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Service Manual
Part No. 119987
Refer to inside cover for additional serial number information
June 2007
(from serial number 1187 to 3241)
Rev A
Introduction
June 2007
Introduction
Important
Serial Number Information
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.
Genie Industries offers the following Service
Manual for this models:
This manual provides detailed scheduled
maintenance information for the machine owner
and user. It also provides repair procedures for
qualified service professionals.
Title
Part No.
Z-34/22 IC Service Manual, First Edition
(from serial number 101 to 1186) ......................... 43037
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.
Z-34/22 IC Service Manual
(from serial number 3242 to 4799) ..................... 128267
Z-34/22 IC Service Manual
(from serial number 4800) .................................. 128300
Technical Publications
Genie Industries has endeavored to deliver the
highest degree of accuracy possible. However,
continuous improvement of our products is a Genie
policy. Therefore product specifications are subject
to change without notice.
Readers are encouraged to notify Genie of errors
and send in suggestions for improvement. All
communications will be carefully considered for
future printings of this and other manuals.
Contact Us:
Copyright © 1997 by Genie Industries
http://www.genieindustries.com
e-mail: [email protected]
119987 Rev A June 2007
Second Edition, First Printing
"Genie" and "Z" are registered trademarks of
Genie Industries in the USA and many other
countries.
Printed on recycled paper
Printed in U.S.A.
ii
Z-34/22 IC
Part No. 119987
June 2007
INTRODUCTION
Serial Number Legend
Model: Z-34/22
Z342207-12345
Serial number:
Model year: 2007 Manufacture date: 02/01/07
Electrical schematic number: ESXXXX
Machine unladen weight:
Rated work load (including occupants): XX kg
Maximum number of platfrm occupants: XX
Maximum allowable side force : XX N
Maximum allowable inclination of the chassis:
0 deg
Z3422 07 - 12345
Maximum wind speed : XX m/s
Maximum platform height : XX m
Model
Maximum platform reach : XX m
Gradeability: N/A
Sequence
number
Model year
Country of manufacture: USA
This machine complies with:
ANSI A92.5
CAN B.354.4
Serial number
stamped on chassis
Genie Industries
18340 NE 76th Street
Serial label
(located under cover)
Redmond, WA 98052
USA
PN - 77055
Part No. 119987
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Z-34/22 IC
Part No. 119987
June 2007
Section 1 • Safety Rules
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. 119987
Z-34/22 IC
v
Section 1 • Safety Rules
June 2007
SAFETY RULES
Be sure to wear protective eye wear and
other protective clothing if the situation
warrants it.
Personal Safety
Any person working on or around a machine must
be aware of all known safety hazards. Personal
safety and the continued safe operation of the
machine should be your top priority.
Read each procedure thoroughly. This
manual and the decals on the machine
use signal words to identify the following:
Safety alert symbol—used to alert
personnel to potential personal
injury hazards. Obey all safety
messages that follow this symbol
to avoid possible injury or death.
Used to indicate the presence of
an imminently hazardous situation
which, if not avoided, will result in
death or serious injury.
Used to indicate the presence of a
potentially hazardous situation
which, if not avoided, could result
in death or serious injury.
With safety alert symbol—used to
indicate the presence of a
potentially hazardous situation
which, if not avoided, may result in
minor or moderate injury.
Without safety alert symbol—used
to indicate the presence of a
potentially hazardous situation
which, if not avoided, may result in
property damage.
Be aware of potential crushing hazards
such as moving parts, free swinging or
unsecured components when lifting or
placing loads. Always wear approved steel-toed
shoes.
Workplace Safety
Be sure to keep sparks, flames and
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 any forklift, overhead crane or
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
time use (i.e., cotter pins and self-locking
nuts) are not reused. These components
may fail if they are used a second time.
Used to indicate operation or
maintenance information.
vi
Z-34/22 IC
Be sure to properly dispose of old oil or
other fluids. Use an approved container.
Please be environmentally safe.
Be sure that your workshop or work area
is properly ventilated and well lit.
Part No. 119987
June 2007
Table of Contents
Introduction
Important Information .................................................................................................. ii
Serial Number Information ........................................................................................... ii
Serial Number Legend ................................................................................................ iii
Section 1
Safety Rules
General Safety Rules ................................................................................................. v
Section 2
Rev
A
Specifications
Machine Specifications .......................................................................................... 2 - 1
Performance Specifications ................................................................................... 2 - 2
Hydraulic Specifications ........................................................................................ 2 - 3
Manifold Component Specifications ...................................................................... 2 - 4
Machine Torque Specifications .............................................................................. 2 - 4
Kubota D-905 Engine Specifications ..................................................................... 2 - 5
Kubota DF-750 Engine Specifications ................................................................... 2 - 6
Kubota DF-752 Engine Specifications ................................................................... 2 - 7
Hydraulic Hose and Fitting Torque Specifications ................................................. 2 - 8
SAE and Metric Fastener Torque Chart ................................................................ 2 - 9
Part No. 119987
Z-34/22 IC
vii
June 2007
TABLE OF CONTENTS
Section 3
Rev
Scheduled Maintenance Procedures
Introduction ........................................................................................................... 3 - 1
Pre-Delivery Preparation ....................................................................................... 3 - 3
Maintenance Inspection Report ............................................................................. 3 - 5
A
Checklist A Procedures
A-1
Inspect the Manuals and Decals .................................................................. 3 - 7
A-2
Perform Pre-operation Inspection ................................................................ 3 - 8
A-3
Perform Function Tests ............................................................................... 3 - 8
A-4
Perform Engine Maintenance ...................................................................... 3 - 9
A-5
Perform 30 Day Service ............................................................................... 3 - 9
A-6
Perform Engine Maintenance .................................................................... 3 - 10
A-7
Perform Engine Maintenance .................................................................... 3 - 10
A-8
Grease the Turntable Rotation Bearing and Worm Drive Gear .................. 3 - 11
A-9
Perform Engine Maintenance .................................................................... 3 - 12
A-10 Drain the Fuel Filter/Water Separator - Diesel Models ............................... 3 - 12
A-11 Perform Engine Maintenance .................................................................... 3 - 14
A
Checklist B Procedures
B-1
Check the Engine Choke - Gasoline/LPG Models ..................................... 3 - 15
B-2
Check the Exhaust System ........................................................................ 3 - 16
B-3
Inspect the Battery ..................................................................................... 3 - 16
B-4
Inspect the Electrical Wiring ....................................................................... 3 - 18
B-5
Inspect the Tires, Wheels and Lug Nut Torque .......................................... 3 - 18
B-6
Confirm the Proper Brake Configuration .................................................... 3 - 19
B-7
Check the Oil Level in the Drive Hubs ....................................................... 3 - 19
B-8
Check the Glow Plugs - Diesel Models ...................................................... 3 - 20
B-9
Check and Adjust the Engine RPM ............................................................ 3 - 21
B-10 Test the Ground Control Override .............................................................. 3 - 22
B-11 Test the Platform Self-leveling ................................................................... 3 - 23
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Z-34/22 IC
Part No. 119987
June 2007
TABLE OF CONTENTS
Section 3
Rev
Scheduled Maintenance Procedures, continued
B-12 Test the Engine Idle Select ........................................................................ 3 - 23
B-13 Test the Fuel Select Operation - Gasoline/LPG Models ............................. 3 - 24
B-14 Test the Drive Brakes ................................................................................ 3 - 25
B-15 Test the Drive Speed - Stowed Position ..................................................... 3 - 26
B-16 Test the Drive Speed - Raised or Extended Position .................................. 3 - 27
B-17 Inspect the Fuel and Hydraulic Tank Cap Venting Systems ....................... 3 - 28
B-18 Perform Hydraulic Oil Analysis ................................................................... 3 - 29
B-19 Test the Alarm Package (if equipped) ........................................................ 3 - 29
B-20 Replace the Diesel Fuel Filter/Water Separator Element Diesel Models ............................................................................................ 3 - 30
B-21 Perform Engine Maintenance - Diesel Models ............................................ 3 - 32
A
A
A
Part No. 119987
Checklist C Procedures
C-1
Clean the Fuel Tank - Diesel Models ......................................................... 3 - 33
C-2
Perform Engine Maintenance - Diesel Models ........................................... 3 - 34
C-3
Perform Engine Maintenance - Diesel Models ........................................... 3 - 34
Checklist D Procedures
D-1
Check the Primary Boom Wear Pads ........................................................ 3 - 35
D-2
Check the Free-wheel Configuration .......................................................... 3 - 35
D-3
Replace the Drive Hub Oil ......................................................................... 3 - 36
D-4
Replace the Hydraulic Filters ..................................................................... 3 - 37
D-5
Check the Turntable Rotation Bearing Bolts .............................................. 3 - 39
D-6
Inspect for Turntable Bearing Wear ........................................................... 3 - 40
D-7
Perform Engine Maintenance .................................................................... 3 - 41
Checklist E Procedures
E-1
Test or Replace the Hydraulic Oil .............................................................. 3 - 42
E-2
Grease the Steer Axle Wheel Bearings, 2WD Models ............................... 3 - 43
E-3
Perform Engine Maintenance .................................................................... 3 - 45
Z-34/22 IC
ix
June 2007
TABLE OF CONTENTS
Section 4
Rev
Repair Procedures
Introduction ............................................................................................................ 4 - 1
A
A
A
A
A
x
Platform Controls
1-1
Horsepower Limiter Board (before serial number 1547) ................................. 4 - 2
1-2
Drive Joystick (after serial number 1546) ..................................................... 4 - 4
Platform Components
2-1
Platform ....................................................................................................... 4 - 8
2-2
Platform Leveling Slave Cylinder .................................................................. 4 - 8
2-3
Platform Rotator ......................................................................................... 4 - 10
Jib Boom Components
3-1
Jib Boom .................................................................................................... 4 - 12
3-2
Jib Boom Bell Crank .................................................................................. 4 - 13
3-2
Jib Boom Lift Cylinder ................................................................................ 4 - 13
Primary Boom Components
4-1
Plastic Cable Track .................................................................................... 4 - 15
4-2
Primary Boom ............................................................................................ 4 - 15
4-3
Primary Boom Lift Cylinder ......................................................................... 4 - 19
4-4
Extension Cylinder ..................................................................................... 4 - 20
4-5
Platform Leveling Master Cylinder .............................................................. 4 - 22
Secondary Boom Components
5-1
Secondary Boom ........................................................................................ 4 - 25
5-2
Secondary Boom Lift Cylinder .................................................................... 4 - 29
Z-34/22 IC
Part No. 119987
June 2007
TABLE OF CONTENTS
Section 4
Rev
A
A
A
A
Part No. 119987
Repair Procedures, continued
Kubota D-905 Engine
6-1
Timing Adjustment ..................................................................................... 4 - 30
6-2
Glow Plugs ................................................................................................. 4 - 30
6-3
RPM Adjustment ........................................................................................ 4 - 30
6-4
Flex Plate ................................................................................................... 4 - 30
6-5
Coolant Temperature and Oil Pressure Switches ........................................ 4 - 31
Kubota DF-750/DF-752 Engine
7-1
Choke Adjustments .................................................................................... 4 - 32
7-2
Timing Adjustment ..................................................................................... 4 - 32
7-3
Carburetor Adjustment ................................................................................ 4 - 32
7-4
RPM Adjustment ........................................................................................ 4 - 32
7-5
Flex Plate ................................................................................................... 4 - 32
7-6
Coolant Temperature and Oil Pressure Switches ........................................ 4 - 33
Hydraulic Pumps
8-1
Auxiliary Pump ........................................................................................... 4 - 34
8-2
Function Pump ........................................................................................... 4 - 35
8-3
Drive Pump ................................................................................................ 4 - 36
Manifolds
9-1
Function Manifold Components .................................................................. 4 - 38
9-2
Valve Adjustments - Function Manifold ...................................................... 4 - 42
9-3
Jib Boom / Platform Rotate Manifold Components ..................................... 4 - 44
9-4
Brake / 2-speed Manifold Components ....................................................... 4 - 45
9-5
2WD Traction Manifold Components .......................................................... 4 - 46
9-6
4WD Traction Manifold Components .......................................................... 4 - 48
9-7
Valve Adjustments - Traction Manifold ....................................................... 4 - 50
9-8
Valve Coils ................................................................................................. 4 - 50
Z-34/22 IC
xi
June 2007
TABLE OF CONTENTS
Section 4
Rev
A
Repair Procedures, continued
Fuel and Hydraulic Tanks
10-1 Fuel Tank ................................................................................................... 4 - 53
10-2 Hydraulic Tank ........................................................................................... 4 - 54
A
Turntable Rotation Components
11-1 Rotation Hydraulic Motor ........................................................................... 4 - 55
A
Axle Components
12-1 Hub and Bearings, 2WD Models ................................................................ 4 - 56
Section 5
Rev
Schematics
Introduction ........................................................................................................... 5 - 1
xii
A
Electrical Symbols Legend .................................................................................... 5 - 2
A
Hydraulic Symbols Legend .................................................................................... 5 - 3
A
Electrical Schematic - Diesel Models
(from serial number 1187 to 1546) ........................................................................ 5 - 5
A
Electrical Schematic - Diesel Models
(from serial number 1547 to 1996) ........................................................................ 5 - 7
A
Electrical Schematic - Diesel Models
(from serial number 1997 to 3241) ........................................................................ 5 - 9
A
Electrical Schematic - Gasoline/LPG Models
(from serial number 1187 to 1546) ...................................................................... 5 - 11
A
Electrical Schematic - Gasoline/LPG Models
(from serial number 1547 to 1996) ...................................................................... 5 - 13
A
Electrical Schematic - Gasoline/LPG Models
(from serial number 1997 to 3241) ...................................................................... 5 - 15
Z-34/22 IC
Part No. 119987
June 2007
TABLE OF CONTENTS
Section 5
Rev
Schematics, continued
A
Ground Control Box Wiring Diagram - Diesel Models
(from serial number 1187 to 1546) ...................................................................... 5 - 17
A
Ground Control Box Wiring Diagram - Diesel Models
(from serial number 1547 to 1985) ...................................................................... 5 - 18
A
Ground Control Box Wiring Diagram - Diesel Models
(from serial number 1986 to 3241) ...................................................................... 5 - 19
A
Ground Control Box Wiring Diagram - Gasoline/LPG Models
(from serial number 1187 to 1546) ...................................................................... 5 - 20
A
Ground Control Box Wiring Diagram - Gasoline/LPG Models
(from serial number 1547 to 1985) ...................................................................... 5 - 21
A
Ground Control Box Wiring Diagram - Gasoline/LPG Models
(from serial number 1986 to 3241) ...................................................................... 5 - 22
A
Platform Control Box Wiring Diagram - Diesel Models
(from serial number 1187 to 1546) ...................................................................... 5 - 23
A
Platform Control Box Wiring Diagram - Diesel Models
(from serial number 1547 to 1996) ...................................................................... 5 - 24
A
Platform Control Box Wiring Diagram - Diesel Models
(from serial number 1997 to 3241) ...................................................................... 5 - 25
A
Platform Control Box Wiring Diagram - Gasoline/LPG Models
(from serial number 1187 to 1546) ...................................................................... 5 - 26
A
Platform Control Box Wiring Diagram - Gasoline/LPG Models
(from serial number 1547 to 1996) ...................................................................... 5 - 27
A
Platform Control Box Wiring Diagram - Gasoline/LPG Models
(from serial number 1997 to 3241) ...................................................................... 5 - 28
A
Generator Option Wiring Diagram (from serial number 1547 to 1996) ................. 5 - 29
A
Generator Option Wiring Diagram (from serial number 1997 to 3241) ................. 5 - 30
A
Load Sense Option Wiring Diagram (from serial number 1187 to 1546) .............. 5 - 31
A
Load Sense Option Wiring Diagram (from serial number 1547 to 1996) .............. 5 - 32
A
Load Sense Option Wiring Diagram (from serial number 1997 to 3241) .............. 5 - 33
A
Hydraulic Schematic, 2WD Models (from serial number 1187 to 1546) ............... 5 - 34
A
Hydraulic Schematic, 2WD Models (from serial number 1547 to 2899) ............... 5 - 36
A
Hydraulic Schematic, 2WD Models (from serial number 2900 to 3241) ............... 5 - 38
A
Hydraulic Schematic, 4WD Models (from serial number 1187 to 1546) ............... 5 - 40
A
Hydraulic Schematic, 4WD Models (from serial number 1547 to 2899) ............... 5 - 42
A
Hydraulic Schematic, 4WD Models (from serial number 2900 to 3241) ............... 5 - 44
Part No. 119987
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Z-34/22 IC
Part No. 119987
June 2007
Section 2 • Specifications
Specifications
REV A
Machine Specifications
Tires and wheels
Tire size
Rough terrain
Industrial
10-16.5 NHS
9-14.5 LT
Tire ply rating
Overall tire diameter
Wheel diameter
Wheel width
Fluid capacities
Tread 6
Sidewall 6
30.5 in
77.5 cm
28 in
71.1 cm
16.5 in
42 cm
14.5 in
36.8 cm
10 in
25.4 cm
7 in
18 cm
Wheel lugs, 4WD
9 @ 5/8-18
Wheel lugs, 2WD
Front
Rear
8 @ 5/8-18
9 @ 5/8-18
8 @ 5/8-18
9 @ 5/8-18
45 psi
3.1 bar
100 psi
6.89 bar
125 ft-lbs
170 Nm
125 ft-lbs
170 Nm
Tire pressure
Lug nut torque
Fuel tank capacity
12 gallons
45.4 liters
Hydraulic tank capacity
18 gallons
68.1 liters
Hydraulic system capacity
(including tank)
22 gallons
83.3 liters
Drive hubs
Drive hub oil type:
17 fl oz
0.5 liter
EP 80-90W gear oil
API service classification GL5
For operational specifications, refer to the
Operator's Manual.
Continuous improvement of our products is a
Genie policy. Product specifications are
subject to change without notice.
Part No. 119987
Z-34/22 IC
2-1
Section 2 • Specifications
June 2007
SPECIFICATIONS
REV A
Performance Specifications
Drive speeds (maximum)
2WD
4WD
Boom stowed, high range 4.5 mph
7.2 km/h
40 ft/6.1 sec
12.2 m/6.1 sec
4.0 mph
6.4 km/h
40 ft/6.8 sec
12.2 m/6.8 sec
Boom raised or extended
0.6 mph
1km/h
40 ft/40 sec
12.2 m/40 sec
0.6 mph
1km/h
40 ft/40 sec
12.2 m/40 sec
Gradeability
See Operator's Manual
Boom function speeds, maximum
from platform controls (with rated load in platform)
Jib boom up
24 to 30 seconds
Jib boom down
15 to 21 seconds
Primary boom up
15 to 21 seconds
Primary boom down
13 to 19 seconds
Primary boom extend
24 to 30 seconds
Primary boom retract
14 to 20 seconds
Secondary boom up
15 to 21 seconds
Secondary boom down
11 to 17 seconds
Turntable rotate, 355°
62 to 68 seconds
Platform rotate, 160°
4 to 7 seconds
Continuous improvement of our products is a
Genie policy. Product specifications are
subject to change without notice.
2-2
Z-34/22 IC
Part No. 119987
June 2007
Section 2 • Specifications
REV A
SPECIFICATIONS
Hydraulic Specifications
Function manifold
Hydraulic fluid
System relief
valve pressure
Dexron equivalent
Drive pump
Type:
bi-directional variable
displacement piston pump
Displacement
per revolution
1.71 cu in
28 cc
Flow rate @ 3000rpm
22 gpm
84 L/min
Function pump
Type:
Fixed displacement gear pump
Displacement
per revolution
0.24 cu in
4 cc
Flow rate @ 3000rpm
3 gpm
11.4 L/min
Primary boom down relief
valve pressure
(before serial number 2901)
(after serial number 2900)
1600 psi
110 bar
Secondary boom down relief
valve pressure
1600 psi
110 bar
Primary boom extend relief
valve pressure
(before serial number 2901)
250 psi
17.2 bar
0.92 cu in
15 cc
2800 psi
193 bar
Type
Fixed displacement gear pump
Displacement
0.5 gpm
1.9 L/min
Auxiliary pump
relief pressure
3400 psi
234.5 bar
Hydraulic filters
Rear drive motors, all models
Displacement per revolution
1800 psi
124 bar
(from serial number 2901 to 3215)
Front drive motors, 4WD models
Displacement per revolution
1400 psi
96.5 bar
Auxiliary pump
Drive manifold
Hot oil shuttle relief pressure
3200 psi
220.7 bar
1.83 cu in
30 cc
Hydraulic tank
return line filter
Beta 10 ≥ 200
with 25 psi / 1.7 bar bypass
Medium pressure filter
Beta 3 ≥ 200
Medium pressure filter
bypass pressure
50 psi
3.45 bar
Continuous improvement of our products is a
Genie policy. Product specifications are
subject to change without notice.
Part No. 119987
Z-34/22 IC
2-3
Section 2 • Specifications
June 2007
SPECIFICATIONS
REV A
Manifold Component
Specifications
Machine Torque Specifications
Plug torque
3 /4
-10 center bolt, GR 8 (dry)
3 /4
-10 center bolt, GR 8 (lubricated)
Platform rotator
SAE No. 2
36 in-lbs / 4 Nm
SAE No. 4
10 ft-lbs / 13 Nm
SAE No. 6
14 ft-lbs / 19 Nm
3 /8
-16 bolts, GR 8 (dry)
SAE No. 8
38 ft-lbs / 51 Nm
3 /8
-16 bolts, GR 8 (lubricated)
SAE No. 10
41 ft-lbs / 55 Nm
SAE No. 12
56 ft-lbs / 76 Nm
380 ft-lbs
515 Nm
280 ft-lbs
379 Nm
44 ft-lbs
60 Nm
33 ft-lbs
45 Nm
Turntable rotate assembly
Rotate bearing mounting bolts, lubricated
Valve Coil Resistance
Note: The following coil resistance specifications are at
an ambient temperature of 68°F / 20°C. As valve coil
resistance is sensitive to changes in air temperature,
the coil resistance will typically increase or decrease by
4% for each 18°F / 20°C that your air temperature
increases or decreases from 68°F / 20°C.
