procedure with the boom in the stowed position 1 Connect 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 With the engine in high rpm hold the primary boom extend switch with the primary boom fully extended and observe the pressure reading on the pressure gauge 4 Turn the machine off Hold the relief valve and remove the cap item 7 function manifold 5 Adjust the internal hex socket Turn it clockwise to increase the pressure or counterclockwise to decrease the pressure Then install the relief valve cap AWARNING Tip over hazard Do not adjust the relief valves higher than specified 6 Repeat steps 2 through 5 and recheck the valve pressure Primary boom extend relief valve specifications FUNCTION MANIFOLD How to Adjust the Secondary Boom Down Relief Valve Perform this procedure with the boom in the stowed position 1 Connect 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 With the engine in high rpm hold down the secondary boom down switch with the secondary boom fully lowered and observe the pressure reading on the pressure gauge 4 Turn the machine off Hold the relief valve and remove the cap item 5 function manifold 5 Adjust the internal hex socket Turn it clockwise to increase the pressure or counterclockwise to
251. s screwdriver is located in the operator s manual storage box in the platform 1 Label the wiring from the component to be removed 2 Use the provided screwdriver to push in and release the wire from the component 3 Locate the removal tab on the bottom or top side of the component 4 Use the provided screwdriver to gently pry up on the tab of the component and remove it Part No 43037 Genie Z 34 22 IC 7 33 Section 7 Repair Procedures Service Manual First Edition Hydraulic Pumps 9 1 Auxiliary Pump How to Test the Auxiliary Pump 1 Disconnect and plug the high pressure 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 the Emergency Stop button to the position 4 Activate any function using auxiliary power Result If the pressure gauge reads 2800 psi 193 bar immediately stop The pump is good Result If pressure fails to reach 2800 psi 193 bar the pump is bad and will need to be Serviced or replaced 5 Remove the pressure gauge and reconnect the hydraulic hose How to Remove the Auxiliary Pump 1 Tag disconnect and cap the hydraul
252. s the finish line Drive speed raised or extended position maximum 0 6 mph 0 98 km h 40 ft 40 sec 12 2 m 40 sec Raised or extended position TABLE B PROCEDURES B 23 Test the Alarm Package Optional Equipment The alarm package includes Travel alarm Descent alarm 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 The alarms and beacon will operate with the engine running or not running 1 At the ground controls pull out the Emergency Stop button to the ow position and turn the key switch to ground control Result The flashing beacon should be on and flashing 2 Move the primary boom switch to the pown position hold for a moment and then release it Move the secondary boom switch to the powN position hold for a moment and then release it Q Result The descent alarm should sound when each switch is held down 3 Turn the key switch to platform control Part No 43037 Genie Z 34 22 IC Section 4 Scheduled Maintenance Procedures Service Manual First Edition 6 TABLE PROCEDURES 4 Atthe platform controls pull out the Emergency B 24 Stop button to th ition p Perform Hydraulic Oil Analysis Result The flashing beacon should be on and flashing See D 1 Test or Replace the Hyaraulic Oil 5 Press down the
253. seconds Booms raised or extended high range All models Part No 43037 Genie Z 34 22 IC Section 7 Repair Procedures Service Manual First Edition PLATFORM CONTROLS Boom Function Speed Controller Adjustments AWARNING Electrocution hazard Contact with electrically charged circuits may result in death or serious injury Remove all rings watches and other jewelry 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 the 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 black wire diode white red wire boom function speed controller max out adjustable trimpot threshold adjustable trimpot 3 Locate the diode between the black wire from the boom function speed controller and the white red wire 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 controller to the CREEP position 6 Setthe threshold Press down the foot switch then move the primary boom switch to the UP position until the voltage reading appears Adjust the voltage to 5 00 to 6 00V DC Turn the threshold trimpot adjustment screw clockwise to increase