Valve coil specifications
2 position 3 way solenoid valve, 10V DC
(schematic items V, S, Q, P, M, U, T,
R, O, N, AA, AB, CA, CB, CC and CD)
6Ω
3 position 4 way solenoid valve, 10V DC
(schematic item E, CH, CI)
6Ω
Proportional solenoid valve, 12V DC
(schematic item D)
5Ω
Rotate bearing motor
mounting bolts, lubricated
180 ft-lbs
244 Nm
93 ft-lbs
126 Nm
Drive motor and hubs
Drive hub mounting bolts, lubricated
Drive motor mounting bolts, lubricated
3/8 -16, GR 5
7/16
-14, GR 5
180 ft-lbs
244 Nm
23 ft-lbs
31 Nm
37 ft-lbs
50 Nm
Continuous improvement of our products is a
Genie policy. Product specifications are
subject to change without notice.
2-4
Z-34/22 IC
Part No. 119987
June 2007
Section 2 • Specifications
REV A
SPECIFICATIONS
Kubota D-905 Engine
Displacement
Injection system
54.86 cu in
0.90 liters
Number of cylinders
Bore and stroke
Horsepower, gross intermittent
Firing order
Compression ratio
Compression pressure
3
2.83 x 2.90 inches
72 x 73.6 mm
26 @ 3600 rpm
19.3kW
1-2-3
23:1
412 to 469 psi
28.4 to 32.3 bar
Low idle
1300 rpm
260 hz
High idle
3000 rpm
600 hz
Injection pump make
Injection timing
Valve clearance, cold
centrifugal mechanical
0.0057 to 0.0072 in
0.145 to 0.183 mm
13° to 25° BTDC
Injection pump pressure
Fuel requirement
1991 psi
137 bar
diesel number 2-D
Battery
Type
12V DC
Group
34/78
Quantity
1
Ampere hour
75AH
Cold cranking ampere
900A
Reserve capacity @ 25A rate
Governor
Bocsh MD
125 minutes
Starter motor
Brush length, new
0.5188 in
13 mm
Brush length, minimum
0.3346 in
8.5 mm
Engine coolant
Capacity
3.3 quarts
3.1 liters
Alternator
Output
30A, 14V DC
Fan belt deflection
1 /4
Lubrication system
Oil pressure
Oil capacity
(including filter)
Oil viscosity
requirements
to 3/8 inch
7 to 9 mm
36 to 64 psi
2.48 to 4.41 bar
5.4 quarts
5.1 liters
10W-30
Engine oil should have properties of API classification
CD/SE or CD/SF grades.
Continuous improvement of our products is a
Genie policy. Product specifications are
subject to change without notice.
Part No. 119987
Z-34/22 IC
2-5
Section 2 • Specifications
June 2007
SPECIFICATIONS
REV A
Kubota DF-750 Engine
Displacement
Starter motor
45.21 cu in
0.74 liters
Number of cylinders
3
Bore & stroke
2.68 x 2.68 inches
68 x 68 mm
Horsepower, gross intermittent
23.8 @ 3600 rpm
17.7 kW @ 3600 rpm
Firing order
1-2-3
Low idle
High idle
Governor
0.669 in
17 mm
Brush length wear limit
0.453 in
11.5 mm
Brush spring tension
Battery
Type
3000 rpm
600 hz
Ampere hour
75AH
Cold cranking ampere
900A
9:1
Reserve capacity @ 25A rate
Valve clearances, cold
Ignition coil secondary
resistance
Oil viscosity requirements
Above 9°F / -13°C
Below 10°F / -12°C
Ignition coil primary
resistance
Spark plug wire resistance
Lubrication system
28 to 64 psi
1.9 to 4.4 bar
3.9 quarts
3.7 liters
10W-30
5W-30
10.7 to 14.5 kΩ
@ 75°F / 24°C
10 to 22 kΩ
0.039 to 0.043 inches
1.0 to 1.1 mm
Engine coolant
Capacity
Fan belt deflection
2-6
1.3 to 1.6Ω
@ 75°F / 24°C
Spark plug gap
Fuel pump
Output
2.84 psi
0.19 bar
0.125 gpm
0.47 L/min
18° BTDC
NGK BCP4ES-11
Alternator
Fuel flow rate
125 minutes
Spark plug type
Use oils meeting API classification SF (labeled SF/CC
or SF/CD) for improved wear protection.
Static pressure
1
Ignition System
Ignition spark advance
0.0057 to 0.0072 inches
0.145 to 0.183 mm
34/78
Quantity
128 to 185 psi
8.8 to 12.7 bar
Pressure (psi) of lowest cylinder must be at least 90%
of highest cylinder
Oil capacity
(including filter)
12V DC
Group
Compression pressure (approx.)
Oil pressure
(operating temp. @ 3850 rpm)
50 to 91 ounces
13.9 to 25.3 Newtons
1600 rpm
320 hz
centrifugal ball
mechanical
Compression ratio
Brush length, new
3.1 quarts
2.9 liters
30A, 14V DC
1
/4 to 3/8 inch
7 to 9 mm
Continuous improvement of our products is a
Genie policy. Product specifications are
subject to change without notice.
Z-34/22 IC
Part No. 119987
June 2007
Section 2 • Specifications
REV A
SPECIFICATIONS
Kubota DF-752 Engine
Displacement
Starter motor
45.21 cu in
0.74 liters
Number of cylinders
3
Bore & stroke
2.68 x 2.68 inches
68 x 68 mm
Horsepower, gross intermittent
24.8 @ 3600 rpm
18.5 kW @ 3600 rpm
Firing order
1-2-3
Low idle
High idle
Governor
Valve clearances, cold
Oil capacity
(including filter)
Oil viscosity requirements
Above 9°F / -13°C
Below 10°F / -12°C
Battery
Type
12V DC
Cold cranking ampere
900A
128 to 185 psi
8.8 to 12.7 bar
0.0057 to 0.0072 inches
0.145 to 0.183 mm
28 to 64 psi
1.9 to 4.4 bar
3.4 quarts
3.25 liters
10W-30
5W-30
34/78
Quantity
Reserve capacity @ 25A rate
1
125 minutes
Ignition System
Ignition spark advance
Ignition coil primary
resistance
18° BTDC
1.3 to 1.6Ω
@ 75°F / 24°C
Ignition coil secondary
resistance
10.7 to 14.5 kΩ
@ 75°F / 24°C
#1 Spark plug wire resistance
2.81 to 4.79 kΩ
#2 Spark plug wire resistance
3.4 to 5.8 kΩ
#3 Spark plug wire resistance
3.57 to 6.09 kΩ
Spark plug type
NGK BKR4E-11
Spark plug gap
0.039 to 0.043 inches
1 to 1.1 mm
Engine coolant
Capacity
2.84 psi
0.19 bar
0.125 gpm
0.47 L/min
Continuous improvement of our products is a
Genie policy. Product specifications are
subject to change without notice.
Part No. 119987
50 to 91 ounces
13.9 to 25.3 Newtons
75AH
Fuel pump
Fuel flow rate
Brush spring tension
Ampere hour
Use oils meeting API classification SF (labeled SH/CC
or SH/CD) for improved wear protection.
Fuel pressure, static
0.453 in
11.5 mm
3000 rpm
600 hz
Lubrication system
Oil pressure
(operating temp. @ 3850 rpm)
Brush length wear limit
Group
9.2:1
Compression pressure (approx.)
0.669 in
17 mm
1600 rpm
320 hz
centrifugal ball mechanical
Compression ratio
Brush length, new
3.1 quarts
2.9 liters
Alternator
Output
30A, 14V DC
Fan belt deflection
1 /4
Z-34/22 IC
to 3/8 inch
7 to 9 mm
2-7
Section 2 • Specifications
June 2007
SPECIFICATIONS
REV A
Seal-Lok® fittings
Hydraulic Hose and Fitting
Torque Specifications
Your machine is equipped with Parker Seal-Lok®
fittings and hose ends. Genie specifications require
that fittings and hose ends be torqued to
specification when they are removed and installed
or when new hoses or fittings are installed.
SAE O-ring Boss Port
(tube fitting - installed into Aluminum)
1 Replace the O-ring. The O-ring must be
replaced anytime the seal has been broken.
The O-ring cannot be re-used if the fitting or
hose end has been tightened beyond finger
tight.
Note: The O-rings used in the Parker Seal Lok®
fittings and hose ends are custom-size O-rings.
They are not standard SAE size O-rings. They are
available in the O-ring field service kit (Genie part
number 49612).
2 Lubricate the O-ring before installation.
SAE Dash size
Torque
-4
11 ft-lbs / 14.9 Nm
-6
23 ft-lbs / 31.2 Nm
-8
40 ft-lbs / 54.2 Nm
-10
69 ft-lbs / 93.6 Nm
-12
93 ft-lbs / 126.1 Nm
-16
139 ft-lbs / 188.5 Nm
-20
172 ft-lbs / 233.2 Nm
-24
208 ft-lbs / 282 Nm
3 Be sure that the face seal O-ring is seated and
retained properly.
4 Position the tube and nut squarely on the face
seal end of the fitting and tighten the nut finger
tight.
5 Tighten the nut or fitting to the appropriate
torque per given size as shown in the table.
6 Operate all machine functions and inspect the
hoses and fittings and related components to
confirm that there are no leaks.
SAE O-ring Boss Port
Seal-Lok Fittings
(tube fitting - installed into Steel)
(hose end)
®
SAE Dash size
Torque
SAE Dash size
-4
16 ft-lbs / 21.7 Nm
-4
18 ft-lbs / 25 Nm
-6
35 ft-lbs / 47.5 Nm
-6
30 ft-lbs / 40 Nm
-8
60 ft-lbs / 81.3 Nm
-8
40 ft-lbs / 55 Nm
-10
105 ft-lbs / 142.4 Nm
-10
60 ft-lbs / 80 Nm
-12
140 ft-lbs / 190 Nm
-12
85 ft-lbs / 115 Nm
-16
210 ft-lbs / 284.7 Nm
-16
110 ft-lbs / 150 Nm
-20
260 ft-lbs / 352.5 Nm
-20
140 ft-lbs / 190 Nm
-24
315 ft-lbs / 427.1 Nm
-24
180 ft-lbs / 245 Nm
2-8
Z-34/22 IC
Torque
Part No. 119987
June 2007
Section 2 • Specifications
REV A
SPECIFICATIONS
SAE FASTENER TORQUE CHART
• This chart is to be used as a guide only unless noted elsewhere in this manual •
SIZE
Grade 5
THREAD
LUBED
20
28
1/4
5/16
3/8
7/16
1/2
9/16
5/8
3/4
7/8
1
1 1/8
1 1/4
1 1/2
LUBED
DRY
DRY
in- lbs
Nm
in- lbs
Nm
in- lbs
Nm
in- lbs
Nm
in- lbs
Nm
80
90
9
10.1
100
120
11.3
13.5
110
120
12.4
13.5
140
160
15.8
18
130
140
14.7
15.8
LUBED
18
24
16
24
14
20
13
20
12
18
11
18
10
16
9
14
8
12
7
12
7
12
6
12
A574 High Strength
Black Oxide Bolts
LUBED
Grade 8
DRY
LUBED
DRY
LUBED
f t - lbs
Nm
f t - lbs
Nm
f t - lbs
Nm
f t - lbs
Nm
f t - lbs
Nm
13
14
23
26
37
41
57
64
80
90
110
130
200
220
320
350
480
530
590
670
840
930
1460
1640
17.6
19
31.2
35.2
50.1
55.5
77.3
86.7
108.4
122
149
176
271
298
433
474
650
718
800
908
1138
1260
1979
2223
17
19
31
35
49
55
75
85
110
120
150
170
270
300
430
470
640
710
790
890
1120
1240
1950
2190
23
25.7
42
47.4
66.4
74.5
101.6
115
149
162
203
230
366
406
583
637
867
962
1071
1206
1518
1681
2643
2969
18
20
33
37
50
60
80
90
120
130
160
180
280
310
450
500
680
750
970
1080
1360
1510
2370
2670
24
27.1
44.7
50.1
67.8
81.3
108.4
122
162
176
217
244
379
420
610
678
922
1016
1315
1464
1844
2047
3213
3620
25
27
44
49
70
80
110
120
150
170
210
240
380
420
610
670
910
990
1290
1440
1820
2010
3160
3560
33.9
36.6
59.6
66.4
94.7
108.4
149
162
203
230
284
325
515
569
827
908
1233
1342
1749
1952
2467
2725
4284
4826
21
24
38
43
61
68
93
105
130
140
180
200
320
350
510
560
770
840
1090
1220
1530
1700
2670
3000
28.4
32.5
51.5
58.3
82.7
92.1
126
142
176
189
244
271
433
474
691
759
1044
1139
1477
1654
2074
2304
3620
4067
METRIC FASTENER TORQUE CHART
• This chart is to be used as a guide only unless noted elsewhere in this manual •
Class 4.6
Size
(m m )
5
6
7
LUBED
DRY
LUBED
Class 10.9
8.8
DRY
LUBED
Class 12.9
10.9
DRY
LUBED
12.9
DRY
in- lbs
Nm
in-lbs
Nm
in- lbs
Nm
in- lbs
Nm
in- lbs
Nm
in- lbs
Nm
in- lbs
Nm
in- lbs
Nm
16
19
45
1.8
3.05
5.12
21
36
60
2.4
4.07
6.83
41
69
116
4.63
7.87
13.2
54
93
155
6.18
10.5
17.6
58
100
167
6.63
11.3
18.9
78
132
223
8.84
15
25.2
68
116
1.95
7.75
13.2
22.1
91
155
260
10.3
17.6
29.4
LUBED
8
10
12
14
16
18
20
22
24
Class 8.8
4.6
DRY
LUBED
DRY
LUBED
DRY
LUBED
DRY
f t - lbs
Nm
f t -lbs
Nm
f t - lbs
Nm
f t - lbs
Nm
f t - lbs
Nm
ft - lbs
Nm
f t - lbs
Nm
f t - lbs
Nm
5.4
10.8
18.9
30.1
46.9
64.5
91
124
157
7.41
14.7
25.6
40.8
63.6
87.5
124
169
214
7.2
14.4
25.1
40
62.5
86.2
121
166
210
9.88
19.6
34.1
54.3
84.8
117
165
225
285
14
27.9
48.6
77.4
125
171
243
331
420
19.1
37.8
66
105
170
233
330
450
570
18.8
37.2
64.9
103
166
229
325
442
562
25.5
50.5
88
140
226
311
441
600
762
20.1
39.9
69.7
110
173
238
337
458
583
27.3
54.1
94.5
150
235
323
458
622
791
26.9
53.2
92.2
147
230
317
450
612
778
36.5
72.2
125
200
313
430
610
830
1055
23.6
46.7
81
129
202
278
394
536
682
32
63.3
110
175
274
377
535
727
925
31.4
62.3
108
172
269
371
525
715
909
42.6
84.4
147
234
365
503
713
970
1233
Part No. 119987
Z-34/22 IC
2-9
Section 2 • Specifications
June 2007
REV A
This page intentionally left blank.
2 - 10
Z-34/22 IC
Part No. 119987
June 2007
Section 3 • Scheduled Maintenance Procedures
Scheduled Maintenance Procedures
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
Observe and Obey:
Safety alert symbol—used to alert
personnel to potential personal
injury hazards. Obey all safety
messages that follow this symbol
to avoid possible injury or death.
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, six months, annually
and every two years as specified on the
Maintenance Inspection Report.
Used to indicate the presence of
an imminently hazardous situation
which, if not avoided, will result in
death or serious injury.
Failure to perform each procedure
as presented and scheduled could
result in death, serious injury or
substantial machine damage.
Used to indicate the presence of a
potentially hazardous situation
which, if not avoided, could result
in death or serious injury.
Immediately tag and remove from service a
damaged or malfunctioning machine.
With safety alert symbol—used to
indicate the presence of a
potentially hazardous situation
which, if not avoided, may result
in minor or moderate injury.
Repair any machine damage or malfunction
before operating machine.
Use only Genie approved replacement parts.
Without safety alert symbol—used
to indicate the presence of a
potentially hazardous situation
which, if not avoided, may result in
property damage.
Keep records on 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
Used to indicate operation or
maintenance information.
· Boom in the stowed position
· Turntable rotated with the boom between
the non-steer wheels
Indicates that a specific result is expected after
performing a series of steps.
· Key switch in the off position with the
key removed
Indicates that an incorrect result has occurred
after performing a series of steps.
· Wheels chocked
· All external AC power supply disconnected
from the machine
Part No. 119987
Z-34/22 IC
3-1
Section 3 • Scheduled Maintenance Procedures
June 2007
SCHEDULED MAINTENANCE PROCEDURES
Pre-delivery Preparation Report
Maintenance Symbols Legend
The following symbols have been
used in this manual to help
communicate the intent of the
instructions. When one or more of
the symbols appear at the
beginning of a maintenance
procedure, it conveys the meaning
below.
Indicates that tools will be required to
perform this procedure.
Indicates that new parts will be required
to perform this procedure.
The pre-delivery preparation report contains
checklists for each type of scheduled inspection.
Make copies of the Pre-delivery Preparation report
to use for each inspection. Store completed forms
as required.
Maintenance Schedule
There are five types of maintenance inspections
that must be performed according to a schedule—
daily, quarterly, six months, annual, and two years.
The Scheduled Maintenance Procedures Section
and the Maintenance Inspection Report have been
divided into five subsections—A, B, C, D and E.
Use the following chart to determine which
group(s) of procedures are required to perform a
scheduled inspection.
Inspection
Indicates that a cold engine will be
required to perform this procedure.
Checklist
Daily or every 8 hours
Quarterly or every 250 hours
Indicates that a warm engine will be
required to perform this procedure.
Six months or every 500 hours
Annual or every 1000 hours
Indicates that dealer service is required
to perform this procedure.
Two years or every 2000 hours
A
A+B
A+B+C
A+B+C+D
A+B+C+D+E
Maintenance Inspection Report
The maintenance inspection report contains
checklists for each type of scheduled inspection.
Make copies of the Maintenance Inspection Report
to use for each inspection. Store completed forms
for three years.
3-2
Z-34/22 IC
Part No. 119987
Pre-Deliver
Pre-Deliveryy Preparation
June 2007
Section 3 • Scheduled Maintenance Procedures
Fundamentals
Instructions
It is the responsibility of the dealer to perform the
Pre-delivery Preparation.
Use the operator’s manual on your machine.
The Pre-delivery Preparation is performed prior to each
delivery. The inspection is designed to discover if anything
is apparently wrong with a machine before it is put into
service.
A damaged or modified machine must never be used. If
damage or any variation from factory delivered condition is
discovered, the machine must be tagged and removed
from service.
Repairs to the machine may only be made by a qualified
service technician, according to the manufacturer's
specifications.
Scheduled maintenance inspections shall be performed by
qualified service technicians, according to the
manufacturer's specifications and the requirements listed
in the responsibilities manual.
The Pre-delivery Preparation consists of completing the
Pre-operation Inspection, the Maintenance items and the
Function Tests.
Use this form to record the results. Place a check in the
appropriate box after each part is completed. Follow the
instructions in the operator’s manual.
If any inspection receives an N, remove the machine from
service, repair and re-inspect it. After repair, place a check
in the R box.
Legend
Y = yes, completed
N = no, unable to complete
R = repaired
Comments
Pre-Delivery Preparation
Y
N
Pre-operation inspection completed
Maintenance items completed
Function tests completed
Model
Serial number
Date
Machine owner
Inspected by (print)
Inspector signature
Inspector title
Inspector company
Genie Industries USA
18340 NE 76th Street
PO Box 97030
Redmond, WA 98073-9730
(425) 881-1800
Genie UK
The Maltings, Wharf Road
Grantham, Lincolnshire
NG31- 6BH England
(44) 1476-584333
Copyright © 2002 by Genie Industries. Genie® is a registered trademark of Genie Industries.
Rev B
Part No. 119987
Z-34/22 IC
3-3
R
Section 3 • Scheduled Maintenance Procedures
June 2007
This page intentionally left blank.
3-4
Z-34/22 IC
Part No. 119987
June 2007
Section 3 • Scheduled Maintenance Procedures
Maintenance Inspection Report
Model
Checklist A - Rev A
A-1 Manuals and decals
Serial number
A-2 Pre-operation
inspection
Date
Hour meter
Machine owner
Inspected by (print)
Inspector signature
B-4 Electrical wiring
Perform after 40 hours:
A-5 30 Day Service
B-5 Tires, wheels and lug
nut torque
Perform after 50 hours:
B-6 Brake configuration
A-6 Engine maintenance
B-7 Drive hub oil level
Perform every 50 hours:
B-8 Glow plugs Diesel models
A-9 Engine maintenance
Instructions
· Make copies of this report to use for
each inspection.
A-10 Fuel filter/water
separator
· Select the appropriate checklist(s) for
the type of inspection to be
performed.
Daily or 8 hour
Inspection:
Quarterly or 250 hour
Inspection:
B-2 Exhaust system
B-3 Battery
A-8 Grease rotation bearing
Perform every 200 hours:
A-11 Engine maintenance
Y N R
B-1 Engine choke Gasoline/LPG models
A-4 Engine maintenance
Perform every 100 hours:
Inspector company
Checklist B - Rev A
A-3 Function tests
A-7 Engine maintenance
Inspector title
Y N R
B-9 Engine RPM
B-10 Ground control override
B-11 Platform self leveling
B-12 Engine idle select
B-13 Fuel select Gasoline/LPG models
B-14 Drive brakes
B-15 Drive speed - stowed
B-16 Drive speed - raised
or extended
A
B-17 Fuel and hydraulic
tank cap venting
A+B
B-18 Hydraulic oil analysis
Six Month or 500 hour
Inspection:
A+B+C
B-19 Alarm and beacon
B-20 Replace fuel filter/
separator Diesel models
Annual or 1000 hours
Inspection:
A+B+C+D
Perform every 400 hours:
2 Year or 2000 hour
Inspection:
A+B+C+D+E
· Place a check in the appropriate box
after each inspection procedure is
completed.
· Use the step-by-step procedures in
this section to learn how to perform
these inspections.
· If any inspection receives an “N”, tag
and remove the machine from service,
repair and re-inspect it. After repair,
place a check in the “R” box.
B-21 Engine maintenance Diesel models
Comments
Legend
Y = yes, acceptable
N = no, remove from service
R = repaired
Part No. 119987
Z-34/22 IC
3-5
Section 3 • Scheduled Maintenance Procedures
June 2007
MAINTENANCE INSPECTION REPORT
Model
Checklist C - Rev A
Serial number
C-1 Clean fuel tank Diesel models
Date
C-2 Engine maintenance Diesel models
Hour meter
Perform every 800 hours:
Machine owner
C-3 Engine maintenance Diesel models
Inspected by (print)
Checklist D - Rev A
Inspector signature
D-1 Boom wear pads
Inspector title
D-2 Free-wheel
configuration
D-4 Replace hydraulic filters
Instructions
· Make copies of this report to use for
each inspection.
D-5 Turntable rotation bolts
· Select the appropriate checklist(s) for
the type of inspection to be
performed.
D-7 Engine maintenance
Quarterly or 250 hour
Inspection:
Y N R
D-3 Drive hub oil
Inspector company
Daily or 8 hour
Inspection:
Y N R
D-6 Turntable bearing
wear
Checklist E - Rev A
Y N R
E-1 Replace hydraulic oil
A
E-2 Grease wheel bearings
E-3 Engine maintenance
A+B
Six Month or 500 hour
Inspection:
A+B+C
Annual or 1000 hours
Inspection:
A+B+C+D
2 Year or 2000 hour
Inspection:
A+B+C+D+E
Comments
· Place a check in the appropriate box
after each inspection procedure is
completed.
· Use the step-by-step procedures in
this section to learn how to perform
these inspections.
· If any inspection receives an “N”, tag
and remove the machine from service,
repair and re-inspect it. After repair,
place a check in the “R” box.
Legend
Y = yes, acceptable
N = no, remove from service
R = repaired
3-6
Z-34/22 IC
Part No. 119987
June 2007
REV A
Section 3 • Scheduled Maintenance Procedures
Checklist A Procedures
A-1
Inspect the Manuals and Decals
Genie specifications require that
this procedure be performed daily
or every 8 hours, whichever
comes first.
Maintaining the operator’s and safety manuals in
good condition is essential to safe machine
operation. Manuals are included with each
machine and should be stored in the container
provided in the platform. An illegible or missing
manual will not provide safety and operational
information necessary for a safe operating
condition.
In addition, maintaining all of the safety and
instructional decals in good condition is mandatory
for safe machine operation. Decals alert operators
and personnel to the many possible hazards
associated with using this machine. They also
provide users with operation and maintenance
information. An illegible decal will fail to alert
personnel of a procedure or hazard and could
result in unsafe operating conditions.
1 Check to make sure that the operator's and
safety manuals are present and complete in the
storage container on the platform.
Part No. 119987
2 Examine the pages of each manual to be sure
that they are legible and in good condition.
Result: The operator's manual is appropriate for
the machine and all manuals are legible and in
good condition.
Result: The operator's manual is not
appropriate for the machine or all manuals are
not in good condition or are illegible. Remove
the machine from service until the manual is
replaced.
3 Open the operator's manual to the decals
inspection section. Carefully and thoroughly
inspect all decals on the machine for legibility
and damage.
Result: The machine is equipped with all
required decals, and all decals are legible and
in good condition.
Result: The machine is not equipped with all
required decals, or one or more decals are
illegible or in poor condition. Remove the
machine from service until the decals are
replaced.
4 Always return the manuals to the storage
container after use.
Z-34/22 IC
Contact your authorized Genie
distributor or Genie Industries if
replacement manuals or decals
are needed.
3-7
Section 3 • Scheduled Maintenance Procedures
CHECKLIST A
June 2007
PROCEDURES
REV A
A-2
Perform Pre-operation Inspection
A-3
Perform Function Tests
Genie specifications require that
this procedure be performed daily
or every 8 hours, whichever
comes first.
Completing a pre-operation inspection is essential
to safe machine operation. The pre-operation
inspection is a visual inspection performed by the
operator prior to each work shift. The inspection is
designed to discover if anything is apparently
wrong with a machine before the operator performs
the function tests. The pre-operation inspection
also serves to determine if routine maintenance
procedures are required.
Complete information on how to perform this
procedure is available in the appropriate
Genie Z-34/22 IC Operator's Manual on your
machine.
3-8
Genie specifications require that
this procedure be performed daily
or every 8 hours, whichever
comes first.
Completing the function tests is essential to safe
machine operation. Function tests are designed to
discover any malfunctions before the machine is
put into service. A malfunctioning machine must
never be used. If malfunctions are discovered, the
machine must be tagged and removed from
service.
Complete information on how to perform this
procedure is available in the appropriate
Genie Z-34/22 IC Operator's Manual on your
machine.
Z-34/22 IC
Part No. 119987
June 2007
Section 3 • Scheduled Maintenance Procedures
CHECKLIST A
REV A
A-4
Perform Engine Maintenance
A-5
Perform 30 Day Service
Engine specifications require that
this procedure be performed every
8 hours or daily, whichever comes
first.
Required maintenance procedures and additional
engine information is available in the
Kubota DF750 Operator's Manual
(Kubota part number EG261-8916-1) OR the
Kubota DF752 Operator's Manual
(Kubota part number EG601-8916-1) OR the
Kubota D905 Operator's Manual
(Kubota part number 16622-8916-5).
Kubota DF750 Operator's Manual
Genie part number
97359
Kubota DF752 Operator's Manual
Genie part number
84250
Kubota D905 Operator's Manual
Genie part number
31743
Part No. 119987
PROCEDURES
The 30 day maintenance procedure is a onetime
sequence of procedures to be performed after the
first 30 days or 40 hours of usage. After this
interval, refer to the maintenance tables for
continued scheduled maintenance.
1 Perform the following maintenance procedures:
· A-11 Perform Engine Maintenance
· B-5 Inspect Tires, Wheels and
Lug Nut Torque
· D-4 Replace the Hydraulic Filters
· D-5 Check the Turnable Rotation Bearing
Bolts
Z-34/22 IC
3-9
Section 3 • Scheduled Maintenance Procedures
CHECKLIST A
June 2007
PROCEDURES
REV A
A-6
Perform Engine Maintenance
A-7
Perform Engine Maintenance
Engine specifications require that
this one time procedure be
performed after the first 50 hours
of operation.
Engine specifications require that
this procedure be performed every
50 hours or weekly, whichever
comes first.
Required maintenance procedures and additional
engine information is available in the
Kubota D905 Operator's Manual
(Kubota part number 16622-8916-5) OR the
Kubota DF750 Operator's Manual
(Kubota part number EG261-8916-1) OR the
Kubota DF752 Operator's Manual
(Kubota part number EG601-8916-1).
Required maintenance procedures and additional
engine information is available in the
Kubota D905 Operator's Manual
(Kubota part number 16622-8916-5) OR the
Kubota DF750 Operator's Manual
(Kubota part number EG261-8916-1) OR the
Kubota DF752 Operator's Manual
(Kubota part number EG601-8916-1).
Kubota D905 Operator's Manual
Genie part number
31743
Kubota D905 Operator's Manual
Genie part number
31743
Kubota DF750 Operator's Manual
Genie part number
97359
Kubota DF750 Operator's Manual
Genie part number
97359
Kubota DF752 Operator's Manual
Genie part number
84250
Kubota DF752 Operator's Manual
Genie part number
84250
3 - 10
Z-34/22 IC
Part No. 119987
June 2007
Section 3 • Scheduled Maintenance Procedures
REV A
CHECKLIST A
PROCEDURES
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.
A-8
Grease the Turntable Rotation
Bearing and Worm Drive Gear
5 Locate the grease fitting on the worm drive
housing.
a
Genie specifications require that
this procedure be performed every
100 hours.
Yearly application of lubrication to the turntable
bearing and worm drive gear is essential to good
machine performance and service life. Continued
use of an improperly greased gear will result in
component damage.
6 Pump grease into the gear until you see it
coming out of the side of the gear housing.
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.
Grease Specification
Crushing hazard. Keep hands
away from the cylinder and all
moving parts when lowering the
secondary boom.
a
grease fitting
7 Grease each tooth on the outside of the
turntable rotation bearing.
Chevron Ultra-duty grease, EP NLGI 2 (lithium based)
or equivalent
The lift cylinder safety chock is
available through Genie Service
Parts (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.
Part No. 119987
Z-34/22 IC
3 - 11
Section 3 • Scheduled Maintenance Procedures
CHECKLIST A
June 2007
PROCEDURES
REV A
A-9
Perform Engine Maintenance
A-10
Drain the Fuel Filter/ Water
Separator - Diesel Models
Engine specifications require that
this procedure be performed every
100 hours.
Required maintenance procedures and additional
engine information is available in the
Kubota D905 Operator's Manual
(Kubota part number 16622-8916-5) OR the
Kubota DF750 Operator's Manual
(Kubota part number EG261-8916-1) OR the
Kubota DF752 Operator's Manual
(Kubota part number EG601-8916-1).
Kubota D905 Operator's Manual
Genie part number
31743
Kubota DF750 Operator's Manual
Genie part number
97359
Kubota DF752 Operator's Manual
Genie part number
84250
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.
Explosion and fire hazard. Engine
fuels are combustible. Perform this
procedure in an open, wellventilated 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.
3 - 12
Z-34/22 IC
Part No. 119987
June 2007
Section 3 • Scheduled Maintenance Procedures
REV A
CHECKLIST A
1 Locate the fuel filter/water separator and loosen
the vent plug located on the fuel filter/water
separator head.
step 5.
2 Loosen the drain plug located at the bottom of
the bowl. Allow the water to drain into a suitable
a starts
b to come out.
container until fuel
Immediately tighten the drain plug.
c
PROCEDURES
4 Start the engine from the ground controls and
check the fuel filter/water separator for leaks.
Bleed the fuel system:
Before bleeding the system, fill the
fuel tank.
5 Loosen the vent plug/screw located on the filter
head.
6 Operate the hand primer until fuel, free of air,
flows from the vent plug/screw. Tighten the vent
plug/screw on the filter head.
7 Loosen the vent screw, located on top of the
fuel injection pump.
d
e
8 Operate the hand primer until fuel, free of air,
flows from the vent plug/screw. Tighten the vent
plug/screw on the injection pump.
9 Clean up any fuel that may have spilled.
10 Attempt to start the engine using the starter
motor for a maximum of 15 seconds, resting the
starter for 30 seconds before trying again.
11 Inspect the fuel filter/water separator for leaks.
a
b
c
d
e
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.
head bolt
vent plug
separator head
filter bowl
drain plug
Information to perform this
procedure is also available in
the Kubota D905 Operator's
Manual (Kubota part number
16622-8916-5).
3 Tighten the vent plug and clean up any spills or
wet surfaces.
If the fuel bowl is completely
drained, you must prime, or bleed,
the fuel filter/water separator
before starting the engine. See
Part No. 119987
Kubota D905 Operator's Manual
Genie part number
Z-34/22 IC
31743
3 - 13
Section 3 • Scheduled Maintenance Procedures
CHECKLIST A
PROCEDURES
June 2007
REV A
A-11
Perform Engine Maintenance
Engine specifications require that
this procedure be performed every
200 hours.
Required maintenance procedures and additional
engine information is available in the
Kubota D905 Operator's Manual
(Kubota part number 16622-8916-5) OR the
Kubota DF750 Operator's Manual
(Kubota part number EG261-8916-1) OR the
Kubota DF752 Operator's Manual
(Kubota part number EG601-8916-1).
Kubota D905 Operator's Manual
Genie part number
31743
Kubota DF750 Operator's Manual
Genie part number
97359
Kubota DF752 Operator's Manual
Genie part number
84250
3 - 14
Z-34/22 IC
Part No. 119987
June 2007
Section 3 • Scheduled Maintenance Procedures
Checklist B Procedures
REV A
2 Turn the key switch to ground control and then
pull out the ground control red Emergency Stop
button to the on position.
B-1
Check the Engine Choke Gasoline/LPG Models
3 While operating the choke switch, inspect the
choke solenoid.
Genie requires that this procedure
be performed every 250 hours or
quarterly, whichever comes first.
A properly functioning choke is essential to good
engine performance. An improperly functioning
choke will result in difficulty with engine starting.
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 red Emergency
Stop button to the on position and then operate
the choke switch and listen for choke solenoid
operation.
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
d
c
a
b
c
d
Part No. 119987
b
b
carburetor
linkage
linkage lock nuts
choke solenoid
Z-34/22 IC
3 - 15
Section 3 • Scheduled Maintenance Procedures
CHECKLIST B
June 2007
PROCEDURES
REV A
B-2
Check the Exhaust System
B-3
Inspect the Battery
Genie requires that this procedure
be performed every 250 hours or
quarterly, whichever comes first.
Genie requires that this procedure
be performed every 250 hours or
quarterly, whichever comes first.
Maintaining the exhaust system is essential to
good engine performance and service life. Running
the engine with a damaged or leaking exhaust
system can cause component damage and unsafe
operating conditions.
Proper battery condition is essential to good
machine performance and operational safety.
Improper fluid levels or damaged cables and
connections can result in component damage and
hazardous conditions.
Bodily injury hazard. Do not
inspect while the engine is
running. Remove the key to
secure from operation.
Electrocution hazard. Contact with
hot or live circuits could result in
death or serious injury. Remove all
rings, watches and other jewelry.
Bodily injury hazard. Beware of
hot engine components. Contact
with hot engine components may
cause severe burns.
Bodily injury hazard. Batteries
contain acid. Avoid spilling or
contacting battery acid. Neutralize
battery acid spills with baking soda
and water.
1 Pull up on the pull pin on the engine pivot plate
located under the pump. Swing the engine pivot
plate away from the machine to access the
exhaust system.
1 Put on protective clothing and eye wear.
2 Be sure that the battery cable connections are
free of corrosion.
2 Be sure that all nuts and bolts are tight.
Adding terminal protectors and a
corrosion preventative sealant will
help eliminate corrosion on the
battery terminals and cables.
3 Inspect all welds for cracks.
4 Inspect for exhaust leaks; i.e., carbon buildup
around seams and joints.
3 Be sure that the battery retainer and cable
connections are tight.
4 Fully charge the battery. Allow the battery to
rest 24 hours before continuing this procedure
to allow the battery cells to equalize.
3 - 16
Z-34/22 IC
Part No. 119987
June 2007
Section 3 • Scheduled Maintenance Procedures
CHECKLIST B
REV A
PROCEDURES
5 Remove the battery vent caps and check the
specific gravity of each battery cell with a
hydrometer. Note the results.
9 Check the ambient air temperature and adjust
the specific gravity reading for each cell as
follows:
6 Check the ambient air temperature and adjust
the specific gravity reading for each cell as
follows:
• Add 0.004 to the reading of each cell for
every 10° F / -12.2° C above 80° F / 26.7° C.
• Add 0.004 to the reading of each cell for
every 10° F / -12.2° C above 80° F / 26.7° C.
• Subtract 0.004 from the reading of each cell for
every 10° F / -12.2° C below 80° F / 26.7° C.
Result: All battery cells display an adjusted
specific gravity of 1.277 or higher. The battery
is fully charged. Proceed to step 10.
Result: One or more battery cells display a
specific gravity of 1.217 or below. Proceed to
step 7.
7 Perform an equalizing charge OR fully charge
the battery and allow the battery to rest at least
6 hours.
8 Remove the battery vent caps and check the
specific gravity of each battery cell with a
hydrometer. Note the results.
Part No. 119987
• Subtract 0.004 from the reading of each cell for
every 10° F / -12.2° C below 80° F / 26.7° C.
Result: All battery cells display a specific
gravity of 1.277 or greater. The battery is fully
charged. Proceed to step 10.
Result: The difference in specific gravity
readings between cells is greater than 0.1 OR
the specific gravity of one or more cells is less
than 1.217. Replace the battery.
10 Check the battery acid level. If needed,
replenish with distilled water to 1/8 inch / 3 mm
below the bottom of the battery fill tube. Do not
overfill.
11 Install the vent caps and neutralize any
electrolyte that may have spilled.
Z-34/22 IC
3 - 17
Section 3 • Scheduled Maintenance Procedures
CHECKLIST B
June 2007
PROCEDURES
REV A
B-4
Inspect the Electrical Wiring
B-5
Inspect the Tires, Wheels and
Lug Nut Torque
Genie requires that this procedure
be performed every 250 hours or
quarterly, whichever comes first.
Maintaining electrical wiring in good condition is
essential to safe operation and good machine
performance. Failure to find and replace burnt,
chafed, corroded or pinched wires could result in
unsafe operating conditions and may cause
component damage.
Electrocution hazard. Contact
with hot or live circuits may
cause death or serious injury.
Remove all rings, watches and
other jewelry.
Genie requires that this procedure
be performed every 250 hours or
quarterly, whichever comes first.
Maintaining the tires and wheels, including proper
wheel fastener torque, is essential to safe
operation and good performance. Tire and/or
wheel failure could result in a machine tip-over.
Component damage may also result if problems
are not discovered and repaired in a timely fashion.
Bodily injury hazard. An overinflated tire can explode and could
cause death or serious injury.
Tip-over hazard. Do not use
temporary flat tire repair products.
1 Inspect the following areas for burnt, chafed,
corroded and loose wires:
The tires on some machines are
foam-filled and do not need air
added to them.
· Engine compartment electrical panel
· Engine wiring harness
· Inside of the ground control box
1 Check all tire treads and sidewalls for cuts,
cracks, punctures and unusual wear.
· Turntable manifold wiring
2 Start the engine from the ground controls.
3 Raise the secondary boom until the mid-pivot is
10 feet / 3 m off the ground.
4 Inspect the turntable center area for burnt,
chafed and pinched cables.
5 Lower the boom to the stowed position and turn
the engine off.
2 Check each wheel for damage, bends and
cracked welds.
3 Check each lug nut for proper torque.
Refer to Section 2, Specifications.
4 Check the pressure in each air-filled tire.
Refer to Section 2, Specifications.
6 Inspect the following areas for burnt, chafed,
corroded, pinched and loose wires:
· Cable track on the primary, jib and
secondary booms
· Jib boom to platform cable harness
· Inside of the platform control box
3 - 18
Z-34/22 IC
Part No. 119987
June 2007
Section 3 • Scheduled Maintenance Procedures
CHECKLIST B
REV A
B-6
Confirm the Proper
Brake Configuration
PROCEDURES
B-7
Check the Oil Level in the
Drive Hubs
Genie requires that this procedure
be performed every 250 hours or
quarterly, whichever comes first.
Proper brake configuration is essential to safe
operation and good machine performance.
Hydraulically-released, spring-applied individual
wheel brakes can appear to operate normally when
they are actually not fully operational.
1 Check each torque hub disconnect cap to be
sure it is in the engaged position.
Genie requires that this procedure
be performed every 250 hours or
quarterly, whichever comes first.
Failure to maintain proper drive hub oil levels may
cause the machine to perform poorly and
continued use may cause component damage.
1 Drive the machine to rotate the hub until the
plugs are located one on top and the other at
90 degrees.
plugs
brake disengaged position
brake engaged position
Models with pipe plugs
plugs
Models with O-ring plugs
Part No. 119987
Z-34/22 IC
3 - 19
Section 3 • Scheduled Maintenance Procedures
CHECKLIST B
June 2007
PROCEDURES
REV A
2 Remove the plug located at 90 degrees and
check the oil level.
B-8
Check the Glow Plugs Diesel Models
Result: The oil level should be even with the
bottom of the plug hole.
3 If necessary, remove the top plug and add oil
until the oil level is even with the bottom of the
side plug hole.
Genie requires that this procedure
be performed every 250 hours or
quarterly, whichever comes first.
4 Apply pipe thread sealant to the plugs, then
install the plugs into the hub.
5 Repeat this procedure for each torque hub.
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
1.0Ω.
2 If the ohm reading is different than 1.0Ω,
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
1.8Ω for each individual glow plug.
3 Turn the key switch to ground control and pull
out the red Emergency Stop button to the on
position.
4 Connect the red (+) lead from a 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 12V DC.
3 - 20
Z-34/22 IC
Part No. 119987
June 2007
Section 3 • Scheduled Maintenance Procedures
REV A
CHECKLIST B
PROCEDURES
2 Turn the low idle adjustment screw on the
carburetor clockwise to increase rpm or
counterclockwise to decrease rpm.
B-9
Check and Adjust the
Engine RPM
a
b
c
d
e
Genie requires that this procedure
be performed every 250 hours or
quarterly, whichever comes first.
Maintaining the engine rpm at the proper setting for
both low and high idle is essential to good engine
performance and service life. The machine will not
operate properly if the rpm is incorrect and
continued use may cause component damage.
Gasoline/LPG Models:
Perform this procedure in gasoline
mode with the engine at normal
operating temperature.
Gasoline/LPG idle adjustments
a
solenoid boot
b
high idle adjustment nut
c
spring lock nut
d
low idle adjustment
e
carburetor
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.
3 Move the engine idle control switch to high idle
(rabbit symbol) from the ground controls.
Result: High idle should be 3000 rpm.
If high idle rpm is correct, disregard
adjustment steps 4 through 6.
4 Loosen the spring lock nut.
5 Turn the high idle adjustment nut and spring
lock nut clockwise to increase the rpm or
counterclockwise to decrease the rpm.
6 Tighten the spring lock nut. Then recheck the
rpm.