254. sembly 3 Block the non steer wheels and then center 5 Remove the dust cap cotter pin and lifting jack under the steering axle slotted nut 4 Raise the machine 6 inches 15 cm and place 6 Pull the hub off the spindle The washer and blocks under the drive chassis for support outer bearing should fall loose from the hub 5 Remove the lug nuts then the tire and 7 Place the hub on a flat surface and gently pry wheel assembly the bearing seal out of the hub Remove the rear bearing 6 Remove the pin retaining fasteners from the upper and lower king pins Part No 43037 Genie Z 34 22 7 47 Section 7 Repair Procedures Service Manual First Edition 2WD STEER AXLE COMPONENTS How to Install the Hub and Bearings 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 grease 2 Place the large inner bearing into the rear of the hub 3 Press the bearing seal evenly into the hub until it is flush 4 Apply a small amount of grease onto the yoke spindle 5 Slide the hub onto the yoke spindle Component damage Do not ACAUTION apply excessive force or damage to the lip of the seal may occur 6 Place the outer bearing into the hub 7 Install the washer and slotted nut 8 Tighten the slotted nut to 35 foot pounds 47 Nm 9 Loosen the slotted nut then re tighten to 8 foot pounds 11 Nm 1
255. sition 3 Operate each boom function through a partial cycle at the ground controls Result All boom functions should operate TABLE B PROCEDURES B 14 Test the Platform Self leveling 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 Emergency Stop button to the on position 2 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 Part No 43037 Genie Z 34 22 Section 4 Scheduled Maintenance Procedures Service Manual First Edition TABLE B PROCEDURES B 15 Test the Service Horn A functioning service horn is essential to safe machine operation The service horn is activated at the platform controls and sounds at the ground as a warning to ground personnel An improperly functioning horn will prevent the operator from alerting ground personnel of hazards or unsafe conditions 1 Turn the key switch to platform control and pull out the Eme
256. so be free of hesitation jerking and unusual noise over the entire proportionally controlled speed range 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 Startthe 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 speed before reaching the start line Begin timing when your reference point on the machine crosses the start line 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 Genie Z 34 22 IC Part No 43037 Service Manual First Edition Section 4 Scheduled Maintenance Procedures 9 Choose a point on the machine 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 crosse
257. ssification Idle gear shaft nuts M6 7108 10 to 11 CC SE CD SE CC SF or CD SF grades Glow plugs M10 14 to 18 20 to 24 Injection system Nozzle holder assembly M20 36 to 50 49 to 69 Injection pump make Bosch MD Injection pipe 18 to 25 25 to 34 Injection timing 13 to 25 BTDC retaining nuts M12 Injection pump pressure 1991 psi 137 bar Part No 43037 Genie Z 34 22 2 7 Section 2 Specifications Service Manual First Edition eee This page intentionally left blank 2 8 Genie Z 34 22 IC Part No 43037 Service Manual First Edition Section 3 Scheduled Maintenance Inspections Scheduled Maintenance Inspections Observe and Obey Maintenance inspections shall be completed by a person trained and qualified on the maintenance of this machine Scheduled maintenance inspections shall be completed daily quarterly annually and every 2 years as specified on the Maintenance Inspection Report Failure to properly complete each AWARNING inspection when required may cause death serious injury or substantial machine damage M Immediately tag and remove from service a damaged or malfunctioning machine Repair any machine damage or malfunction before operating machine Keep records on all inspections for three years Machines that have been out of service for a period longer than 3 months must complete the quarterly inspection About This Section The Schedule There are four types o
258. still inoperative please continue troubleshooting from beginning of chart Part No 43037 Genie Z 34 22 IC Section 5 Troubleshooting Flow Charts TA CHART 28 Continued from the previous page With key switch in ground position and both Emergency Stop switches pulled out to the on position activate the function enable toggle switch TS19 if equipped and theplatform rotate toggle switch TS25 on ground panel in right direction and check voltage on yellow wire on boom function directional valve coil item D 12V or more Continued on the next page Service Manual First Edition With key switch in ground position and both Emergency Stop switches pulled out to the on position activate the function enable toggle switch TS19 if equipped and theplatform rotate toggle switch TS25 on ground panel in right direction and check voltage at TB18 With key switch in platform position both Emergency Stop switches pulled out to the on position and boom function speed controller turned to 9 activate footswitch and platform rotate function toggle switch TS11 on platform control panel in right direction and check voltage on yellow wire on boom function directional valve coil item D Troubleshoot platform rotate function toggle switch TS25 on ground control panel OR replace diode on TS25 OR repair open in grn blk 18 wire circuit from 525 to boom function directiona