Part No. 119987
Z-34/22 IC
3 - 21
Section 3 • Scheduled Maintenance Procedures
CHECKLIST B
June 2007
PROCEDURES
REV A
Diesel models:
1 Connect an rpm gauge to the engine, and then
start the engine from the ground controls.
B-10
Test the Ground Control Override
Result: Low idle should be 1300 rpm.
Skip to step 3 if the low idle rpm is correct.
2 Loosen the lock nut, then turn the low idle
adjustment screw clockwise to increase the rpm
or counterclockwise to decrease the rpm.
Tighten the lock nut and recheck the rpm.
c
Genie requires that this procedure
be performed every 250 hours or
quarterly, whichever comes first.
A properly functioning ground control override is
essential to safe machine operation. The ground
control override function is intended to allow
ground personnel to operate the machine from the
ground controls whether or not the red Emergency
Stop button on the platform controls is in the on or
off position. This function is particularly useful if the
operator at the platform controls cannot return the
boom to the stowed position.
1 Push in the platform red Emergency Stop
button to the off position.
d
b
2 Turn the key switch to ground control and pull
out the red Emergency Stop button to the on
position.
a
Diesel idle adjustments
a
lock nut
b
high idle adjustment nut
c
low idle adjustment screw
d
rpm solenoid
3 Start the engine from the ground controls and
operate each boom function through a
partial cycle at the ground controls.
3 Move the engine idle control switch to high idle
(rabbit symbol) from the ground controls.
Result: All boom functions should operate.
Result: High idle should be 3000 rpm.
If high idle rpm is correct, disregard
adjustment step 4.
4 Loosen the lock nut on the solenoid, then turn
the solenoid boot counterclockwise to increase
the rpm or clockwise to decrease the rpm.
Tighten the lock nut and recheck the rpm.
3 - 22
Z-34/22 IC
Part No. 119987
June 2007
Section 3 • Scheduled Maintenance Procedures
CHECKLIST B
REV A
B-11
Test the Platform Self-leveling
B-12
Test the Engine Idle Select
Genie requires that this procedure
be performed every 250 hours or
quarterly, whichever comes first.
Automatic platform self-leveling throughout
the full cycle of boom raising and lowering is
essential for safe machine operation. The
platform is maintained at level by the platform
leveling slave cylinder which is controlled by the
master cylinder located at the base of the primary
boom. A platform self-leveling failure creates an
unsafe working condition.
1 Turn the key switch to ground control and pull
out the red Emergency Stop button to the on
position.
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.
PROCEDURES
Genie requires that this procedure
be performed every 250 hours or
quarterly, whichever comes first.
A properly operating engine idle select switch
is essential to good 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 idle.
Foot switch activated high idle (rabbit and foot
switch symbols) should be used for normal
machine operation. This selection activates high
idle only when the foot switch is pressed down.
1 Pull out the red Emergency Stop button to the
on position at both the ground and platform
controls.
2 Start the engine from the ground controls. Then
move the engine idle control switch to high idle
(rabbit symbol) and hold in the ON position.
Result: The engine should change to high idle.
3 Release the engine idle control switch.
Result: The engine should return to low idle.
4 Turn the key switch to platform controls.
5 At the platform controls, move the engine idle
control switch to high idle (rabbit symbol).
Result: The engine should change to high idle.
Part No. 119987
Z-34/22 IC
3 - 23
Section 3 • Scheduled Maintenance Procedures
CHECKLIST B
June 2007
PROCEDURES
REV A
6 Move the engine idle control switch to low idle
(turtle symbol).
Result: The engine should change to low idle.
B-13
Test the Fuel Select Operation Gasoline/LPG Models
7 Move the engine idle control switch to foot
switch activated high idle (rabbit and foot switch
symbol).
Genie requires that this procedure
be performed every 250 hours or
quarterly, whichever comes first.
Result: The engine should not change to
high idle.
8 Press down the foot switch.
Result: The engine should change to high idle.
The ability to select and switch between
gasoline and LPG fuels as needed is essential to
safe machine operation. A fuel selection can be
made when the engine is running or not.
Switching malfunctions and/or the failure of the
engine to start and run properly in both fuel
modes and through all idle speeds can indicate
fuel system problems that could develop into a
hazardous situation.
Perform this test after checking
the gasoline and LPG fuel levels,
and warming the engine to normal
operating temperature.
1 Move the fuel select switch to gasoline and then
move the engine idle control switch to foot
switch activated high idle (rabbit and foot switch
symbol).
2 Start the engine from the platform controls and
allow it to run at low idle.
3 Press down the foot switch to allow the engine
to run at high idle.
Result: The engine should start promptly and
operate smoothly in low and high idle.
3 - 24
Z-34/22 IC
Part No. 119987
June 2007
Section 3 • Scheduled Maintenance Procedures
CHECKLIST B
REV A
4 Release the foot switch and stop the engine.
PROCEDURES
B-14
Test the Drive Brakes
5 Move the fuel select switch to LPG.
6 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.
Genie requires that this procedure
be performed every 250 hours or
quarterly, whichever comes first.
Proper brake action is essential to safe machine
operation. The drive brake function should operate
smoothly, free of hesitation, jerking and unusual
noise. Hydrostatic brakes and hydraulicallyreleased individual wheel brakes can appear to
operate normally when not fully operational.
Bodily injury hazard. Be sure that
the machine is not in free-wheel or
partial free-wheel configuration.
See B-6, Confirm the Proper
Brake Configuration.
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.
Part No. 119987
Z-34/22 IC
3 - 25
Section 3 • Scheduled Maintenance Procedures
CHECKLIST B
June 2007
PROCEDURES
REV A
6 Choose a point on the machine; i.e., contact
patch of a tire, as a visual reference for use
when crossing the test line.
7 Bring the machine to top drive speed before
reaching the test line. Release the drive joystick
when your reference point on the machine
crosses the test line.
B-15
Test the Drive Speed Stowed Position
Genie requires that this procedure
be performed every 250 hours or
quarterly, whichever comes first.
8 Measure the distance between the test line and
your machine reference point.
The brakes must be able to hold
the machine on any slope it is able
to climb.
Proper drive function movement is essential to safe
machine operation. The drive function should
respond quickly and smoothly to operator control.
Drive performance should also be free of
hesitation, jerking and unusual noise over the
entire proportionally controlled speed range.
Select a test area that is firm, level
and free of obstructions.
1 Create start and finish lines by marking two
lines on the ground 40 feet / 12.2 m apart.
2 Start the engine from the platform controls.
3 Select high range drive (machine on level
surface symbol).
4 Move the engine idle control switch to foot
switch activated high idle (rabbit and foot
switch).
5 Lower the boom into the stowed position.
6 Choose a point on the machine; i.e., contact
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.
3 - 26
Z-34/22 IC
Part No. 119987
June 2007
Section 3 • Scheduled Maintenance Procedures
CHECKLIST B
REV A
PROCEDURES
7 Continue at full speed and note the time when
the machine reference point crosses the finish
line.
B-16
Test the Drive Speed Raised or Extended Position
8 Lower the boom to the stowed position and
extend the boom 1 foot / 30 cm.
Genie requires that this procedure
be performed every 250 hours or
quarterly, whichever comes first.
Proper drive function movement is essential to
safe machine operation. The drive function should
respond quickly and smoothly to operator control.
Drive performance should also be free of
hesitation, jerking and unusual noise over the
entire proportionally controlled speed range.
9 Choose a point on the machine; i.e., contact
patch of a tire, as a visual reference for use
when crossing the start and finish lines.
10 Bring the machine to top drive speed before
reaching the start line. Begin timing when your
reference point on the machine crosses the
start line.
11 Continue at top speed and note the time when
the machine reference point crosses the finish
line.
Select a test area that is firm, level
and free of obstructions.
1 Create start and finish lines by marking two
lines on the ground 40 feet / 12.2 m apart.
2 Start the engine from the platform controls.
3 Move the engine idle select switch to foot switch
activated high idle (rabbit and foot switch
symbol).
4 Press down the foot switch and raise the
primary boom above horizontal.
5 Choose a point on the machine; i.e., contact
patch of a tire, as a visual reference for use
when crossing the start and finish lines.
6 Bring the machine to top drive speed before
reaching the start line. Begin timing when your
reference point on the machine crosses the
start line.
Part No. 119987
Z-34/22 IC
3 - 27
Section 3 • Scheduled Maintenance Procedures
CHECKLIST B
June 2007
PROCEDURES
REV A
1 Remove the cap from the fuel tank.
B-17
Inspect the Fuel and Hydraulic
Tank Cap Venting Systems
2 Check for proper venting.
Result: Air passes through the fuel tank cap.
Proceed to step 4.
Result: If air does not pass through the cap,
clean or replace the cap. Proceed to step 3.
Genie requires that this procedure
be performed every 250 hours or
quarterly, whichever comes first.
Perform this procedure more often
if dusty conditions exist.
Free-breathing fuel and hydraulic tank caps are
essential for good machine performance and
service life. A dirty or clogged tank cap may cause
the machine to perform poorly and continued use
may cause component damage. Extremely dirty
conditions may require that the caps be inspected
more often.
Explosion and fire hazard. Engine
fuels are combustible. Perform this
procedure in an open, wellventilated area away from heaters,
sparks, flames and lighted
tobacco. Always have an
approved fire extinguisher within
easy reach.
When checking for positive tank
cap venting, air should pass freely
through the cap.
3 Using a mild solvent, carefully wash the cap
venting system. Dry using low pressure
compressed air. Repeat this procedure
beginning with step 2.
4 Install the fuel tank cap onto the fuel tank.
5 Remove the breather cap from the hydraulic
tank.
6 Check for proper venting.
Result: Air passes through the fuel tank cap.
Proceed to step 8.
Result: If air does not pass through the cap,
clean or replace the cap. Proceed to step 7.
Note: When checking for positive tank cap venting,
air should pass freely through the cap.
7 Using a mild solvent, carefully wash the cap
venting system. Dry using low pressure
compressed air. Repeat this procedure
beginning with step 6.
8 Install the breather cap onto the hydraulic tank.
3 - 28
Z-34/22 IC
Part No. 119987
June 2007
Section 3 • Scheduled Maintenance Procedures
REV A
CHECKLIST B
B-18
Perform Hydraulic Oil Analysis
PROCEDURES
B-19
Test the Alarm Package
(if equipped)
Genie requires that this procedure
be performed every 250 hours or
quarterly, whichever comes first.
Replacement or testing of the hydraulic oil is
essential for good machine performance and
service life. Dirty oil and a clogged suction strainer
may cause the machine to perform poorly and
continued use may cause component damage.
Extremely dirty conditions may require oil changes
to be performed more often.
Before replacing the hydraulic oil,
the oil may be tested by an oil
distributor for specific levels of
contamination to verify that
changing the oil is necessary.
If the hydraulic oil is not
replaced at the two year
inspection, test the oil quarterly.
Replace the oil when it fails the
test. See E-1, Test or Replace the
Hydraulic Oil.
Genie requires that this procedure
be performed every 250 hours or
quarterly, whichever comes first.
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 red
Emergency Stop button to the on 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 down
position, hold for a moment and then release
it. Move the secondary boom switch to the
down position, hold for a moment and then
release it.
Result: The descent alarm should sound when
each switch is held down.
3 Turn the key switch to platform control.
Part No. 119987
Z-34/22 IC
3 - 29
Section 3 • Scheduled Maintenance Procedures
CHECKLIST B
June 2007
PROCEDURES
REV A
4 At the platform controls pull out the red
Emergency Stop button to the on position.
Result: The flashing beacon should be on
and flashing.
5 Press down the foot switch. Move the primary
boom switch to the down position, hold for a
moment and then release it. Move the
secondary boom switch to the down position,
hold for a moment and then release it.
Result: The descent alarm should sound when
each control switch is held down.
6 Press down the foot switch. Move the drive
control handle off center, hold for a moment
and then release it. Move the drive control
handle off center in the opposite direction, hold
for a moment and then release it.
B-20
Replace the Diesel Fuel Filter/
Water Separator Element Diesel Models
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.
Explosion and fire hazard. Engine
fuels are combustible. Replace the
fuel filter in an open, wellventilated area away from heater,
sparks, flames and lighted
tobacco. Always have an
approved fire extinguisher within
easy reach.
Result: The travel alarm should sound when the
drive control handle is moved off center in
either direction.
Perform this procedure with the
engine off.
1 Locate the fuel filter/water separator and loosen
the vent plug located on the fuel filter/water
separator head.
3 - 30
Z-34/22 IC
Part No. 119987
June 2007
Section 3 • Scheduled Maintenance Procedures
CHECKLIST B
REV A
a
PROCEDURES
Bleed the fuel system:
b
Before bleeding the system, fill the
fuel tank.
c
10 Loosen the vent plug/screw located on the filter
head.
11 Operate the hand primer until fuel, free of air,
flows from the vent plug/screw. Tighten the vent
plug/screw on the filter head.
d
e
12 Loosen the vent screw, located on top of the
fuel injection pump.
13 Operate the hand primer until fuel, free of air,
flows from the vent plug/screw. Tighten the vent
plug/screw on the injection pump.
14 Clean up any fuel that may have spilled.
a
b
c
d
e
15 Attempt to start the engine using the starter
motor for a maximum of 15 seconds, resting the
starter for 30 seconds before trying again.
head bolt
vent plug
seperator head
filter bowl
drain plug
16 Inspect the fuel filter/water separator for leaks.
Explosion and fire hazard. If a fuel
leak is discovered, keep any
additional personnel from entering
the area and do not operate the
machine. Repair the leak
immediately.
2 Place a container under the filter bowl. Loosen
the drain plug located at the bottom of the bowl.
Completely drain the fuel.
3 Loosen the head bolt then rotate the filter bowl
counterclockwise and remove it.
Information to perform this
procedure is also available in the
Kubota D905 Operator's Manual
(Kubota part number
16622-8916-5).
4 Remove the filter element from the bowl.
5 Apply a thin layer of oil to the bowl gasket and
then install the new filter element onto the bowl.
6 Tighten the drain plug and fill the bowl and filter
assembly with clean diesel fuel.
Kubota D905 Operator's Manual
Genie part number
31743
7 Install the filter and bowl assembly onto the filter
head. Torque the head bolt to 65 in lbs / 7 Nm.
8 Tighten the vent plug.
9 Clean up any diesel fuel that may have spilled
during the installation procedure.
Part No. 119987
Z-34/22 IC
3 - 31
Section 3 • Scheduled Maintenance Procedures
CHECKLIST B
PROCEDURES
June 2007
REV A
B-21
Perform Engine Maintenance Kubota D905 Models
Engine specifications require that
this procedure be performed every
400 hours.
Required maintenance procedures and additional
engine information is available in the
Kubota D905 Operator's Manual
(Kubota part number 16622-8916-5).
Kubota D905 Operator's Manual
Genie part number
3 - 32
31743
Z-34/22 IC
Part No. 119987
June 2007
Section 3 • Scheduled Maintenance Procedures
Checklist C Procedures
REV A
2 Using an approved hand-operated pump, drain
the fuel tank into a suitable container. Refer to
Section 2, Specifications, for tank capacity.
C-1
Clean the Fuel Tank Diesel Models
Explosion and fire hazard. When
transferring fuel, connect a
grounding wire between the
machine and pump or container.
Genie requires that this procedure
be performed every 500 hours or
six months, whichever comes first.
Removing sediment from the fuel tank is essential
to good engine performance and service life. A
dirty fuel tank may cause the fuel filter to clog
prematurely resulting in poor engine performance
and possible component damage.
Explosion and fire hazard. Engine
fuels are combustible. Clean the
fuel tank in an open, wellventilated area away from heater,
sparks, flames and lighted
tobacco. Always have an
approved fire extinguisher within
easy reach.
Immediately clean up any fuel that
may have spilled during this
procedure.
1 Models with fuel shutoff valve: Turn the
manual fuel shutoff valve, located next to the
tank, to the closed position.
Be sure to only use a hand
operated pump suitable for use
with gasoline and/or diesel fuel.
3 Tag, disconnect and plug the fuel supply and
return hoses at the tank. Clean up any fuel that
may have spilled.
4 Models with metal fuel tank: Remove the tank
strap fasteners and remove the straps. Remove
the tank from the machine.
Models with plastic fuel tank: Remove the
tank retainer plate fasteners at the bulkhead.
Remove the tank from the machine.
Component damage hazard. The
fuel tank is plastic and may
become damaged if allowed to fall.
5 Rinse out the inside of the tank using a mild
solvent.
6 Models with metal fuel tank: Install the tank
onto the machine. Install the tank straps and
tighten the tank strap retaining fasteners.
Models with plastic fuel tank: Install the tank
onto the machine. Install the tank retainer plate
fasteners at the bulkhead.
7 Install the fuel supply and return hoses to the
tank. Tighten the clamps.
8 Models with fuel shutoff valve: Turn the
manual fuel shutoff valve, located next to the
tank, to the open position.
Part No. 119987
Z-34/22 IC
3 - 33
Section 3 • Scheduled Maintenance Procedures
June 2007
CHECKLIST C PROCEDURES
REV A
C-2
Perform Engine Maintenance Diesel Models
C-3
Perform Engine Maintenance Diesel Models
Engine specifications require that
this procedure be performed every
500 hours.
Engine specifications require that
this procedure be performed every
800 hours.
Required maintenance procedures and additional
engine information is available in the
Kubota D905 Operator's Manual
(Kubota part number 16622-8916-5).
Required maintenance procedures and additional
engine information is available in the
Kubota D905 Operator's Manual
(Kubota part number 16622-8916-5).
Kubota D905 Operator's Manual
Genie part number
Kubota D905 Operator's Manual
Genie part number
3 - 34
31743
Z-34/22 IC
31743
Part No. 119987
June 2007
Section 3 • Scheduled Maintenance Procedures
Checklist D Procedures
REV A
D-2
Check the Free-wheel
Configuration
D-1
Check the Primary Boom
Wear Pads
Genie requires that this procedure
be performed every 1000 hours or
annually, whichever comes first.
Genie requires that this procedure
be performed every 1000 hours or
annually, whichever comes first.
Maintaining the primary boom wear pads in good
condition is essential to safe machine operation.
Wear pads are placed on boom tube surfaces to
provide a low friction, replaceable wear pad
between moving parts. Improperly shimmed wear
pads or continued use of worn out wear pads may
result in component damage and unsafe operating
conditions.
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
site that is firm and level.
1 Turn the key switch to ground control and pull
out the red Emergency Stop button to the on
position.
1 Chock the steer wheels to prevent the machine
from rolling.
2 Extend the primary boom approximately
10 inches / 25 cm.
2 Center a lifting jack of ample capacity
(15000 lbs / 7000 kg) under the drive chassis
between the non-steering wheels.
3 Measure each wear pad. Replace the wear pad
if it is less than 0.41 inch / 1 cm thick. If the
wear pad is more than 0.41 inch / 1 cm thick,
shim as necessary to obtain zero clearance and
zero drag.
4 Extend and retract the primary boom through
the entire range of motion to check for tight
spots that could cause binding or scraping.
3 Lift the wheels off the ground and then place
jack stands under the drive chassis for support.
4 Disengage the torque hubs by turning over the
torque hub disconnect caps on each
non-steering wheel hub.
Always maintain squareness
between the primary boom outer
and inner tubes.
Part No. 119987
Z-34/22 IC
brake disengaged position
brake engaged position
3 - 35
Section 3 • Scheduled Maintenance Procedures
CHECKLIST
D
June 2007
PROCEDURES
REV A
5 Manually rotate each non-steering wheel.
Result: Each non-steering wheel should rotate
with minimum effort.
D-3
Replace the Drive Hub Oil
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.
Collision hazard. Failure to
re-engage the torque hubs may
cause death or serious injury and
property damage.
Genie requires that this procedure
be performed every 1000 hours or
annually, whichever comes first.
Replacing the torque hub oil is essential for good
machine performance and service life. Failure to
replace the torque hub oil at yearly intervals may
cause the machine to perform poorly and
continued use may cause component damage.
1 Select the drive torque hub to be serviced.
Drive the machine to rotate the hub until the
plugs are located one on top and the other at
90 degrees.
plugs
Models with pipe plugs
plugs
Models with O-ring plugs
3 - 36
Z-34/22 IC
Part No. 119987
June 2007
Section 3 • Scheduled Maintenance Procedures
REV A
CHECKLIST
2 Remove both plugs and drain the oil.
D-4
Replace the Hydraulic Filters
3 Drive the machine until one plug is at the top
and the other is at 90 degrees.
4 Fill the hub with oil from the top hole until the oil
level is even with the bottom of the side hole.
Refer to Section 2, Specifications.
5 Models with pipe plugs: Apply pipe thread
sealant to the plugs. Install the plugs into the
drive hub.
Models with O-ring plugs: Install the plugs
into the drive hub.
6 Repeat this procedure for each torque hub.
D PROCEDURES
Genie requires that this procedure
be performed every 1000 hours or
annually, whichever comes first.
Replacement of the hydraulic filters are
essential for good machine performance and
service life. A dirty or clogged filter may cause the
machine to perform poorly and continued use may
cause component damage. Extremely dirty
conditions may require that the filter be replaced
more often.
Hydraulic Return Filter:
Burn hazard. Beware of hot oil.
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.
Part No. 119987
Z-34/22 IC
3 - 37
Section 3 • Scheduled Maintenance Procedures
CHECKLIST
D
June 2007
PROCEDURES
REV A
Hydraulic Suction Filter
(before serial number 1547):
Medium pressure filter
(after serial number 1546):
Burn hazard. Beware of hot oil.
Contact with hot oil may cause
severe burns.
Burn hazard. Beware of hot oil.
Contact with hot oil may cause
severe burns.
The suction hydraulic filter is
mounted in the engine
compartment.
The medium pressure filter is
mounted in the engine
compartment.
4 Close the shut off valve behind the filter.
5 Clean the area around the oil filter, then remove
the filter with an oil filter wrench.
6 Apply a thin layer of oil to the new oil filter
gasket.