259. te directional valve coil ohms item O Remove coil and test resistance Continued from the previous page Replace turntable rotate right directional valve coil item O 4108 ohms Exchange turntable rotate left and right directional valves item P O and activate turntable rotate right function Replace defective directional valve function inoperative Install a 0 to 3000 PSI Check for mechanical pressure gauge at the restrictions keeping quick disconnect turntable rotate right coupling on the boom function from moving function manifold and OR the 0 050 orifice activate the turntable item X could be rotate right function plugged OR repair motor E worm gear OR consult Genie less than 1750 PSI Industries Service Department Reset turntable rotate right relief item 1 pressure OR replace turntable rotate right relief valve item OR repair hydraulic motor or worm gear OR boom function manifold could have an internal fault Consult Genie Industries Service Department 5 56 Genie Z 34 22 IC Part No 43037 Service Manual First Edition Section 5 Troubleshooting Flow Charts All Platform Leveling Functions inoperative Be sure all other functions operate normally Be sure both automatic and manual platform leveling do not operate If automatic leveling operates but manual leveling does not troubleshoot platform leveling up function ino
260. tem Q Continued from the previous page 12V or more Continued on the next page Service Manual First Edition l With key switch in ground position and both Emergency Stop switches pulled out to the on position activate the function enable toggle switch TS19 if equipped and the secondary boom toggle switch TS21 on ground panel in up direction and check voltage at TB10 With key switch in 2 position both mergency Stop switches pulled out to the on position and boom function speed controller turned to 9 activate footswitch and secondary boom toggle switch TS7 on platform control panel in up direction and check voltage at TB10 Troubleshoot secondary boom function toggle switch TS21 on ground control panel OR replace diode TS21 OR repair open in blu 10 wire circuit from TS21 to TB10 OR consult Genie Industries Service Department Repair open in blu 10 wire circuit from TB10 to boom function directional valve coil item Q OR repair open in ground wire circuit to manifold item Q Troubleshoot secondary boom function toggle switches TS21 and TS7 on ground and platform control panels OR replace diodes on TS21 and TS2 OR repair open in blu 10 wire circuit from TS21 and TS7 to 10 OR consult Genie Industries Service Department If voltage to TB10 from TS21 TS7 has been restored and secondary boom up function is still inoperative please continue troubl
261. the Primary Boom Wear Pads 2 Check the Turntable Rotation Bearing Bolts C 3 Check the Free wheel Configuration C 4 Grease the Turntable Rotation Bearing and Worm Drive Gear C 5 Replace the Torque Hub Oil 6 Replace the Hydraulic Filters C 7 Replace the Gasoline Fuel Filter x 7 Kubota Gasoline LPG Models 221 C 8 Clean or Replace the Distributor Cap A and Rotor Kubota Gasoline LPG Models A 9 Replace the Spark Plugs Kubota Gasoline LPG Models C 10 Check and Adjust the Air LPG Mixture x n Kubota Gasoline LPG Models xt A C 11 Replace the Engine Air Filter C 12 Check and Adjust the Ignition Timing n Kubota Gasoline LPG Models 13 Check the Engine Valve Clearances n Kubota Gasoline LPG Models 14 Bleed the Platform Rotator Part No 43037 Genie Z 34 22 IC Section Scheduled Maintenance Inspections Service Manual First Edition MAINTENANCE TABLES Warm Cold Dealer Table D Tools are New parts engine engine service required required required required suggested D 1 Test or Replace the Hydraulic Oil D 2 Change or Recondition the Engine Coolant T D 3 Change the Fuel Lines 3 6 Genie Z 34 22 IC Part No 43037 Service Manual First Edition Section 3 Scheduled Maintenance Inspections Maintenance Inspection Report Model Serial number Date Hour meter Machine owner Inspected by print Inspector signature I
262. the hydraulic system and cause severe component damage Dealer service is recommended 1 Remove the fuel tank See 11 1 How to Remove the Fuel Tank 2 Locate the drain hose on the bottom of the hydraulic tank and drain the oil into a suitable container AWARNING Burn hazard Contact with hot oil may cause severe burns 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 hoses from the return filter Remove the suction hoses from the bottom of the tank 5 Remove the mounting fasteners from the tank straps 6 Use an appropriate lifting device to remove the tank from the machine Clean the hydraulic tank and inspect for rust and corrosion before installing Part No 43037 Genie Z 34 22 7 45 Section 7 Repair Procedures Service Manual First Edition Turntable Rotation Components 12 1 Rotation Hydraulic Motor The 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 turntable has to be removed How to Remove the Turntable Rotation Motor 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 mo
263. the relief valves higher than specified 6 Repeat steps 2 through 5 and recheck the valve pressure Primary boom down relief valve specifications How to Adjust the Turntable Rotate Relief Valves before serial number 674 Perform this procedure with the boom in the stowed position 1 Connect 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 With the engine in high rpm hold the turntable rotate right switch with the turntable rotated to the right until it is against the rotation stop and observe the pressure reading on the pressure gauge 4 Turn the machine off Hold the relief valve and remove the cap item 4 function manifold If adjusting the turntable rotate left hold switch to the left and adjust the left relief valve item 3 function manifold 5 Adjust the internal hex socket Turn it clockwise to increase the pressure or counterclockwise to decrease the pressure Then install the relief valve cap Tip over hazard Do not adjust AWARNING the relief valves higher than specified Pressure 1400 psi 6 Repeat steps 2 through 5 and recheck the valve 97 bar pressure Turntable rotate relief valve specifications Pressure 1750 psi 121 bar 7 42 Genie Z 34 22 IC Part No 43037 Service Manual First Edition Section 7 Repair Procedures How to Adjust the Primary Boom Extend Relief Valve Perform thi
264. tify which connector to use for testing 3 Press down the foot switch Connect the leads from an ohmmeter or continuity tester to each wire combination listed below and check for continuity Test Desired result red to black no continuity infinite red to white no continuity black to white continuity zero Q Part No 43037 Genie Z 34 22 IC 7 5 Section 7 Repair Procedures PLATFORM CONTROLS 1 4 Toggle Switches Toggle switches used for single function switching are single pole double throw SPDT switches Dual function switching requires a double pole double throw DPDT switch How to Test a Toggle Switch Continuity is the equivalent of 0 to 3 ohms A simple continuity tester may not accurately test the switch This procedure covers fundamental switch testing and does not specifically apply to all varieties of toggle switches 1 Turn the key switch to the position Tag and disconnect all wiring from the toggle switch to be tested 2 Connect the leads of an ohmmeter to the switch terminals in the following combinations listed below to check for continuity Left Center Right Single pole double throw SPDT 4 5 6 Double pole double throw DPDT Service Manual First Edition Test Left position Desired result terminal 1 to 2 3 4 5 amp 6 no continuity infinite O terminal 2 to 3 continuity zero Q terminal 2 to 4 5 amp 6 n
265. tion activate the function enable toggle switch TS19 if equipped and thejib toggle switch TS26 on ground panel in up direction and check voltage on blk wire on boom function directional valve coil item A 12V or more Continued on the next page Section 5 Troubleshooting Flow Charts s With key switch in ground position and both Emergency Stop switches pulled out to the on position activate the function enable toggle switch TS19 if equipped and thejib toggle switch TS26 on ground panel in up direction and check voltage at TB43 With key switch in platform position both Emergency Stop switches pulled out to the on position and boom function speed controller turned to 9 activate footswitch and jib function toggle switch TS12 on platform control panel in up direction and check voltage on blk wire on boom function directional valve coil item A Troubleshoot jib function toggle switch TS26 on ground control panel OR replace diode on TS26 OR repair open in grn 43 wire circuit from TS26 to boom function directional valve coil item A OR consult Genie Industries Service Department CHART 29 Repair open in grn 43 wire circuit from TB43 to boom function directional valve coil item A OR repair open in ground wire circuit to manifold item A Troubleshoot jib function toggle switches TS26 and TS12 on ground and platform control panels OR replace diodes on TS26 and