4 Place a suitable container under the medium
pressure filter.
5 Remove the filter housing by using a wrench on
the nut provided on the bottom of the housing.
6 Remove the filter element from the housing.
7 Install the new filter and tighten it securely by
hand. Clean up any oil that may have spilled.
7 Inspect the housing seal and replace it if
necessary.
8 Start the engine from the ground contols.
8 Install the new filter element into the housing
and tighten securely.
9 Activate any boom function and inspect the
filters and related components to be sure that
there are no leaks.
10 Use a permanent ink marker to write the date
and number of hours from the hour meter on
the filters.
9 Clean up any oil that may have spilled during
the installation procecure.
10 Start the engine from the ground contols.
11 Activate any boom function and inspect the
filters and related components to be sure that
there are no leaks.
12 Use a permanent ink marker to write the date
and number of hours from the hour meter on
the filters.
3 - 38
Z-34/22 IC
Part No. 119987
June 2007
Section 3 • Scheduled Maintenance Procedures
REV A
CHECKLIST
D PROCEDURES
3 Remove the safety chock. Lower the boom to
the stowed position.
D-5
Check the Turntable Rotation
Bearing Bolts
4 Access the turntable bearing bolts through the
access hole on the side of the chassis.
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.
5 Check to ensure that each bearing mounting
bolt under the drive chassis is torqued in
specified order to 180 ft-lbs / 244 Nm.
1 Raise the secondary boom and place a safety
chock on the secondary boom lift cylinder.
Carefully lower the boom onto the lift cylinder
safety chock. Turn the machine off.
Crushing hazard. Keep hands
away from the cylinder and all
moving parts when lowering the
secondary boom.
Bolt torque sequence
The lift cylinder safety chock is
available through Genie (part
number 36555).
2 Check to ensure that each turntable bearing
bolt is torqued in specified order to
180 ft-lbs / 244 Nm.
Bolt torque sequence
Part No. 119987
Z-34/22 IC
3 - 39
Section 3 • Scheduled Maintenance Procedures
CHECKLIST
D
June 2007
PROCEDURES
REV A
the primary boom.
D-6
Inspect for Turntable Bearing
Wear
4 Place a dial indicator between the drive chassis
and the turntable at a point that is directly
under, or in line with, the boom and no more
than 1 inch / 2.5 cm from the bearing.
To obtain an accurate
measurement, place the dial
indicator no more than 1 inch / 2.5
cm from the turntable rotation
bearing.
Genie requires that this procedure
be performed every 1000 hours or
annually, whichever comes first.
Periodic inspection of turntable bearing wear is
essential to safe machine operation, good machine
performance and service life. Continued use of a
worn turntable bearing could create an unsafe
operating condition, resulting in death or serious
injury and component damage.
1 Grease the turntable bearing. See A-8, Grease
the Turntable Rotation Bearing and Worm Drive
Gear.
2 Torque the turntable bearing bolts to
specification. See D-5, Check the Turntable
Rotation Bearing Bolts.
a
b
c
d
a
b
c
d
3 Raise the primary and secondary booms to full
height using the ground controls. Do not extend
turntable
dial indicator
drive chassis
turntable rotation bearing
5 Adjust the dial indicator to "0".
6 Lower the secondary boom to the stowed
position and lower the primary boom to a
horizontal position. Fully extend the primary
boom.
7 Note the reading on the dial indicator.
Result: The measurement is less than
0.055 inch / 1.4 mm. The bearing is good.
Result: The measurement is more than
0.055 inch / 1.4 mm. The bearing is worn and
3 - 40
Z-34/22 IC
Part No. 119987
June 2007
Section 3 • Scheduled Maintenance Procedures
REV A
CHECKLIST
needs to be replaced.
8 Fully retract the primary boom. Raise the
primary and secondary booms to full height.
Visually inspect the the dial indicator to be sure
the needle returns to the "0" position.
D-7
Perform Engine Maintenance
Engine specifications requires that
this procedure be performed every
1000 hours or annually, whichever
comes first.
9 Remove the dial indicator and rotate the
turntable 90°.
10 Repeat steps 4 through 9 until the rotation
bearing has been checked in at least four
equally spaced areas 90° apart.
11 Lower the primary and secondary booms to the
stowed position and turn the machine off.
12 Remove the dial indicator from the machine.
Part No. 119987
D PROCEDURES
Required maintenance procedures and additional
engine information is available in the
Kubota DF750 Operator's Manual
(Kubota part number EG261-8916-1) OR the
Kubota DF752 Operator's Manual
(Kubota part number EG601-8916-1) OR the
Kubota D905 Operator's Manual
(Kubota part number 16622-8916-5).
Kubota DF750 Operator's Manual
Genie part number
97359
Kubota DF752 Operator's Manual
Genie part number
84250
Kubota D905 Operator's Manual
Genie part number
31743
Z-34/22 IC
3 - 41
Section 3 • Scheduled Maintenance Procedures
June 2007
Checklist E Procedures
E-1
Test or Replace the Hydraulic Oil
2 Close the two hydraulic tank shut-off valves at
the hydraulic tank.
Component damage hazard. The
engine must not be started with
the hydraulic tank shut-off valves
in the closed position or
component damage will occur. If
the tank valves are closed,
remove the key from the key
switch and tag the machine to
inform personnel of the condition.
Genie requires that this procedure
be performed every 2000 hours or
two years, whichever comes first.
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.
REV A
open
closed
3 Remove the drain plug from the hydraulic tank
and completely drain the tank into a container
of suitable capacity. Refer to Section 2,
Specifications.
Bodily injury hazard. Beware of
hot oil. Contact with hot oil may
cause severe burns.
4 Tag, disconnect and plug the hoses from the
return filter. Cap the fittings on the return filter.
1 Place a suitable container under the hydraulic
tank. Refer to Section 2, Specifications.
5 Tag, disconnect and plug the suction hoses
from the bottom of the tank. Cap the fittings.
6 Remove the fasteners from the hydraulic tank
hold down straps. Remove the straps.
7 Remove the turntable cover using a suitable
lifting device.
Crushing hazard. The turntable
cover could become unbalanced
and fall if not properly supported
when removed from the machine.
3 - 42
Z-34/22 IC
Part No. 119987
June 2007
Section 3 • Scheduled Maintenance Procedures
REV A
CHECKLIST E
8 Support and secure the hydraulic tank to a
suitable lifting device. Remove the hydraulic
tank from the machine.
9 Remove the suction strainers and clean them
using a mild solvent.
E-2
Grease the Steer Axle
Wheel Bearings, 2WD Models
10 Rinse out the inside of the tank using a mild
solvent.
Genie requires that this procedure
be performed every 2000 hours or
every two years, whichever comes
first.
11 Install the suction strainers using a pipe thread
sealant on the threads.
12 Install the drain plug into the tank using a pipe
thread sealant on the threads.
13 Install the hydraulic tank on to the machine.
Install the hydraulic tank hold down straps and
tighten the retaining fasteners.
14 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.
15 Open the two hydraulic tank shut-off valves at
the hydraulic tank.
Component damage hazard. The
engine must not be started with
the hydraulic tank shut-off valves
in the closed position or
component damage will occur. If
the tank valves are closed,
remove the key from the key
switch and tag the machine to
inform personnel of the condition.
PROCEDURES
Maintaining the steer axle wheel bearings is
essential for safe machine operation and service
life. Operating the machine with loose or worn
wheel bearings may cause an unsafe operating
condition and continued use may result in
component damage. Extremely wet or dirty
conditions or regular steam cleaning and pressure
washing of the machine may require that this
procedure be performed more often.
1 Loosen the wheel lug nuts. Do not remove
them.
2 Block the non-steer wheels and center a lifting
jack of ample capacity under the steer axle.
3 Raise the machine 6 inches / 15 cm and place
blocks under the drive chassis for support.
Crushing damage. The machine
may fall if not properly supported.
4 Remove the lug nuts. Remove the tire and
wheel assembly.
5 Check for wheel bearing wear by attempting to
move the wheel hub side to side, then up and
down.
Result: There should be no side to side or up
and down movement.
open
closed
Skip to step 10 if there is no movement.
16 Clean up any oil that may have spilled. Properly
discard of oil.
17 Start the engine and check for leaks.
Part No. 119987
Z-34/22 IC
3 - 43
Section 3 • Scheduled Maintenance Procedures
CHECKLIST E
June 2007
PROCEDURES
REV A
6 Remove the dust cap from the hub. Remove the
cotter pin from the castle nut.
7 Tighten the castle nut to 158 ft-lbs / 214 Nm to
seat the bearings.
Rotate the hub by hand while
torquing the castle nut to make
sure the bearings seat properly.
8 Loosen the castle nut one full turn and then
torque to 35 ft-lbs / 47 Nm.
13 Pack both bearings with clean, fresh grease.
14 Place the large inner bearing into the rear of the
hub.
15 Install a new bearing grease seal into the hub
by pressing it evenly into the hub until it is flush.
Always replace the bearing grease
seal when removing the hub.
16 Slide the hub onto the yoke spindle.
Component damage hazard. Do
not apply excessive force or
damage to the lip of the seal may
occur.
9 Check for wheel bearing wear by attempting to
move the wheel hub side to side, then up and
down.
Result: If there is no side to side or up and
down movement, continue with step 10 to
grease the wheel bearings.
17 Fill the hub cavity with clean, fresh grease.
18 Place the outer bearing into the hub.
Result: If there is side to side or up and down
movement, continue to step 10 and replace the
wheel bearings with new ones.
19 Install the washer and castle nut.
20 Tighten the castle nut to 158 ft-lbs / 214 Nm to
seat the bearings.
When replacing a wheel bearing,
both the inner and outer bearings,
including the pressed-in races,
must be replaced.
Rotate the hub by hand while
torquing the castle nut to make
sure the bearings seat properly.
21 Loosen the castle nut one full turn and then
torque to 35 ft-lbs / 47 Nm.
10 Remove the castle nut.
11 Pull the hub off of the spindle. The washer and
outer bearing should fall loose from the hub.
22 Install a new cotter pin. Bend the cotter pin
to lock it in.
12 Place the hub on a flat surface and gently pry
the bearing seal out of the hub. Remove the
rear bearing.
Always use a new cotter pin when
installing a castle nut.
23 Install the dust cap, then the tire and wheel
assembly. Torque the wheel lug nuts to
specification. Refer to Section 2, Specifications.
3 - 44
Z-34/22 IC
Part No. 119987
June 2007
Section 3 • Scheduled Maintenance Procedures
REV A
CHECKLIST E
PROCEDURES
E-3
Perform Engine Maintenance
Engine specifications requires that
this procedure be performed every
2000 hours or every two years,
whichever comes first.
Required maintenance procedures and additional
engine information is available in the
Kubota DF750 Operator's Manual
(Kubota part number EG261-8916-1) OR the
Kubota DF752 Operator's Manual
(Kubota part number EG601-8916-1) OR the
Kubota D905 Operator's Manual
(Kubota part number 16622-8916-5).
Kubota DF750 Operator's Manual
Genie part number
97359
Kubota DF752 Operator's Manual
Genie part number
84250
Kubota D905 Operator's Manual
Genie part number
31743
Part No. 119987
Z-34/22 IC
3 - 45
Section 3 • Scheduled Maintenance Procedures
June 2007
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3 - 46
Z-34/22 IC
Part No. 119987
June 2007
Section 4 • Repair Procedures
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.
Observe and Obey:
Repair procedures shall be completed by a
person trained and qualified on the repair of this
machine.
Perform disassembly procedures to the point
where repairs can be completed. To re-assemble,
perform the disassembly steps in reverse order.
Symbols Legend
Immediately tag and remove from service a
damaged or malfunctioning machine.
Safety alert symbol—used to alert
personnel to potential personal
injury hazards. Obey all safety
messages that follow this symbol
to avoid possible injury or death.
Repair any machine damage or malfunction
before operating the machine.
Before Repairs Start:
Used to indicate the presence of
an imminently hazardous situation
which, if not avoided, will result in
death or serious injury.
Read, understand and obey the safety rules
and operating instructions in the appropriate
Genie Z-34/22 IC Operator's Manual on your
machine.
Used to indicate the presence of a
potentially hazardous situation
which, if not avoided, could result
in death or serious injury.
Be sure that all necessary tools and parts are
available and ready for use.
With safety alert symbol—used to
indicate the presence of a
potentially hazardous situation
which, if not avoided, may cause
minor or moderate injury.
Use only Genie approved replacement parts.
Read each procedure completely and adhere to
the instructions. Attempting shortcuts may
produce hazardous conditions.
Unless otherwise specified, perform each repair
procedure with the machine in the following
configuration:
Without safety alert symbol—used
to indicate the presence of a
potentially hazardous situation
which, if not avoided, may result in
property damage.
· Machine parked on a firm, level surface
· Boom in the stowed position
Used to indicate operation or
maintenance information.
· Turntable rotated with the boom between
the non-steer wheels
Indicates that a specific result is expected after
performing a series of steps.
· Key switch in the off position with the key
removed
Indicates that an incorrect result has occurred
after performing a series of steps.
· Wheels chocked
· All exernal AC power disconnected from the
machine
Part No. 119987
Z-34/22 IC
4-1
Section 4 • Repair Procedures
June 2007
Platform Controls
REV A
2 Open the control box lid and locate the
horsepower limiter board.
1-1
Horsepower Limiter Board
(before serial number 1547)
Electrocution hazard. Contact with
electrically charged circuits could
result in death or serious injury.
Remove all rings, watches and
other jewelry.
The horsepower limiter board is responsible for
governing drive pump output. It senses engine rpm
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.
a
How to Adjust the Horsepower
Limiter Board
The engine rpm must be correct
before performing this procedure.
Refer to Maintenance Procedure
B-9, 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.
a
3 Connect the black(-) lead from a DC volt meter
to the no. 2 terminal, and the red(+) lead to the
no. 10 terminal.
Gasoline/LPG models: Perform
this procedure in gasoline mode.
1 Remove the fasteners from the platform
control box lid.
a
12V DC or greater
ground
engine rpm sensor
not used
not used
low drive speed limit switch
not used
not used
not used
output to drive controller
a
b
c
4-2
horsepower limiter board
Z-34/22 IC
b
c
"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
Part No. 119987
June 2007
Section 4 • Repair Procedures
REV A
PLATFORM CONTROLS
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.
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.
"A" potentiometer specifications - all models
Voltage setting
8.5 V DC
7 Move the engine idle control switch to low idle
(turtle symbol).
12 Disconnect the volt meter.
8 Press down the foot switch and then adjust
the "C" potentiometer counterclockwise to
increase voltage or clockwise to decrese
voltage to obtain a 0V DC voltage reading.
13 Raise the primary boom above the drive limit
switch.
9 Move the engine idle control switch to foot
switch activated high idle (rabbit and foot switch
symbol). Move the drive select switch
to high range (machine on level ground
symbol).
a
10 Press down the foot switch and re-adjust the
"A" potentiometer to the previous voltage
setting in step 6.
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 clockwise to
increase voltage or counterclockwise to
decrease voltage until raised drive speed meets
specification. Refer to Section 2, Specifications.
16 Close the platform control box lid and install
the fasteners.
Part No. 119987
Z-34/22 IC
4-3
Section 4 • Repair Procedures
June 2007
PLATFORM CONTROLS
REV A
3 Locate and disconnect the wire connected to
terminal "A" on the drive joystick circuit board.
1-2
Drive Joystick
(after serial number 1546)
4 Set a multimeter to read DC current.
The multimeter, when set to read
DC current, should be capable of
reading up to 1200 mA.
How to Adjust the Drive Joystick
Perform this procedure with the
engine off.
5 Connect the black(-) lead from the multimeter to
the wire that was just disconnected. Connect
the red(+) lead of the multimeter to terminal "A"
on the joystick.
1 Remove the fasteners from the platform
control box lid.
2 Open the control box lid and locate the drive
joystick.
a
X
R B
Electrocution hazard. Contact with
electrically charged circuits could
result in death or serious injury.
Remove all rings, watches and
other jewelry.
b
c
d
-
e
+
f
A
g
h
i
X
-
+
A
a
b
c
d
e
f
g
h
i
C
R
L
A
+
-
X
B
R
R
a
D
TS1
a
b
4-4
b
low range potentiometer
terminal "R", activates low range
terminal "B", drive reverse
terminal "X", brake release
terminal "-", ground
terminal "+", positive
terminal "A", drive forward
threshold potentiometer
high range potentiometer
6 Turn the keyswitch to platform controls and pull
out the red Emergency Stop button out to the
on position at both the ground and platform
controls. Do not start the engine.
boom function speed controller
drive joystick
Z-34/22 IC
Part No. 119987
June 2007
Section 4 • Repair Procedures
PLATFORM CONTROLS
REV A
Set the stowed drive speed:
Set the threshold:
The drive joystick adjustments are
not final adjustments. Final
adjustments will need to be made
to meet drive speed specifications.
Refer to Section 2, Specifications.
7 Press down the foot switch. Move the drive
joystick off center in either direction just until a
current reading appears on the mulitmeter
display.
8 Hold the drive joystick in position and adjust the
THRESHOLD potentiometer until the multimeter
displays approximately 600 mA.
Set the high range:
9 Press down the foot switch. Move and hold the
drive joystick full stroke in either direction.
10 Hold the drive joystick in position and adjust the
HI RANGE potentiometer until the multimeter
displays slightly higher than 1100 mA.
Set the low range:
11 Start the engine from the platform controls and
raise the primary boom approximately
3 feet / 1 m. Turn the engine off.
12 Press down the foot switch. Move and hold the
drive joystick full stroke in either direction.
13 Hold the drive joystick in position and adjust the
LO RANGE potentiometer until the multimeter
displays approximately 700 mA.
Select a test area that is firm, level
and free of obstructions.
17 Pull out the red Emergency Stop button out to
the on position at both the ground and platform
controls.
18 Create start and finish lines by marking two
lines on the ground 40 feet / 12.2 m apart.
19 Start the engine from the platform controls and
move the engine idle select switch to foot
switch activated high idle (rabbit and foot
switch symbol).
20 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.
21 Bring the machine to top drive speed before
reaching the start line. Begin timing when your
reference point on the machine crosses the
start line.
22 Continue at full speed and note the time when
the machine reference point passes over the
finish line. Refer to Section 2, Specifications.
Result: The stowed drive speed does not meet
specification. Adjust the HI RANGE potentiometer
on the drive joystick clockwise to increase the
speed or counterclockwise to decrease the
stowed drive speed. Continue to perform steps
20 through 22 until the stowed drive speed
meets specification.
14 Push in the red Emergency Stop button to the
off position at the platform controls.
15 Disconnect the multimeter.
16 Connect the wire that was disconnected in
step 3 to terminal "A" of the drive joystick.
Part No. 119987
Z-34/22 IC
4-5
Section 4 • Repair Procedures
June 2007
PLATFORM CONTROLS
REV A
Set the raised drive speed:
Select a test area that is firm, level
and free of obstructions.
23 Press down the foot switch and raise the
primary boom approximately 3 feet / 1 m.
24 Choose a point on the machine; i.e., contact
patch of a tire, as a visual reference for use
when crossing the start and finish lines.
25 Bring the machine to top drive speed before
reaching the start line. Begin timing when your
reference point on the machine crosses the
start line.
26 Continue at full speed and note the time when
the machine reference point passes over the
finish line. Refer to Section 2, Specifications.
Result: The raised drive speed does not meet
specification. Adjust the LO RANGE potentiometer
on the drive joystick clockwise to increase the
speed or counterclockwise to decrease the
raised drive speed. Continue to perform steps
24 through 26 until the raised drive speed
meets specification.
27 Lower the primary boom to the stowed position.
Turn the engine off.
28 Close the platform control box lid and install
the fasteners.
4-6
Z-34/22 IC
Part No. 119987
June 2007
Section 4 • Repair Procedures
REV A
PLATFORM CONTROLS
3 Locate the diode between the black wire from
the boom function speed controller and the
white/red wire.
1-3
Boom Function Speed
Controller
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.
Boom Function Speed
Controller Adjustments
Electrocution hazard. Contact with
electrically charged circuits could
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
out the red Emergency Stop button to the on
position at both the ground and platform
controls.
2 Open the platform control box lid and locate the
boom function speed controller.
e
a
f
b
c
5 Turn the boom function speed controller to the
CREEP position.
6 Set the threshold: Press down the foot switch.
Move the primary boom toggle switch in the
up direction until the voltage reading appears.
Adjust the voltage to 5.5 to 6V DC. Turn the
threshold trimpot adjustment screw clockwise to
increase the voltage or counterclockwise to
decrease the voltage.
7 Turn the boom function speed controller to
the 9 position.
8 Set the max-out: Press down the foot switch.
Move the primary boom toggle switch in the up
direction. Adjust the voltage to 8.5 to 9V DC.
Turn the max-out trimpot adjustment screw
clockwise to increase the voltage or
counterclockwise to decrease the voltage.
Boom function speed
controller specifications
Threshold
d
a
b
c
d
e
f
Part No. 119987
Max-out
5 to 6V DC
8.5 to 9V DC
black wire
diode
white/red wire
boom function speed controller
max-out adjustable trimpot
threshold adjustable trimpot
Z-34/22 IC
4-7
Section 4 • Repair Procedures
June 2007
Platform Components
REV A
2-1
Platform
2-2
Platform Leveling Slave Cylinder
How to Remove the Platform
The slave cylinder and the rotator pivot are the
two primary supports for the platform. The slave
cylinder keeps the platform level through the
entire range of primary boom motion. It operates in
a closed-circuit hydraulic loop with the master
cylinder. The slave cylinder is equipped with
counterbalance valves to prevent movement in
the event of a hydraulic line failure.
1 Separate the foot switch wiring quick disconnect
plug from the platform toeboard.
2 Remove the platform control box mounting
fasteners and 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.
How to Remove the Platform
Leveling Slave Cylinder
3 Place blocks under the platform for support.
Carefully lower the platform onto the blocks.
When removing a hose assembly
or fitting, the O-ring (if equipped)
on the fitting and/or the hose end
must be replaced. All connections
must be torqued to specification
during installation. Refer to
Section 2, Hydraulic Hose and
Fitting Torque Specifications.
4 Remove the platform mounting fasteners and
remove the platform.
Before cylinder removal is
considered, bleed the slave
cylinder to be sure there is no
air in the closed loop.
1 Extend the boom until the slave cylinder
barrel-end pivot pin is accessible.
2 Raise the boom slightly and place blocks under
the platform for support. Lower the boom until
the platform is resting on the blocks.
4-8
Z-34/22 IC
Part No. 119987
June 2007
Section 4 • Repair Procedures
PLATFORM COMPONENTS
REV A
3 Remove the pin retainer fastener from the
rod-end pivot pin.
How to Bleed the Slave Cylinder
4 Remove the external snap ring from the
barrel-end pivot pin.
1 Raise the jib boom to a horizontal position.
2 Activate the platform level toggle switch up and
down through two platform leveling cycles to
remove any air that might be in the system.
5 Use a soft metal drift to remove the rod-end
pivot pin.
6 Use a soft metal drift to remove the barrel-end
pivot pin.
7 Carefully pull the cylinder out of the boom.
8 Tag and disconnect the hydraulic hoses from
the slave cylinder and connect them together
with a connector. Cap the fittings on the
cylinder.
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.
Part No. 119987
Z-34/22 IC
4-9
Section 4 • Repair Procedures
June 2007
PLATFORM COMPONENTS
REV A
5 Support the platform rotator with a suitable
lifting device. Do not apply any lifting pressure.
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
6 Remove the pin retaining fasteners from the jib
boom and leveling links to platform rotator pivot
pins. Do not remove the pins.
7 Use a soft metal drift to remove the leveling link
pivot pin. Lower the leveling links to the ground.
8 Support the jib boom and jib boom lift cylinder
with an overhead crane.
When removing a hose assembly
or fitting, the O-ring (if equipped)
on the fitting and/or the hose end
must be replaced. All connections
must be torqued to specification
during installation. Refer to
Section 2, Hydraulic Hose and
Fitting Torque Specifications.
9 Use a soft metal drift to drive both pins out and
remove the platform rotator from the machine.
Crushing hazard. The jib boom
and jib boom lift cylinder could fall
when when the platform rotator is
removed if not properly supported
by the overhead crane.
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. Cap the
fittings on the manifold.
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.
3 Support the platform mounting weldment with a
suitable lifting device. Do not apply any lifting
pressure.
4 Remove the six mounting bolts from the
platform mounting weldment. Remove the
center bolt and slide the platform mounting
weldment off of the platform rotator.
4 - 10
Z-34/22 IC
Part No. 119987
June 2007
Section 4 • Repair Procedures
REV A
PLATFORM COMPONENTS
How to Bleed the Platform
Rotator
5 Hold the platform rotate toggle switch in the left
direction for approximately 5 seconds, then
release it.
1 Connect a clear hose to the top bleed screw.
Place the other end of the hose in a container
to collect any discharge.
6 Fully rotate the platform to the left and continue
holding the platform rotate toggle switch until air
stops coming out of the bleed screw.
Immediately release the platform rotate toggle
switch and close the bleed screw.
7 Rotate the platform to the right until it is
centered.
a
8 Connect the clear hose to the bottom bleed
screw. Open the bottom bleed screw, but do
not remove it.
b
c
9 Rotate the platform to the right and continue
holding the platform rotate switch until air stops
coming out of the bleed screw.
d
a
b
c
d
Crushing hazard. Keep hands
clear of the platform pivot
weldment during rotation.
clear hose
top bleed valve
bottom bleed valve
container
10 Close the bleed screw and remove the hose.
2 Open the top bleed screw, but do not remove it.
11 Turn the key switch to the off position and clean
up any hydraulic oil that may have spilled.
3 Turn the key switch to ground control and pull
out the red Emergency Stop button to the on
position.
12 Turn the key switch to ground control and pull
out the red Emergency Stop button to the on
position.
4 Hold the platform rotate toggle switch in the
right direction for approximately 5 seconds,
then release it. Repeat three times.
13 Rotate the platform full left and right and inspect
the bleed screws for leaks.
Crushing hazard. Keep hands
clear of the platform pivot
weldment during rotation.
Part No. 119987
Z-34/22 IC
4 - 11
Section 4 • Repair Procedures
June 2007
Jib Boom Components
REV A
5 Tag, disconnect and plug the hydraulic hoses
from ports "T" and "P" of the jib boom manifold.
Cap the fittings on the manifold.
3-1
Jib Boom
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.
How to Remove the Jib Boom
Perform this procedure with the
boom in the stowed position.
When removing a hose assembly
or fitting, the O-ring on the fitting
and/or hose end must be replaced
and then torqued to specification
during installation. Refer to
Section Two, Hydraulic Hose and
Fitting Torque Specifications.
6 Tag and disconnect the electrical wiring from
the jib boom manifold.
7 Attach a lifting strap from an overhead crane to
the jib boom.
1 Remove the platform. See 2-1,
How to Remove the Platform.
8 Remove the pin retaining fasteners from the jib
boom pivot pin at the jib boom bellcrank.
2 Remove the platform mounting weldment
and the platform rotator. See 2-3, How to
Remove the Platform Rotator.
9 Use a soft metal drift to remove the jib boom
pivot pin. Remove the jib boom from the jib
boom bellcrank.
3 Tag, disconnect and plug the jib boom lift
cylinder hydraulic hoses. Cap the fittings on the
jib boom lift cylinder.
Bodily injury hazard. Spraying
hydraulic oil can penetrate and
burn skin. Loosen hydraulic
connections very slowly to allow
the oil pressure to dissipate
gradually. Do not allow oil to squirt
or spray.
4 Remove the cable cover from the side of the
jib boom.
Crushing hazard. The jib boom
could fall when the pin is removed
if not properly supported by the
overhead crane.
10 Remove the pin retaining fasteners from the jib
boom lift cylinder rod-end pivot pin. Do not
remove the pin.
11 Remove both of the jib boom leveling links from
the bellcrank.
12 Attach a lifting strap from an overhead crane to
the rod-end of the jib boom lift cylinder.
13 Use a soft metal drift to remove the jib boom lift
cylinder rod-end pivot pin. Remove the jib boom
lift cylinder from the jib boom bellcrank.
Crushing hazard. The jib boom
lift cylinder could fall when the pin
is removed if not properly
supported by the overhead crane.
4 - 12
Z-34/22 IC
Part No. 119987
June 2007
Section 4 • Repair Procedures
JIB BOOM COMPONENTS
REV A
3-2
Jib Boom Bell Crank
3-3
Jib Boom Lift Cylinder
How to Remove the Jib Boom
Bell Crank
How to Remove the Jib Boom
Lift Cylinder
Perform this procedure with the
boom in the stowed position.
Perform this procedure with the
boom in the stowed position.
When removing a hose assembly
or fitting, the O-ring on the fitting
and/or hose end must be replaced
and then torqued to specification
during installation. Refer to
Section Two, Hydraulic Hose and
Fitting Torque Specifications.
When removing a hose assembly
or fitting, the O-ring on the fitting
and/or hose end must be replaced
and then torqued to specification
during installation. Refer to
Section Two, Hydraulic Hose and
Fitting Torque Specifications.
1 Remove the platform. See 2-1, How to Remove
the Platform.
2 Remove the Jib Boom, See 3-1, How to
Remove the Jib Boom.
1 Raise the jib boom slightly and place blocks
under the platform mounting weldment. Lower
the jib boom until the platform is resting on the
blocks.
3 Support and secure the jib boom bell crank to
an appropriate lifting device.
4 Remove the pin retaining fasteners from the
slave cylinder rod-end pivot pin. Do not remove
the pin.
5 Remove the pin retaining fasteners from the jib
boom bell crank at the extension boom. Use a
soft metal drift to remove the pin.
6 Use a soft metal drift to remove the slave
cylinder rod-end pivot pin.
7 Remove the jib boom bell crank from the
extension boom.
Crushing hazard. The jib boom
bell crank could become
unbalanced and fall when the pins
are removed if not properly
supported and secured to the
lifting device.
Part No. 119987
Z-34/22 IC
4 - 13
Section 4 • Repair Procedures
June 2007
JIB BOOM COMPONENTS
REV A
2 Tag, disconnect and plug the jib boom lift
cylinder hydraulic hoses. Cap the fittings on the
jib boom lift cylinder.
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.
3 Remove the pin retaining fasteners from the jib
boom lift cylinder rod-end pivot pin. Do not
remove the pin.
4 Use a soft metal drift to tap the rod-end pivot
pin half way out and lower one of the leveling
links to the ground. Tap the pin the other
direction and lower the opposite leveling link.
Do not remove the pin.
5 Attach a lifting strap from an overhead crane to
the rod end of the jib boom lift cylinder.
6 Remove the pin retaining fasteners from the jib
boom lift cylinder barrel-end pivot pin. Use a
soft metal drift to remove the barrel-end pivot
pin.
Crushing hazard. The jib boom
and/or platform could fall when the
pin is removed if not properly
supported.
7 Use a soft metal drift to remove the jib boom lift
cylinder rod-end pivot pin. Remove the jib boom
lift cylinder from the machine.
Crushing hazard. The jib boom lift
cylinder could fall when the pins
are removed if not properly
supported by the overhead crane.
4 - 14
Z-34/22 IC
Part No. 119987
June 2007
Section 4 • Repair Procedures
Primary Boom Components
REV A
4-1
Plastic Cable Track
4-2
Primary Boom
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 Shim the Primary Boom
How to Repair the Plastic Cable
Track
1 Extend the boom until the wear pads are
accessible.
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.
2 Loosen the wear pad mounting fasteners.
Component damage hazard. The
primary boom cable track can be
damaged if it is twisted.
3 Install the new shims under the wear pad to
obtain zero clearance and zero drag.
4 Tighten the mounting fasteners.
5 Extend and retract the boom through an entire
cycle. Check for tight spots that could cause
scraping or binding.
Always maintain squareness
between the outer and inner boom
tubes.
a
b
a
b
link separation point
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.
Part No. 119987
Z-34/22 IC
4 - 15
Section 4 • Repair Procedures
June 2007
PRIMARY BOOM COMPONENTS
REV A
How to Remove the
Primary Boom
Bodily injury hazard. This
procedure requires specific repair
skills, lifting equipment and a
suitable workshop. Attempting this
procedure without these skills and
tools could result in death or
serious injury and significant
component damage. Dealer
service is strongly recommended.
When removing a hose assembly
or fitting, the O-ring on the fitting
and/or hose end must be replaced
and then torqued to specification
during installation. Refer to
Section Two, Hydraulic Hose and
Fitting Torque Specifications.
6 Tag and disconnect the hydraulic hoses to the
slave cylinder and connect them together using
a connector. Plug the slave cylinder hoses from
the cable track.
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.
7 Remove the external snap ring from the slave
cylinder barrel-end pivot pin.
8 Use a soft metal drift to remove the slave
cylinder barrel-end pin.
9 Remove the slave cylinder from the primary
boom.
10 Support the cable track with an overhead crane
or similar lifting device.
Perform this procedure with the
boom in the stowed position.
11 Remove the cable track mounting fasteners,
then remove the cable track from the
boom and lay it off to the side.
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 Rotator.
3 Remove the jib boom. See 3-1,
How to Remove the Jib Boom.
4 Remove the jib boom bell crank. See 3-2,
How to Remove the Jib Boom Bell Crank.
5 Support the slave cylinder.
Component damage hazard.
The boom cable track can be
damaged if it is twisted.
12 Remove the turntable end cover.
13 Remove the pin retaining fasteners from the
master cylinder rod-end pivot pin. Use a soft
metal drift to remove the pin. Pull the cylinder
back and secure it from moving.
14 Remove the drive speed limit switch
mounted on the side of the boom at the pivot
end. Do not disconnect the wiring.
4 - 16
Z-34/22 IC
Part No. 119987
June 2007
Section 4 • Repair Procedures
REV A
PRIMARY BOOM COMPONENTS
15 Tag, disconnect and plug the extension cylinder
hydraulic hoses. Cap the fittings on the
cylinder.
Bodily injury hazard. Spraying
hydraulic oil can penetrate and
burn skin. Loosen hydraulic
connections very slowly to allow
the oil pressure to dissipate
gradually. Do not allow oil to
squirt or spray.
16 Attach an overhead 5 ton / 5,000 kg crane to the
center point of the boom.
17 Attach a similar lifting device to the primary
boom lift cylinder.
23 Remove the hose clamp from the side of the
primary boom.
24 Remove the limit switch cam mounting
fastener (if equipped).
Note the position of the cam
before removing it.
25 Remove the pin retaining fasteners from the
primary boom pivot pin.
26 Use a soft metal drift to remove the primary
boom pivot pin. Carefully remove the boom
from the machine and place it on a structure
capable of supporting it.
Crushing hazard. If the overhead
crane is not properly attached,
the boom could become
unbalanced and fall when it is
removed from the machine.
18 Using the overhead crane, raise the primary
boom to a horizontal position.
19 Place support blocks across the secondary
boom to support the boom lift cylinder.
During removal, the overhead
crane strap will need to be
carefully adjusted for proper
balancing.
20 Remove the pin retaining fasteners from the
primary boom lift cylinder rod-end pin. Use a
soft metal drift to remove the pin.
Crushing hazard. The boom lift
cylinder will fall unless it is
properly supported.
21 Lower the rod-end of the primary boom lift
cylinder onto support blocks. Protect the
cylinder rod from damage.
22 Remove the hose clamp brackets from the
underside of the primary boom.
Part No. 119987
Z-34/22 IC
4 - 17
Section 4 • Repair Procedures
June 2007
PRIMARY BOOM COMPONENTS
REV A
7 Support and slide the extension tube out of the
outer primary boom tube. Place the extension
boom tube on blocks for support.
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
boom. See 4-4, How to Remove
the Extension Cylinder.
1 Remove the boom. See 4-2,
How to Remove the Primary Boom.
Crushing hazard. The boom tubes
could become unbalanced and fall
if not properly supported by the
overhead crane.
During removal, the overhead
crane strap will need to be
carefully adjusted for proper
balancing.
2 Place blocks under the extension cylinder for
support.
8 Remove the external snap rings from the
extension cylinder rod-end pivot pins at the
platform end of the extension tube. Use a soft
metal drift to remove the pins.
3 Remove the retaining fasteners from the
extension cylinder barrel-end pivot pin. Use a
soft metal drift to remove the pin.
9 Support and slide the extension cylinder out of
the base end of the extension tube. Place the
extension cylinder on blocks for support.
4 Label the location of all wear pads from the
outer boom tube at the platform end. Remove
all wear pads, including shims, from the
platform end of the boom.
Pay careful attention to the
location and amount of shims
used with each wear pad.
During removal, the overhead
crane strap will need to be
carefully adjusted for proper
balancing.
10 Remove and label the wear pads from the
extension cylinder.
5 Carefully rotate the barrel end of the extension
cylinder until the pin mounting bore is in a
vertical position.
Pay careful attention to the
location of each wear pad.
6 Attach a lifting strap from an overhead crane to
the extension tube at the platform end.
4 - 18
Z-34/22 IC
Part No. 119987
June 2007
Section 4 • Repair Procedures
REV A
PRIMARY BOOM COMPONENTS
4-3
Primary Boom Lift Cylinder
4 Place a block of wood across the upper
secondary boom to support the cylinder when
the rod-end pivot pin is removed.
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.
5 Attach a lifting strap from a second overhead
crane or other similar lifting device to the
primary boom lift cylinder.
How to Remove the Primary
Boom Lift Cylinder
7 Place a 4x4 inch / 10 x 10 cm block between
the lower compression arms and the cross
member of the upper secondary boom.
Carefully lower the secondary boom onto the
block.
Bodily injury hazard. This
procedure requires specific repair
skills, lifting equipment and a
suitable workshop. Attempting this
procedure without these skills and
tools could result in death or
serious injury and significant
component damage. Dealer
service is strongly recommended.
When removing a hose assembly
or fitting, the O-ring on the fitting
and/or hose end must be replaced
and then torqued to specification
during installation. Refer to
Section Two, Hydraulic Hose and
Fitting Torque Specifications.
1 Raise the primary boom enough to access the
primary boom lift cylinder rod-end pivot pin.
2 Raise the secondary boom enough to access
the primary boom lift cylinder barrel-end
pivot pin.
3 Attach a lifting strap from an overhead crane to
the primary boom for support. Do not apply any
lifting pressure.
6 Remove the rear turntable cover.
Crushing hazard. Keep hands
away from the block and all
moving parts when lowering the
secondary boom.
8 Remove the pin retaining fasteners from the
primary boom lift cylinder rod-end pivot pin. Use
a soft metal drift to remove the pin.
Crushing hazard. The primary
boom could fall when the primary
boom lift cylinder rod-end pivot pin
is removed if not properly
supported by the overhead crane.
9 Lower the rod end of the cylinder onto the
blocks that were placed on the upper
secondary boom.
10 Remove the pin retaining fasteners from the
upper compression arm pivot pin (same side of
machine as the primary boom lift cylinder
barrel-end pivot pin retaining fasteners).
11 Place a rod through the compression arm pivot
pin and twist to remove the pin.
12 Swing the compression arm up out of the way
and secure it from moving.
Part No. 119987
Z-34/22 IC
4 - 19
Section 4 • Repair Procedures
June 2007
PRIMARY BOOM COMPONENTS
REV A
13 Tag, disconnect and plug the primary boom lift
cylinder hydraulic hoses. Cap the fittings on the
cylinder.
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.
14 Support the primary boom lift cylinder with
straps or ropes to restrict it from swinging freely
when the barrel-end pivot pin is removed.
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
Bodily injury hazard. This
procedure requires specific repair
skills, lifting equipment and a
suitable workshop. Attempting this
procedure without these skills and
tools could result in death or
serious injury and significant
component damage. Dealer
service is strongly recommended.
15 Remove the pin retaining fasteners from the lift
cylinder barrel-end pivot pin. Do not remove the
pivot pin.
16 Use the overhead crane to raise the primary
boom 1 inch / 2.5 cm. This will relieve pressure
on the barrel-end pivot pin.
17 Place a rod through the barrel-end pivot pin and
twist to remove the pin.
When removing a hose assembly
or fitting, the O-ring on the fitting
and/or hose end must be replaced
and then torqued to specification
during installation. Refer to
Section Two, Hydraulic Hose and
Fitting Torque Specifications.
Crushing hazard. The primary
boom lift cylinder may fall when
the barrel-end pivot pin is removed
if not properly supported by the
overhead crane.
18 Attach a lifting strap from an overhead crane or
similar lifting device to the rod end of the
primary boom lift cylinder. Carefully loosen the
straps and allow the barrel end of the primary
boom lift cylinder to slowly swing down.
1 Raise the primary boom to a horizontal position.
Then extend the boom approximately
3 to 4 feet / 1 m until the extension cylinder
rod-end pivot pins are accessible.
19 Carefully remove the cylinder from the machine.
4 - 20
Z-34/22 IC
Part No. 119987
June 2007
Section 4 • Repair Procedures
PRIMARY BOOM COMPONENTS
REV A
2 Remove the external snap rings from the
extension cylinder rod-end pivot pins. Use a
soft metal drift to remove the pins.
9 Remove the pin retaining fasteners from the
extension cylinder pivot pin. Use a soft metal
drift to remove the pin.
3 Remove the rear turntable cover.
10 Carefully pull out and properly support the
extension cylinder from the primary boom using
a lifting strap from an overhead crane.
4 Raise the secondary boom until the master
cylinder rod-end pivot pin is accessible.
5 Remove the drive speed limit switch from the
pivot end of the primary boom. Do not
disconnect the wiring.
6 Remove the pin retaining fasteners from the
master cylinder rod end pivot pin. Use a soft
metal drift to remove the pin.
7 Manually retract the master cylinder and push it
toward the platform end of the boom to obtain
enough clearance for the extension cylinder
removal.
8 Tag, disconnect and plug the extension cylinder
hydraulic hoses. Cap the fittings on the
cylinder.
Crushing hazard. The cylinder
may become unbalanced and fall
if not properly supported by the
overhead crane when removed
from the extension tube.
During removal, the overhead
crane strap will need to be
carefully adjusted for proper
balancing.
To make installation of the
extension cylinder easier, be sure
that the cylinder rod is extended
3 to 4 feet /1 m.
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.
Part No. 119987
Z-34/22 IC
4 - 21
Section 4 • Repair Procedures
June 2007
PRIMARY BOOM COMPONENTS
REV A
2 Raise the secondary boom until the master
cylinder barrel-end pivot pin is above the
turntable counterweights.
4-5
Platform Leveling Master
Cylinder
The master cylinder acts as a pump for the slave
cylinder. It is part of the closed circuit hydraulic
loop that keeps the platform level through the
entire range of primary boom motion. The master
cylinder is located inside the upper mid-pivot at the
pivot end of the primary boom.
3 Raise the primary boom until the master
cylinder rod-end pivot pin is accessible.
4 Attach a lifting strap from an overhead crane to
the upper pivot for support. Do not apply any
lifting pressure.
5 Secure the upper secondary boom to the pivot
end of the primary boom with a strap.
How to Remove the Platform
Leveling Master Cylinder
Bodily injury hazard. This
procedure requires specific repair
skills, lifting equipment and a
suitable workshop. Attempting this
procedure without these skills and
tools could result in death or
serious injury and significant
component damage. Dealer
service is strongly recommended.
Securing the upper secondary
boom to the pivot will prevent the
upper secondary boom from falling
when the master cylinder barrelend pivot pin is removed from the
cylinder.
6 Tag, disconnect and plug the master cylinder
hydraulic hoses. Cap the fittings on the
cylinder.
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.
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.