266. tions please call Genie Industries Genie North America Telephone 206 881 1800 Toll Free 800 536 1800 in U S A Toll Free 800 426 8089 in Canada Fax 206 883 3475 E mail techpub genieind com http www genielift com Genie Europe Telephone 44 0636 813943 Fax 44 0636 815270 http www genielift com Genie Industries Copyright 1997 by Genie Industries 43037 Rev B January 2007 First Printing Second Printing Genie is a registered trademark of Genie Industries Registered 2009987 Printed on recycled paper Printed in U S A 7 34 22 43037 Service Manual First Edition Safety Rules Danger Failure to obey the instructions and safety rules in this manual and the appropriate Genie Z 34 22 IC Operator s Manual will result in death or serious injury Many of the hazards identified in the operator s manual are also safety hazards when maintenance and repair procedures are performed 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 You have the appropriate tools lifting equipment and a suitable workshop Part No 43037 Genie Z 34 22 IC lii Service Manual First Edition SAFETY RULES Personal S
267. to the machine Indicates special operation or maintenance information Indicates that a specific result is expected after performing a series of steps Part No 43037 Genie 7 34 22 7 1 Section 7 Repair Procedures Service Manual First Edition Platform Controls 1 1 Horsepower Limiter Board The horsepower limiter board is responsible for governing drive pump output It senses engine rom from the alternator The horsepower limiter board senses drops in rpm normally due to increased drive resistance rough terrain or incline and decreases voltage to the drive controller which in turn decreases voltage to the drive pump thereby reducing pump output to maintain optimum engine rpm and horsepower Three adjustments are required for optimum performance How to Adjust the Horsepower Limiter Board The engine must be correct before performing this procedure See Maintenance Procedure B 10 Check and Adjust the Engine RPM Do not adjust the horsepower limiter board unless the static battery voltage is above 12V DC and the alternator is operating properly with 12 5 to 14 5V DC output Kubota Gasoline LPG models Perform this procedure in gasoline mode 1 Remove the fasteners from the platform control box lid 2 Open the control box lid and locate the horsepower limiter board Electrocution hazard Contact AWARNING with electrically charged circuits may result in death or serious injury
268. top switches pulled out to the on position activate the function enable toggle switch TS19 if equipped and thejib toggle switch TS26 on ground panel in up direction and check voltage at TB6 With key switch in platform position both Emergency Stop switches pulled out to the on position and boom function speed controller turned to 9 activate footswitch and jib toggle switch TS12 on platform control panel in up direction and check voltage at TB6 Troubleshoot jib function toggle switch TS26 on ground control panel OR repair open in wht red 6 wire circuit from TS26 to TB6 OR consult Genie Industries Service Department Repair open in wht red 6 wire circuit from TB6 to boom function proportional valve coil item D OR open in ground wire circuit to valve coil item D Troubleshoot jib function toggle switches 7526 and TS12 on ground and platform control panels OR repair open in wht red 6 wire circuit from TS26 to TB6 and from TS12 to red wire on boom function speed controller OR consult Genie Industries Service Department If voltage to TB6 from TS26 and TS12 has been restored and jib up function is still inoperative please continue troubleshooting from beginning of chart Genie Z 34 22 IC Part No 43037 Service Manual First Edition Continued from the previous page With key switch in ground position and both Emergency Stop switches pulled out to the on posi
269. tor Genie Z 34 22 IC Part No 43037 Service Manual First Edition Section 7 Repair Procedures 3 Remove the jib boom See 3 1 How to Remove the Jib Boom 4 Support the slave cylinder 5 Remove the external retaining ring from the slave cylinder barrel end pivot pin 6 Use a soft metal drift and drive the slave cylinder barrel end pin out 7 Remove the slave cylinder from the primary boom 8 Supportthe cable track with an overhead crane Remove the hose cable cover from the pivot end of the boom 10 Remove the cable track mounting fasteners then remove the cable track from the boom and lay it off to the side Component damage hazard ACAUTION The boom cable track can be damaged if it is twisted 11 Remove the turntable end cover 12 Remove the retaining bolt 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 13 Remove the drive speed limit switch mounted on the side of the pivot end of the boom Do not disconnect the wiring 14 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 15 Attach an overhead 5 ton crane to the center point of the boom PRIMAR