When removing a hose assembly
or fitting, the O-ring on the fitting
and/or hose end must be replaced
and then torqued to specification
during installation. Refer to
Section Two, Hydraulic Hose and
Fitting Torque Specifications.
1 Remove the rear turntable cover.
4 - 22
7 Tie a strap around the lug on the rod end of the
master cylinder and secure the strap to the
primary boom.
The strap will be used to lower the
cylinder out of the upper pivot.
8 Remove the pin retaining fasteners from the
master cylinder rod-end pivot pin. Use a soft
metal drift to remove the pin.
Z-34/22 IC
Part No. 119987
June 2007
Section 4 • Repair Procedures
REV A
PRIMARY BOOM COMPONENTS
9 Remove the pin retaining fasteners from the
master cylinder barrel-end pivot pin.
10 Use a soft metal drift to remove the pin from the
cylinder. Do not remove the pin from the upper
mid-pivot. Push the pin to one side, only far
enough to remove the cylinder.
Crushing hazard. The upper
secondary boom and the upper
pivot may fall if the pivot pin is
completely removed.
The pin should remain in one side
of the upper secondary boom and
upper mid-pivot.
11 Use the strap around the rod-end lug to lower
the cylinder out of the machine.
Part No. 119987
Z-34/22 IC
4 - 23
Section 4 • Repair Procedures
June 2007
Secondary Boom Components
a
REV A
b
b
c
h
f
d
g
f
e
Secondary Boom
a
upper pivot
b
upper compression arm
c
mid-pivot
d
compression link
e
lower secondary boom
f
lower compression arm
g
turntable pivot
h
upper secondary boom
4 - 24
Z-34/22 IC
Part No. 119987
June 2007
Section 4 • Repair Procedures
SECONDARY BOOM COMPONENTS
REV A
6 Locate the cables from the primary boom cable
track to the platform control box. Number each
cable and its entry location at the platform
control box.
5-1
Secondary Boom
How to Disassemble the
Secondary Boom
7 Open the platform control box.
Bodily injury hazard. The
procedures in this section require
specific repair skills, lifting
equipment and a suitable
workshop. Attempting this
procedure without these skills and
tools could result in death or
serious injury and significant
component damage. Dealer
service is required.
When removing a hose assembly
or fitting, the O-ring on the fitting
and/or hose end must be replaced
and then torqued to specification
during installation. Refer to
Section 2, Hydraulic Hose and
Fitting Torque Specifications.
8 Tag and disconnect each wire from the cables
in the platform control box.
Electrocution hazard. Contact with
electrically charged circuits could
result in death or serious injury.
Remove all rings, watches and
other jewelry.
9 Pull the cables out of the 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 hydraulic hoses at
the union located on the bottom side of the
primary boom. Cap the fittings on the union.
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.
1 Remove the rear turntable cover.
2 Place a suitable lifting device under the platform
for support.
3 Disconnect the battery.
4 Remove the cable cover from the side of the jib
boom.
5 Remove the wire loom from the cables at the
platform control box.
Part No. 119987
13 Remove the hose clamp from the side of the
primary boom at the pivot end.
14 Remove the primary boom extend drive speed
limit switch mounted on the side of the primary
boom at the pivot end. Do not disconnect the
wiring.
Z-34/22 IC
4 - 25
Section 4 • Repair Procedures
June 2007
SECONDARY BOOM COMPONENTS
REV A
15 Attach a lifting strap from an overhead crane to
the pivot end of the primary boom.
16 Using the overhead crane, carefully lift the
secondary and primary boom assembly until
the master cylinder and primary boom lift
cylinder hydraulic hoses are accessible.
22 Remove the pin retaining fasteners from the
upper pivot to upper secondary compression
arm pivot pins. Place a rod through the
compression arm pivot pin and twist to remove
the pins.
23 Swing the compression arms down and out of
the way. Secure them from moving.
17 Remove the cable covers from the top of the
upper secondary boom.
18 Tag, disconnect and plug the primary boom lift
cylinder and master cylinder hydraulic hoses.
Cap the fittings on the cylinders.
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.
24 Remove the pin retaining fasteners from the
upper pivot to the upper secondary boom pivot
pin. Use a soft metal drift to remove the pin.
25 Carefully remove the entire primary boom
assembly from the machine (primary boom
assembly, jib boom assembly, platform, master
cylinder, primary lift cylinder and upper pivot).
Crushing hazard. The primary
boom assembly could become
unbalanced and fall when
removed from the machine if not
properly supported by the
overhead crane. Do not remove
the assembly from the machine
until it is properly balanced.
19 Using the overhead crane, lower the boom
assembly to the fully stowed position.
20 Pull all the cables and hoses through the upper
pivot.
Component damage hazard.
Cables and hoses can be
damaged if they are kinked or
pinched.
21 Position a lifting strap from the overhead crane
approximately 2 feet / 60 cm from the platform
end of the primary boom. Measure from the
platform end of the primary boom tube.
4 - 26
During removal, the overhead
crane strap will need to be
carefully adjusted for proper
balancing.
26 Place the entire assembly onto a structure
capable of supporting it.
27 Remove the pin retaining fasteners from the
upper secondary compression arm pivot pins.
Do not remove the pins.
Z-34/22 IC
Part No. 119987
June 2007
Section 4 • Repair Procedures
REV A
SECONDARY BOOM COMPONENTS
28 Position a lifting strap from an overhead crane
at the center of the control box side upper
compression arm.
36 Remove the upper secondary boom with
compression link from the machine.
Crushing hazard. The upper
secondary boom with
compression link could become
unbalanced and fall when
removed from the machine if not
properly supported by the
overhead crane.
29 Place a rod through the compression arm pivot
pin and twist to remove the pin. Remove the
compression arm from the machine.
Crushing hazard. The upper
compression arm could become
unbalanced and fall when
removed from the machine if not
properly supported by the
overhead crane.
30 Repeat step 29 for the engine side upper
compression arm.
31 Remove the plastic plug in the bulkhead to
access the secondary boom lift cylinder rod-end
pivot pin.
32 Remove the pin retaining fasteners from the rod
end of the secondary boom lift cylinder. Use a
soft metal drift to remove the pin. Secure the
cylinder from moving.
33 Remove the pin retaining fasteners from the
lower pivot pin of the compression link. Use a
soft metal drift to remove the pin.
34 Attach a lifting strap from an overhead crane to
the upper secondary boom.
37 Remove the drive speed limit switch
mounted on the inside of the lower mid-pivot.
Do not disconnect the wiring.
38 Remove the cable covers from the top of the
lower secondary boom. Pull all the cables and
hoses towards the counterweight end of the
turntable.
39 Gasoline/LPG models: Remove the LPG hose
from the tank and then remove the LPG tank.
40 Remove the battery hold down and battery.
41 Remove the pin retaining fasteners from the
secondary boom lift cylinder barrel-end pivot
pins.
42 Attach a lifting strap from an overhead crane to
the lug on the rod-end of the secondary boom
lift cylinder.
35 Remove the pin retaining fasteners from the
mid-pivot to upper secondary boom pivot pin.
Use a soft metal drift to remove the pin.
Part No. 119987
Z-34/22 IC
4 - 27
Section 4 • Repair Procedures
June 2007
SECONDARY BOOM COMPONENTS
REV A
43 Tag, disconnect and plug the hydraulic hoses
from the secondary boom lift cylinder. Cap the
fittings on the cylinder.
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.
44 Use a slide hammer to remove the secondary
boom lift cylinder barrel-end pivot pins. Remove
the secondary boom lift cylinder from the
machine.
48 Remove the mid-pivot from the machine.
Crushing hazard. The mid-pivot
could become unbalanced and fall
when removed from the machine if
not properly supported by the
overhead crane.
49 Attach a lifting strap from an overhead crane to
the control box side lower compression arm.
50 Remove the pin retaining fasteners from the
lower compression arm to turntable pivot pins.
Place a rod through the compression arm pivot
pin and twist to remove the pin. Remove the
compression arm from the machine.
Crushing hazard. The lower
compression arm could become
unbalanced and fall when
removed from the machine if not
properly supported by the
overhead crane.
Crushing hazard. The secondary
boom lift cylinder could become
unbalanced and fall when
removed from the machine if not
properly supported by the
overhead crane.
Access the pins using the access
holes located in the bulkheads,
one on each side.
45 Attach a lifting strap from an overhead crane to
the mid-pivot for support. Do not lift it.
46 Remove the pin retaining fasteners from the
mid-pivot to lower compression arm pivot pins.
Place a rod through the compression arm pivot
pins and twist to remove the pins.
51 Repeat step 50 for the engine side lower
compression arm.
52 Attach a liftiing strap from an overhead crane to
the lower secondary boom.
53 Remove the pin retaining fasteners from the
lower secondary boom to turntable pivot pin.
Use a soft metal drift to remove the pin.
54 Remove the lower secondary boom from the
machine.
47 Remove the pin retaining fasteners from the
mid-pivot to lower secondary boom pivot pins.
Use a soft metal drift to remove the pin.
4 - 28
Z-34/22 IC
Crushing hazard. The lower
secondary boom could become
unbalanced and fall when
removed from the machine if not
properly supported by the
overhead crane.
Part No. 119987
June 2007
Section 4 • Repair Procedures
REV A
SECONDARY BOOM COMPONENTS
5-2
Secondary Boom Lift Cylinder
The secondary boom lift cylinder raises and
lowers the secondary boom. The secondary
boom lift cylinder is equipped with counterbalance
valves to prevent movement in the event of a
hydraulic line failure.
How to Remove the Secondary
Boom Lift Cylinder
Bodily injury hazard. This
procedure requires specific repair
skills, lifting equipment and a
suitable workshop. Attempting this
procedure without these skills and
tools could result in death or
serious injury and significant
component damage. Dealer
service is strongly recommended.
When removing a hose assembly
or fitting, the O-ring on the fitting
and/or hose end must be replaced
and then torqued to specification
during installation. Refer to
Section Two, Hydraulic Hose and
Fitting Torque Specifications.
4 Open the engine side turntable cover. Pull up
on the engine tray lock pin and swing the
engine tray out and away from the machine.
Secure the engine tray from moving.
5 Remove the pin retaining fasteners from the
secondary boom lift cylinder barrel-end pivot
pins.
6 Use a slide hammer to remove the barrel-end
pivot pins.
Access the pins using the access
holes located in the bulkheads,
one on each side.
7 Remove the pin retaining fasteners from the
secondary boom lift cylinder rod-end pivot pin.
Use a soft metal drift to remove the pin.
8 Carefully lower the cylinder down through the
secondary boom, just enough to access the
hydraulic hoses.
Component damage hazard.
Hoses can be damaged if they are
kinked or pinched.
9 Tag, disconnect and plug the hydraulic hoses
from the secondary boom lift cylinder. Cap the
fittings on the cylinder.
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.
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. Turn the machine off.
3 Attach a lifting strap from an overhead crane to
the lug on the rod-end of the secondary boom
lift cylinder.
10 Carefully remove the cylinder by raising it
through the top of the secondary boom using
the overhead crane.
Crushing hazard. The secondary
boom lift cylinder could become
unbalanced and fall when
removed from the machine if not
properly supported by the
overhead crane.
Part No. 119987
Z-34/22 IC
4 - 29
Section 4 • Repair Procedures
June 2007
Kubota D-905 Engine
REV A
6-1
Timing Adjustment
6-4
Flex Plate
Complete information to perform this procedure is
available in the Kubota D-905 Workshop Manual
(Kubota part number: 97897-02432).
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.
Kubota D905 Workshop Manual
Genie part number
How to Remove the Flex Plate
31742
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.
6-2
Glow Plugs
Refer to maintenance procedure B-8, Check The
Glow Plugs - Diesel Models.
6-3
RPM Adjustment
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
raised spline away from the flywheel.
See the scheduled maintenance procedure B-9,
Check and Adjust the Engine RPM.
b
a
a
b
c
d
e
4 - 30
Z-34/22 IC
c
d
e
pump
pump shaft
pump coupler
flex plate
flywheel
Part No. 119987
June 2007
Section 4 • Repair Procedures
REV A
KUBOTA D-905 ENGINE
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
65-70 ft-lbs / 88-95 Nm.
Component damage hazard. Do
not force the drive pump during
installation or the flex plate teeth
may become damaged.
6-5
Coolant Temperature and
Oil Pressure Switches
The engine coolant temperature switch is a
normally open switch. The switch contacts close at
approximately 225°F / 107°C. If the coolant
temperature rises above the switch point, the
switch contacts close and the engine will shut off to
prevent damage. The engine will not start until the
temperature drops below the switch point. An overtemperature indicator light at the ground controls
should turn on when the switch closes.
Component damage hazard.
Do not crank the engine with
the over-temperature light on.
The engine oil switch is a normally closed switch.
The switch contacts open at approximately
7 psi / 0.48 bar. If the oil pressure drops below the
switch point, the contacts open and the engine will
shut off to prevent damage. A low oil pressure
indicator light at the ground controls should turn on
when the switch opens.
Component damage hazard.
Do not crank the engine with the
low oil pressure light on.
Part No. 119987
Z-34/22 IC
4 - 31
Section 4 • Repair Procedures
June 2007
Kubota DF750 / DF752 Engine
REV A
7-1
Choke Adjustments
7-4
RPM Adjustment
The choke is solenoid-operated and functions only
in the gasoline mode. This choke will not operate in
LPG mode.
See the scheduled maintenance procedure B-9,
Check and Adjust the Engine RPM.
Choke adjustments are affected
by climate. Richer adjustment will
be necessary in colder climates,
leaner adjustment in warmer
climates.
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.
7-2
Timing Adjustment
How to Remove the Flex Plate
The ignition timing cannot be
adjusted. The timing adjustment
screw is factory sealed with a
tamper resistant cap installed by
the manufacturer. If service or
repair is needed, contact your
local Kubota dealer.
1 Support the drive pump with a suitable lifting
device.
2 Remove all of the pump mounting plate to
engine fasteners.
3 Carefully pull the pump assembly away from the
engine and secure it from moving.
3 Remove the flex plate mounting fasteners.
Remove the flex plate from the flywheel.
7-3
Carburetor Adjustment
The carburetor cannot be
adjusted. The carburetor mixture
screws are factory sealed with
tamper resistant caps installed by
the manufacturer. If service or
repair is needed, contact your
local Kubota dealer.
4 - 32
Z-34/22 IC
Part No. 119987
June 2007
Section 4 • Repair Procedures
KUBOTA DF750 / DF752 ENGINE
REV A
How to Install the Flex Plate
7-6
Coolant Temperature and
Oil Pressure Switches
1 Install the flex plate onto the flywheel with the
raised spline against the flywheel.
The engine coolant temperature switch is a
normally open switch. The switch contacts close at
approximately 225°F / 107°C. If the coolant
temperature rises above the switch point, the
switch contacts close and the engine will shut off to
prevent damage. The engine will not start until the
temperature drops below the switch point. An overtemperature indicator light at the ground controls
should turn on when the switch closes.
Component damage hazard.
Do not crank the engine with
the over-temperature light on.
b
a
a
b
c
d
e
c
d
e
pump
pump shaft
pump coupler
flex plate
flywheel
2 Apply removable Loctite® thread sealant to the
flex plate mounting fasteners. Torque the flex
plate mounting fasteners to 36 ft-lbs / 49 Nm.
The engine oil switch is a normally closed switch.
The switch contacts open at approximately
7 psi / 0.48 bar. If the oil pressure drops below the
switch point, the contacts open and the engine will
shut off to prevent damage. A low oil pressure
indicator light at the ground controls should turn on
when the switch opens.
3 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.
Component damage hazard.
Do not crank the engine with the
low oil pressure light on.
4 Apply removable Loctite® thread sealant to the
coupler set screw. Torque the set screw to
65-70 ft-lbs / 88-95 Nm.
Component damage hazard. Do
not force the drive pump during
installation or the flex plate teeth
may become damaged.
Part No. 119987
Z-34/22 IC
4 - 33
Section 4 • Repair Procedures
June 2007
Hydraulic Pumps
REV A
8-1
Auxiliary Pump
How to Remove the Auxiliary
Pump
When removing a hose assembly
or fitting, the O-ring on the fitting
and/or hose end must be replaced
and then torqued to specification
during installation. Refer to
Section Two, Hydraulic Hose and
Fitting Torque Specifications.
How to Test the Auxiliary Pump
When removing a hose assembly
or fitting, the O-ring on the fitting
and/or hose end must be replaced
and then torqued to specification
during installation. Refer to
Section Two, Hydraulic Hose and
Fitting Torque Specifications.
1 Tag, disconnect and plug the hydraulic hoses
from the pump.
1 Tag, disconnect and plug the high pressure
hydraulic hose from the auxiliary pump.
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.
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 pump mounting fasteners.
Carefully remove the pump.
2 Connect a 0 to 5000 psi / 0 to 350 bar pressure
gauge to the high pressure port on the pump.
3 Turn the key switch to ground control and pull
out the red Emergency Stop button to the on
position at both the ground and platform
controls.
4 Activate any function using auxiliary power.
Result: The pressure gauge reads 2800 psi /
193 bar, immediately stop. The pump is good.
Result: The pressure fails to reach 2800 psi /
193 bar, the pump is faulty and will need to be
serviced or replaced.
5 Remove the pressure gauge and install the
hydraulic hose.
4 - 34
Z-34/22 IC
Part No. 119987
June 2007
Section 4 • Repair Procedures
HYDRAULIC PUMPS
REV A
5 Observe the pressure gauge while cranking the
engine. Immediately stop if the pressure
reaches or exceeds 3000 psi / 206 bar.
8-2
Function Pump
How to Test the Function Pump
When removing a hose assembly
or fitting, the O-ring on the fitting
and/or hose end must be replaced
and then torqued to specification
during installation. Refer to
Section Two, Hydraulic Hose and
Fitting Torque Specifications.
Result: The pressure gauge reads 3000 psi /
206 bar, immediately stop cranking the engine.
The pump is good.
Result: The pressure fails to reach 3000 psi /
206 bar, the pump is faulty and will need to be
serviced or replaced.
Component damage hazard.
Hydraulic pressure in excess of
3000 psi / 206 bar may result in
severe component damage.
1 Tag, disconnect and plug the high pressure
hydraulic hose from the function pump.
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 Connect a 0 to 5000 psi / 0 to 350 bar pressure
gauge to the high pressure port on the pump.
6 Remove the pressure gauge and install the
hydraulic hose.
7 Gasoline/LPG models: Install the ignition coil
wire to the center of the ignition coil.
Diesel models: Release the manual fuel
shutoff lever.
How to Remove the Function
Pump
3 Gasoline/LPG models: Disconnect the ignition
coil wire from the center of the ignition coil.
When removing a hose assembly
or fitting, the O-ring on the fitting
and/or hose end must be replaced
and then torqued to specification
during installation. Refer to
Section Two, Hydraulic Hose and
Fitting Torque Specifications.
Diesel models: Hold the manual fuel shutoff
lever clockwise to the closed position.
4 Turn the key switch to ground control and pull
the Emergency Stop button to the on position at
both the ground and platform controls.
1 Tag, disconnect and plug the hydraulic hoses
from the pump.
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 pump mounting fasteners.
Carefully remove the pump.
Part No. 119987
Z-34/22 IC
4 - 35
Section 4 • Repair Procedures
June 2007
HYDRAULIC PUMPS
REV A
2 Tag,disconnect and plug the hydraulic hoses
from the pump.
8-3
Drive Pump
The drive pump is a bi-directional variable
displacement piston pump. The pump output is
controlled by an electronic displacement controller,
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 Sauer
Danfoss service center.
Models before serial number 1547
were equipped with an EDC
(electrical displacement control)
proportional control. Models after
serial number 1546 were equipped
with a NFPE (non-feedback
proportional electrical) proportional
control.
How to Remove the Drive Pump
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
that could result in severe
component damage. Dealer
service is recommended.
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.
3 Support the pump with a suitable lifting device.
4 Remove the drive pump mounting bolts.
Carefully remove the pump.
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 Gasoline/LPG models: Disconnect the ignition
coil wire from the center of the ignition coil.
Diesel models: Hold the manual fuel shutoff
lever clockwise to the closed position.
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.
When removing a hose assembly
or fitting, the O-ring on the fitting
and/or hose end must be replaced
and then torqued to specification
during installation. Refer to
Section Two, Hydraulic Hose and
Fitting Torque Specifications.
1 Before serial number 1547: Disconnect the
electrical connection at the electronic
displacement controller (EDC) located on the
drive pump.
After serial number 1546: Disconnect the
electrical connectors from the coils of the NFPE
controller (NFPE) located on the drive pump.
4 - 36
Z-34/22 IC
Part No. 119987
June 2007
Section 4 • Repair Procedures
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Part No. 119987
Z-34/22 IC
4 - 37
Section 4 • Repair Procedures
June 2007
Manifolds
REV A
9-1
Function Manifold Components
The function manifold is mounted to the turntable under the ground control box.
Index
No.