270. tor Cap the fittings on the motor AWARNING we 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 turntable rotation motor mounting bolts then remove the motor 7 46 Genie Z 34 22 Part No 43037 Service Manual First Edition Section 7 Repair Procedures 2WD Steer Axle Components 13 1 7 Attach a strap from a lifting device to the Yoke and Hub yoke hub assembly for support 2 2 2 8 Place rod through the king pin and twist to How to Remove the Yoke and Hub AWARNING Crushing hazard The yoke hub assembly will fall when the king 1 Remove the cotter pin and the clevis pin from pins are removed if it is not both the steering cylinder and the tie rod properly supported Always use a new cotter pin when installing a clevis pin Specifications Lubricated Dry Lug nut torque 94 ft lbs 125 ft Ibs 127 Nm 169 Nm How to Remove the Hub and Bearings 1 Loosen the wheel lug nuts Do not remove a axe b retaining fastener them d oo 2 Block the non steer wheels and place a lifting a jack under the steer axle x oie pin 3 Raise the machine and place blocks under h tie rod the drive chassis for support 2 Loosen the wheel lug nuts Do not 4 Remove the lug nuts Then remove the tire remove them and wheel as
271. ture in the distributor cap will cause the engine to run poorly 6 Inspect the cap and rotor for corrosion cracks and abrasion Replace the cap and rotor if they are damaged 7 Install the rotor cap then connect the coil and spark plug wires 8 Start the engine and check for smooth operation 9 Replace the Spark Plugs Kubota Gasoline LPG Models Periodic replacement of the spark plugs is essential to good engine performance and service life Worn loose or corroded spark plugs will cause the engine to perform poorly and may result in component damage Perform this procedure with the engine off Label then disconnect the plug wires from the spark plugs by grasping the molded boot Do not pull on the plug wire Blow out any debris around spark plugs Remove all the spark plugs from the engine Adjust the gap on each new spark plug Install the new spark plugs then connect the wires Be sure that each spark plug wire is attached to the correct spark plug Spark plug specifications Spark plug type NGK BCP4ES 11 Spark plug gap 0 039 to 0 043 inch 1 0 to 1 1 mm Spark plug torque 14 to 18 ft lbs 20 to 24 Nm 4 36 Genie Z 34 22 IC Part No 43037 Service Manual First Edition Section 4 Scheduled Maintenance Procedures C 10 Check and Adjust the Air LPG Mixture Kubota Gasoline LPG Models Maintaining the proper air to fuel mixture during liquid propane gas LPG
272. uel Filter Water Separator Kubota Diesel Models 4 11 A 17 Check the Engine B lt iiis rete nie ween 4 12 A 18 Replace the Engine Oil and Filter 4 12 1 Check the since 4 14 2 Check the Engine Choke Kubota Gasoline LPG Models 4 14 B 3 Check the Exhaust System 4 15 B 4 Check the Battery 4 15 B 5 Inspect the Electrical entente rnit kun euni 4 16 B 6 Inspect the Tires and Wheels including lug nut torque 4 16 B 7 Confirm the Proper Brake Configuration 4 17 B 8 Check the Oil Level the Torque 4 17 B 9 Check the Glow Plugs Kubota Diesel Models 4 18 B 10 Check and Adjust the Engine RPM 000001 4 18 B311 est the Key SWItChuur p huu 4 20 B 12 Test the Emergency Stop Buttons 444 00000 4 20 B 13 Test the Ground Control Ovefride 4 21 B 14 Test the Platform Self leveling 4 21 B 15 Test the Service Horn 4 22 B 16 Test the Foot Switch 4 22 B 17 Test the Engine Idle 0 040 4 23
273. ully adjusted for proper balancing 10 Remove and label the wear pads from the extension cylinder Pay careful attention to the location of each wear pad 7 16 Genie Z 34 22 IC Part No 43037 Service Manual First Edition Section 7 Repair Procedures 4 3 Primary Boom Lift Cylinder The lift cylinder 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 Bodily injury hazard This procedure requires specific repair skills lifting equipment and a suitable workshop Attempting this procedure without these skills and tools may result in death or serious injury and significant component damage Dealer service is strongly recommended 1 Raise the primary boom enough to access the primary boom lift cylinder rod end pivot pin 2 Attach an overhead crane to the primary boom for support Do not lift it 3 Place a block of wood across the upper secondary boom to support the cylinder when the rod end pin is removed Support the cylinder with a lifting device 4 Raise the secondary boom enough to access the primary boom lift cylinder barrel end pivot pin 5 Remove the rear turntable cover 6 Place a 4x4 inch block between the lower compression arms and the cross member of the upper secondary boom Carefully lower the secondary boom onto the block Crushin
274. ure all other functions operate normally Hold the steer switch Repair open in blu wire left and check voltage circuit from steer switch at TB36 to TB36 Hold the steer switch left Repair open in blu wire and check voltage at blu circuit from TB36 to wire on steer valve steer valve 0 or Remove both wires from infinite steer left coil and check ohms Replace steer left resistance across coil valve coil terminals 4 to 8 ohms Replace steer valve OR consult Genie Industries Service Department 5 76 Genie Z 34 22 IC Part No 43037 Service Manual First Edition Section 5 Troubleshooting Flow Charts Chart 32 Steer Right Start the engine from por or the platform press down steer microswitch in Function foot switch hold the controller handle Inoperative steer switch right and check voltage at terminal 7 on the drive Be sure all other controller blu blk wire functions operate normally Hold the steer switch Repair open in blu blk right and check voltage wire circuit from steer at TB37 Switch to TB37 Hold the steer switch right and check voltage at blu blk wire on steer valve Repair open in blu blk wire circuit from TB37 to steer valve 0 or Remove both wires from infinite steer right coil and ohms check resistance across coil terminals Replace steer right valve coil 4 to 8 ohms Replace steer valve OR consult Genie Indust
275. ut off valve is in the on position Be sure the engine glow plugs operate normally See the Maintenance Section no continuity Check battery condition OR check alternator OR check for short circuits OR check battery cables OR replace the battery Check if radiator and or engine block feels excessively hot not hot Remove wht wire from continuit temperature sending unit Check continuity to ground on temperature sending unit no continuity Remove wht wire from TB24 continuit Chart 3 Check engine oil level OR check radiator fins for clogging OR check engine fan belts OR see Kubota service manual for troubleshooting an overheating engine Replace temperature switch sender Repair short in wht wire circuit from TB24 to temperature sender no continuity Repair short in wht wire circuit from ign start module to TB24 OR consult Genie Industries Service Department Hold start switch and 12V Replace the fuel check voltage at the blk solenoid wire where connects to the red wire of the fuel solenoid pull side Continued on the next page Part No 43037 Genie Z 34 22 IC 5 11 Section 5 Troubleshooting Flow Charts Service Manual First Edition CHART 3 Hold start switch and Repair open in wht 21 check voltage at wht 21 12V wire from CR2 to where wire on terminal 87 of it connects to the wht CR2 wire of the fuel solenoid hold
276. ut to the on position activate the function enable toggle switch TS19 if equipped and thejib toggle switch TS26 on ground panel in down direction and check voltage at TB44 With key switch in platform position both Emergency Stop switches pulled out into on position and boom function speed controller turned to 9 activate footswitch and jib function toggle switch TS12 on platform control panel in down direction and check voltage on wht wire on boom function directional valve coil item B Troubleshoot jib function toggle switch TS26 on ground control panel OR replace diode on TS26 OR repair open in grn blk 44 wire circuit from TS26 to boom function directional valve coil item B OR consult Genie Industries Service Department Repair open in grn blk 44 wire circuit from TB44 to boom function directional valve coil item B OR repair open in ground wire circuit to manifold item B Troubleshoot jib function toggle switches TS26 and TS12 on ground and platform control panels OR replace diodes on TS26 and 512 OR repair open in grn blk 44 wire circuit from TS26 and TS12 to boom function directional valve coil item B OR consult Genie Industries Service Department If voltage to boom function directional valve coil item B from TS26 and TS12 has been restored and jib down function is still inoperative please continue troubleshooting from beginning of chart Genie Z 34 22 I
277. ve Exchange platform level up and down counterbalance valves Replace defective item F G and counterbalance valve activate platform level down function function inoperative Install a 0 to 5000 PSI Check for mechanical pressure gauge at the restrictions keeping quick disconnect platform level down coupling on the boom function from moving function manifold and OR repair or replace activate the platform slave cylinder OR level down function replace slave cylinder m valves consult Genie less than 3200 PSI Industries Service Department Test master cylinder refer to Chart 22 OR repair or replace slave cylinder or slave cylinder counterbalance valves OR boom function manifold could have an internal fault Consult Genie Industries Service Department Part No 43037 Genie 2 34 22 IC 5 63 Section 5 Troubleshooting Flow Charts Service Manual First Edition Chart 27 Platform Rotate Left Function inoperative Be sure all other functions operate normally If platform rotate left function operates normally from the ground controls but not from the platform controls troubleshoot the platform controller or diode See Repair Section If platform rotate left function operates normally from the platform controls but not from the ground controls troubleshoot the ground control toggle switch OR diode OR R1 resistor See Repair Section With key switch in ground position and both Emergency Stop
278. ve the fasteners from the hydraulic tank hold down straps Remove the straps 4 Attach a strap from an overhead crane to the hydraulic tank and remove it from the machine 5 Remove the suction strainers and clean them using a mild solvent 6 Rinse out the inside of the tank with a mild solvent 7 Install the suction strainers using a thread sealant on the threads 8 Re install the tank the machine Install the hydraulic tank hold down straps 9 Install the plug on the drain hose 10 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 11 Clean up any oil that may have spilled Properly discard of oil Hydraulic Oil Specifications Hydraulic oil type Dexron equivalent Hydraulic tank capacity 18 gallons 68 1 liters Hydraulic system 2WD Models 21 gallons including tank 79 5 liters Hydraulic system 4WD Models 22 gallons including tank 83 3 liters 4 40 Genie Z 34 22 IC Part No 43037 Service Manual First Edition Section 4 Scheduled Maintenance Procedures D 2 Change or Recondition the Engine Coolant Replacing or reconditioning the engine coolant is essential to good engine performance and service life Old or dirty coolant may cause the engine to perform poorly and continued use may cause engine damage Extremely dirty conditions may require coolant to be changed more frequently Bodily in
279. wire on boom function speed controller OR consult Genie Industries Service Department If voltage to TB6 from TS23 TS9 has been restored and boom extend function is still inoperative please continue troubleshooting from beginning of chart Part No 43037 Genie Z 34 22 IC Section 5 Troubleshooting Flow Charts CHART 20 With key switch in ground position and both Emergency Stop switches pulled out to the on position activate the function enable toggle switch TS19 if equipped and the ext ret boom toggle switch TS23 on ground panel in extend direction and check voltage on blk 7 wire on boom function directional valve coil item U Continued from the previous page 12V or more Continued on the next page Service Manual First Edition SS With key switch in ground position and both Emergency Stop switches pulled out to the on position activate the function enable toggle switch TS19 if equipped and the ext ret boom toggle switch TS23 on ground panel in extend direction and check voltage at TB7 With key switch in platform position both Emergency Stop switches pulled out to the on position and boom function speed controller turned to 9 activate footswitch and ext ret boom function toggle switch TS9 on platform control panel in extend direction and check voltage TB7 Troubleshoot ext ret boom function toggle switch TS23 on ground cont
280. ys or 50 hours of usage After this interval refer to the maintenance tables for continued scheduled maintenance 1 Perform the following maintenance procedures A 18 Replace the Engine Oil and Filter B 6 Inspect Tires and Wheels C 2 Check the Turnable Rotation Bearing Bolts C 6 Replace the Hydraulic Filters A 15 Clean the Air Filter Element Kubota engine specifications require that this procedure be performed every 50 hours Perform this procedure more often if dusty conditions exist 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 Perform this procedure with the engine off 1 Diesel models Remove the retaining fastener from the air cleaner element end cap Remove the end cap Gasoline LPG models Release the latches from the air cleaner canister end cap Remove the end cap 2 Remove the filter element 3 Clean the inside of the canister and the end cap with a damp cloth 4 Inspect the air filter element If needed blow from the inside out using low pressure dry compressed air or carefully tap out dust Replace the filter if needed 5 Install the filter element 6 Diesel models Install the air cleaner element end cap retaining fastener Gasoline LPG models Install the air cleaner end cap and secure the latches 4 10 Genie Z 34 22 IC Part No

Service Manual - Genie Industries

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