Description
Schematic
Item
Function
Torque
1
Counterbalance valve,
3000 psi / 207 bar .............................. F ........... Platform level up ............................... 25-30 ft-lbs / 34-41 Nm
2
Counterbalance valve,
3000 psi / 207 bar .............................. G ........... Platform level down .......................... 25-30 ft-lbs / 34-41 Nm
3
Counterbalance valve,
1500 psi / 103 bar .............................. H ........... Turntable rotate left ........................... 25-30 ft-lbs / 34-41 Nm
4
Counterbalance valve,
1500 psi / 103 bar
(after serial number 673) ................... I ............ Turntable rotate right ........................ 25-30 ft-lbs / 34-41 Nm
5
Relief valve, 1600 psi / 110 bar ......... J ............ Secondary boom down ..................... 25-30 ft-lbs / 34-41 Nm
6
Relief valve, 1400 psi / 97 bar
(before serial number 2901)
Relief valve, 1600 psi / 110 bar
(after serial number 2900) ................ K ........... Primary boom down ......................... 25-30 ft-lbs / 34-41 Nm
7
Relief valve, 1800 psi / 124 bar
(before serial number 2901)
Relief valve, 2800 psi / 193 bar
(from serial number 2901 to 3215) ... L ........... Primary boom extend ....................... 25-30 ft-lbs / 34-41 Nm
8
Proportional solenoid valve .............. D ........... System flow regulating circuit ........... 35-40 ft-lbs / 47-54 Nm
9
Solenoid valve, 3 position 4 way ...... E ........... Steer left/right .................................... 10-12 ft-lbs / 14-16 Nm
10
Flow regulator valve,
0.1 gpm / 0.38 L/min .......................... W .......... Differential sensing circuit ................. 35-40 ft-lbs / 47-54 Nm
11
Differential sensing valve .................. C ........... All functions ....................................... 35-40 ft-lbs / 47-54 Nm
12
Diagnostic fitting ............................................... Testing
13
Priority flow regulator valve,
1 gpm / 4.5 L/min ............................... A ........... Steering ............................................. 34-40 ft-lbs / 47-54 Nm
14
Relief valve, 3200 psi / 221 bar ......... B ........... System relief ..................................... 25-30 ft-lbs / 34-41 Nm
15
Solenoid valve, 2 position 3 way ....... V ........... Primary boom retract .......................... 8-10 ft-lbs / 11-14 Nm
16
Solenoid valve, 2 position 3 way ....... S ........... Primary boom up ................................. 8-10 ft-lbs / 11-14 Nm
This list continues. Please turn the page.
4 - 38
Z-34/22 IC
Part No. 119987
June 2007
Section 4 • Repair Procedures
REV A
MANIFOLDS
1
F
3
2
G
H
4
I
5
J
6
K
8
7
L
D
E
W
C
26
X
9
10
11
12
A 13
B
V
S
Q
P
M
25
N
U
T
R
O
Y
24
Part No. 119987
Z-34/22 IC
14
15
16
17
18
19
20
21
22
23
4 - 39
Section 4 • Repair Procedures
June 2007
MANIFOLDS
REV A
Function Manifold Components, continued
The function manifold is mounted to the turntable under the ground control box.
Index
No.
Description
17
Solenoid valve, 2 position 3 way ....... Q ........... Secondary boom up ............................ 8-10 ft-lbs / 11-14 Nm
18
Solenoid valve, 2 position 3 way ....... P ........... Turntable rotate left ............................. 8-10 ft-lbs / 11-14 Nm
19
Solenoid valve, 2 position 3 way ....... M .......... Platform level up ................................. 8-10 ft-lbs / 11-14 Nm
20
Solenoid valve, 2 position 3 way ....... U ........... Primary boom extend .......................... 8-10 ft-lbs / 11-14 Nm
21
Solenoid valve, 2 position 3 way ....... T ........... Primary boom down ............................ 8-10 ft-lbs / 11-14 Nm
22
Solenoid valve, 2 position 3 way ....... R ........... Secondary boom down ....................... 8-10 ft-lbs / 11-14 Nm
23
Solenoid valve, 2 position 3 way ....... O ........... Turntable rotate right .......................... 8-10 ft-lbs / 11-14 Nm
24
Orifice, 0.052 inch / 1.32 mm ............ Y ........... Turntable rotate circuit
25
Solenoid valve, 2 position 3 way ...... N ........... Platform level down ............................ 8-10 ft-lbs / 11-14 Nm
26
Orifice, 0.052 inch / 1.32 mm ............ X ........... Turntable rotate circuit
4 - 40
Schematic
Item
Function
Z-34/22 IC
Torque
Part No. 119987
June 2007
Section 4 • Repair Procedures
REV A
MANIFOLDS
1
F
3
2
G
H
4
I
5
J
6
K
8
7
L
D
E
W
C
26
X
9
10
11
12
A 13
B
V
S
Q
P
M
25
N
U
T
R
O
Y
24
Part No. 119987
Z-34/22 IC
14
15
16
17
18
19
20
21
22
23
4 - 41
Section 4 • Repair Procedures
June 2007
MANIFOLDS
REV A
9-2
Valve Adjustments Function Manifold
How to Adjust the Primary Boom
Extend Relief Valve
(before serial number 3216)
How to Adjust the Primary Boom
Down Relief Valve
1 Connect a 0 to 3000 psi / 0 to 206 bar pressure
gauge to the test port on the function manifold.
2 Start the engine from the ground controls.
3 Hold the function enable/rpm select toggle
switch to the high rpm position and activate and
hold the primary boom toggle switch in the
down direction with the primary boom fully
lowered.
4 Observe the pressure reading on the pressure
gauge. Refer to Section 2, Specifications.
5 Turn the machine off. Hold the relief valve and
remove the cap (item K).
6 Adjust the internal hex socket. Turn it clockwise
to increase the pressure or counterclockwise to
decrease the pressure. Install the relief valve
cap.
1 Connect a 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 Hold the function enable/rpm select toggle
switch to the high rpm position and activate and
hold the primary boom extend toggle switch in
the extend direction with the primary boom fully
extended.
4 Observe the pressure reading on the pressure
gauge. Refer to Section 2, Specifications.
5 Turn the machine off. Hold the relief valve and
remove the cap (item L).
6 Adjust the internal hex socket. Turn it clockwise
to increase the pressure or counterclockwise to
decrease the pressure. Install the relief valve
cap.
Tip-over hazard. Do not adjust
the relief valve higher than
specified.
7 Repeat steps 2 through 6 to confirm the relief
valve pressure setting.
Tip-over hazard. Do not adjust
the relief valve higher than
specified.
7 Repeat steps 2 through 6 to confirm the relief
valve pressure setting.
4 - 42
Z-34/22 IC
Part No. 119987
June 2007
Section 4 • Repair Procedures
MANIFOLDS
REV A
How to Adjust the Secondary
Boom Down Relief Valve
1 Connect a 0 to 3000 psi / 0 to 206 bar pressure
gauge to the test port on the function manifold.
2 Start the engine from the ground controls.
3 Hold the function enable/rpm select toggle
switch to the high rpm position and activate and
hold the secondary boom toggle switch in the
down direction with the secondary boom fully
lowered.
4 Observe the pressure reading on the pressure
gauge. Refer to Section 2, Specifications.
5 Turn the machine off. Hold the relief valve and
remove the cap (item J).
6 Adjust the internal hex socket. Turn it clockwise
to increase the pressure or counterclockwise to
decrease the pressure. Install the relief valve
cap.
Tip-over hazard. Do not adjust
the relief valve higher than
specified.
7 Repeat steps 2 through 6 to confirm the relief
valve pressure setting.
Part No. 119987
Z-34/22 IC
4 - 43
Section 4 • Repair Procedures
June 2007
MANIFOLDS
REV A
9-3
Jib Boom / Platform Rotate Manifold Components
The jib boom/platform rotate manifold is mounted to the jib boom.
Index
No.
Description
Schematic
Item
1
Solenoid valve, 3 position 4 way ...... CH ........ Jib boom up/down ............................ 8-10 ft-lbs / 11-14 Nm
2
Solenoid valve, 3 position 4 way ...... CI .......... Platform rotate left/right ..................... 8-10 ft-lbs / 11-14 Nm
3
Solenoid valve, 2 position 3 way ...... CA ........ Jib boom down ................................. 8-10 ft-lbs / 11-14 Nm
4
Solenoid valve, 2 position 3 way ...... CB ........ Platform rotate left ............................. 8-10 ft-lbs / 11-14 Nm
5
Flow regulator valve,
0.3 gpm / 1.14 L/min .......................... CG ........ Platform rotate circuit ........................ 8-10 ft-lbs / 11-14 Nm
6
Solenoid valve, 2 position 3 way ...... CC ........ Platform rotate right .......................... 8-10 ft-lbs / 11-14 Nm
7
Solenoid valve, 2 position 3 way ...... CD ........ Jib boom up ...................................... 8-10 ft-lbs / 11-14 Nm
8
Orifice, 0.025 in / 0.64 mm
(from serial number 1187 to 1891)
Orifice, 0.022 in / 0.56 mm
(from serial number 1892 to 1969) ... CE ........ Platform rotate circuit
9
Orifice, 0.028 in / 0.71 mm
(located in "P" port) ........................... CF ......... Platform rotate and jib boom circuit
1
CH
Function
Torque
2
CI
CA
CB
CG
9
5
3
4
5
CF
CG
before serial number 2005
CF
after serial number 2006
9
4 - 44
CE
8
Z-34/22 IC
CD
7
CC
6
Part No. 119987
June 2007
Section 4 • Repair Procedures
REV A
MANIFOLDS
9-4
Brake / 2-speed Manifold Components
The brake / 2-speed manifold is located under the drive chassis cover at the non-steer end.
Index
No.
Description
1
Check Valve ...................................... AC ........ Pressure circuit ................................... 8-10 ft-lbs / 10-15 Nm
2
Solenoid valve, 2 position 3 way ....... AB ......... 2-speed motor shift ........................... 25-30 ft-lbs / 34-41 Nm
3
Solenoid valve, 2 position 3 way ....... AA ......... Brake ................................................. 25-30 ft-lbs / 34-41 Nm
4
Orifice Plug, 0.025 inch / 0.64 mm .... AD ........ Tank return circuit
4
3
Schematic
Item
Function
Torque
AD
AA
AB
AC
2
Part No. 119987
1
Z-34/22 IC
4 - 45
Section 4 • Repair Procedures
June 2007
MANIFOLDS
REV A
9-5
2WD Traction Manifold Components
The 2WD traction is mounted inside the drive chassis at the non-steer end.
Index
No.
Description
Schematic
Item
1
Relief valve, 210 psi / 14.5 bar ......... B ........... Charge pressure circuit .................... 35-40 ft-lbs / 47-54 Nm
2
Diagnostic fitting ............................................... Testing
3
Flow divider/combiner valve ............. C ........... Controls flow to drive motors
in forward and reverse ............. 130-140 ft-lbs / 176-190 Nm
4
Orifice 0.070 inch / 1.78 mm ............. D ........... Equalizes pressure on both sides
divider/combiner valve C.
5
Shuttle valve, 3 position 3 way ......... A ........... Charge pressure circuit
that gets hot oil out of low pressure
side of drive pump and allows low
pressure flow path for brake
release and 2-speed motor shift ....... 10-12 ft-lbs / 14-16 Nm
Function
1
Torque
2
B
C
D
5
3
4
A
4 - 46
Z-34/22 IC
Part No. 119987
June 2007
Section 4 • Repair Procedures
REV A
MANIFOLDS
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Part No. 119987
Z-34/22 IC
4 - 47
Section 4 • Repair Procedures
June 2007
MANIFOLDS
REV A
9-6
4WD Traction Manifold Components
The 4WD traction manifold is mounted inside the drive chassis at the non-steer end.
Index
No.
Description
1
Diagnostic fitting ............................................... Testing
2
Directional control valve,
2 position 3 way ................................. H ........... Diverts all flow to steer
end drive motors when
in high range ............................. 130-140 ft-lbs / 176-190 Nm
3
Flow divider/combiner valve .............. E ........... Controls flow to flow
divider/combiner valves
D and F ..................................... 130-140 ft-lbs / 176-190 Nm
4
Orifice plug, 0.052 inch / 1.32 mm ..... G ........... Equalizes pressure across
flow divider/combiner valve F
5
Flow divider/combiner valve .............. F ........... Controls flow to steer end drive
motors in forward and reverse .......... 15-18 ft-lbs / 20-24 Nm
6
Flow divider/combiner valve .............. D ........... Controls flow to non-steer end
drive motors in forward
and reverse ....................................... 15-18 ft-lbs / 20-24 Nm
7
Orifice plug, 0.045 inch / 1.14 mm ..... K ........... Equalizes pressure across
flow divider/combiner valve D
8
Check valve ....................................... I ............ Direction control circuit ..................... 25-30 ft-lbs / 34-41 Nm
9
Relief valve, 210 psi / 14.5 bar .......... B ........... Charge pressure circuit ..................... 35-40 ft-lbs / 47-54 Nm
10
Orifice plug, 0.052 inch / 1.32 mm ..... C ........... Equalizes pressure across
flow divider/combiner valve E
11
Check valve, pilot operated ............... J ............ Smoothes the shift
from low to high range ...................... 10-12 ft-lbs / 14-16 Nm
12
Shuttle valve, 3 position 3 way .......... A ........... Charge pressure circuit
that gets hot oil out of low pressure
side of drive pump and allows low
pressure flow path for brake
release and 2-speed motor shift ....... 10-12 ft-lbs / 14-16 Nm
4 - 48
Schematic
Item
Function
Z-34/22 IC
Torque
Part No. 119987
June 2007
Section 4 • Repair Procedures
REV A
MANIFOLDS
1
2
H
3
E
4
G
F
D
K
I
B
C
J
A
Part No. 119987
Z-34/22 IC
5
6
7
8
9
10
11
12
4 - 49
Section 4 • Repair Procedures
June 2007
MANIFOLDS
REV A
9-7
Valve Adjustments Traction Manifold
9-8
Valve Coils
How to Test a Coil
How to Adjust the Charge
Pressure Relief Valve
A properly functioning coil provides an
electromotive force which operates the solenoid
valve. Critical to normal operation is continuity
within the coil. Zero resistance indicates the coil
has failed.
1 Connect a 0 to 600 psi / 0 to 41 bar pressure
gauge to the test port located on the traction
manifold.
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 Drive the machine slowly in either direction and
observe the pressure reading on the pressure
gauge. Refer to Section 2, Specifications.
Since coil resistance is sensitive to temperature,
resistance values outside specification can
produce erratic operation. When coil resistance
decreases below specification, amperage
increases. As resistance rises above specification,
voltage increases.
While valves may operate when coil resistance is
outside specification, maintaining coils within
specification will help ensure proper valve function
over a wide range of operating temperatures.
Electrocution hazard. Contact with
electrically charged circuits could
result in death or serious injury.
Remove all rings, watches and
other jewelry.
4 Turn the engine off. Hold the relief valve and
remove the cap (item B).
5 Adjust the internal hex socket. Turn it clockwise
to increase the pressure or counterclockwise
to decrease the pressure. Install the relief valve
cap.
6 Start the engine. Drive the machine in either
direction and check the relief valve pressure.
7 Turn the engine off and remove the pressure
gauge.
1 Tag and disconnect the wiring from the coil to
be tested.
2 Test the coil resistance.
Coils with 2 terminals: Connect the leads from
the ohmmeter to the valve coil terminals.
Coils with 1 terminal: Connect the positive
lead from the ohmmeter to the valve coil
terminal, then connect the negative lead from
the ohmmeter to the internal ring of the valve
coil.
Result: The resistance should be within
specification, plus or minus 30%.
Result: If the resistance is not within
specification, plus or minus 30%, replace the
coil.
4 - 50
Z-34/22 IC
Part No. 119987
June 2007
Section 4 • Repair Procedures
REV A
MANIFOLDS
Valve Coil Resistance
Specification
Note: The following coil resistance specifications
are at an ambient temperature of 68°F / 20°C. As
valve coil resistance is sensitive to changes in air
temperature, the coil resistance will typically
increase or decrease by 4% for each 18°F / 20°C
that your air temperature increases or decreases
from 68°F / 20°C.
2 Connect a 10Ω resistor to the negative terminal
of a known good 9V DC battery. Connect the
other end of the resistor to a terminal on the
coil.
The battery should read 9V DC or
more when measured across the
terminals.
Ω
Resistor, 10Ω
Genie part number
27287
Valve coil specifications
2 position 3 way solenoid valve, 10V DC
(schematic items V, S, Q, P, M, U, T,
R, O, N, AA, AB, CA, CB, CC and CD)
6Ω
3 position 4 way solenoid valve, 10V DC
(schematic item E, CH, CI)
6Ω
Proportional solenoid valve, 12V DC
(schematic item D)
5Ω
COIL
MULTI
METER
d
a
+
c
10 W
RESISTOR
b
9V
BATTERY
+
c
How to Test a Coil Diode
Genie incorporates spike suppressing diodes in all
of its valve coils. Properly functioning coil diodes
protect the electrical circuit by suppressing voltage
spikes. Voltage spikes naturally occur within a
function circuit following the interruption of
electrical current to a coil. Faulty diodes can fail to
protect the electrical system, resulting in a tripped
circuit breaker or component damage.
a
b
c
d
b
multimeter
9V DC battery
10Ω resistor
coil
Note: Dotted lines in illustration indicate a
reversed connection as specified in
step 6
3 Set a multimeter to read DC current.
Electrocution hazard. Contact with
electrically charged circuits could
result in death or serious injury.
Remove all rings, watches and
other jewelry.
The multimeter, when set to read
DC current, should be capable of
reading up to 800 mA.
1 Test the coil for resistance. See How to Test a
Coil.
Part No. 119987
Z-34/22 IC
4 - 51
Section 4 • Repair Procedures
June 2007
MANIFOLDS
REV A
4 Connect the negative lead to the other terminal
on the coil.
If testing a single-terminal coil,
connect the negative lead to the
internal metallic ring at either end
of the coil.
5 Momentarily connect the positive lead from the
multimeter to the positive terminal on the 9V DC
battery. Note and record the amperage reading.
6 At the battery or coil terminals, reverse the
connections. Note and record the current
reading.
Result: Both current readings are greater than
0 mA and are different by a minimum of 20%.
The coil is good.
Result: If one or both of the current readings are
0 mA, or if the two current readings do not differ
by a minimum of 20%, the coil and/or its
internal diode are faulty and the coil should be
replaced.
4 - 52
Z-34/22 IC
Part No. 119987
June 2007
REV A
Section 4 • Repair Procedures
Fuel and Hydraulic Tanks
10-1
Fuel Tank
7 Tag, disconnect and plug the fuel hoses from
the fuel tank. Cap the fittings on the fuel tank.
Clean up any fuel that may have spilled.
How to Remove the Fuel Tank
8 Metal fuel tank: Remove the fuel tank strap
retaining fasteners located under the tank
mounting tray.
1 Raise the secondary boom so the upper pivot is
approximately 12 feet / 4 m off the ground.
2 Gasoline/LPG models: Turn the LPG shutoff
valve to the closed position on the LPG tank.
3 Gasoline/LPG models: Remove the LPG hose
from the tank and then remove the tank from
the machine.
Plastic fuel tank: Remove the fuel tank
retaining plate fasteners at the bulkhead.
9 Remove the fuel tank from the machine using
an appropriate lifting device.
4 Gasoline/LPG models: Remove the mounting
fasteners from the LPG bottle bracket then
remove the bracket from the machine.
5 Turn the manual fuel shutoff valve (if equipped)
to the closed position on the fuel tank.
Metal fuel tank: Clean the fuel
tank and inspect for rust and
corrosion before installing.
Plastic fuel tank: Clean the fuel
tank and inspect for cracks and
damage before installing.
6 Using an approved hand-operated pump, drain
the fuel tank into a suitable container. Refer to
Section 2, Specifications.
Explosion and fire hazard. Engine
fuels are combustible. Remove the
fuel tank in an open, wellventilated area away from heaters,
sparks, flames and lighted
tobacco. Always have an
approved fire extinguisher within
easy reach.
Explosion and fire hazard. When
transferring fuel, connect a
grounding wire between the
machine and pump or container.
Be sure to only use a handoperated pump suitable for use
with gasoline and diesel fuel.
Part No. 119987
Z-34/22 IC
4 - 53
Section 4 • Repair Procedures
June 2007
FUEL AND HYDRAULIC TANKS
REV A
10-2
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
3 Remove the drain plug from the hydraulic tank
and completely drain the tank into a container
of suitable capacity. Refer to Section 2,
Specifications.
Bodily injury hazard. Beware of
hot oil. Contact with hot oil may
cause severe burns.
4 Tag, disconnect and plug the hoses from the
return filter. Cap the fittings on the return filter.
5 Tag, disconnect and plug the suction hoses
from the bottom of the tank. Cap the fittings.
1 Place a suitable container under the hydraulic
tank. Refer to Section 2, Specifications.
6 Remove the fasteners from the hydraulic tank
hold down straps. Remove the straps.
2 Close the two hydraulic tank shut-off valves at
the hydraulic tank.
7 Remove the turntable cover using a suitable
lifting device.
Component damage hazard. The
engine must not be started with
the hydraulic tank shut-off valves
in the closed position or
component damage will occur. If
the tank valves are closed,
remove the key from the key
switch and tag the machine to
inform personnel of the condition.
open
4 - 54
Crushing hazard. The turntable
cover could become unbalanced
and fall if not properly supported
when removed from the machine.
8 Support and secure the hydraulic tank to a
suitable lifting device. Remove the hydraulic
tank from the machine.
Crushing hazard. The hydraulic
tank could become unbalanced
and fall if not properly supported
when removed from the machine.
closed
Z-34/22 IC
Part No. 119987
June 2007
REV A
Section 4 • Repair Procedures
Turntable Rotation Components
11-1
Rotation Hydraulic Motor
The turntable rotation hydraulic motor is the only
serviceable component of the turntable rotation
assembly. The worm gear may not be removed
from the housing. In order to remove the housing,
the entire turntable assembly has to be removed.
How to Remove the Turntable
Rotation Motor
Do not allow the turntable to rotate
until the hydraulic motor is
installed.
1 Tag, disconnect and plug the hydraulic hoses
from the turntable rotation motor. Cap the
fittings on the motor.
Bodily injury hazard. Spraying
hydraulic oil can penetrate and
burn skin. Loosen hydraulic
connections very slowly to allow
the oil pressure to dissipate
gradually. Do not allow oil to squirt
or spray.
2 Remove the turntable rotation motor mounting
fasteners. Remove the motor from the worm
gear housing.
Part No. 119987
Z-34/22 IC
4 - 55
Section 4 • Repair Procedures
June 2007
Axle Components
REV A
12-1
Hub and Bearings, 2WD Models
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.
How to Remove the
Hub and Bearings
1 Loosen the wheel lug nuts. Do not remove
them.
1 Be sure that both bearings are packed
with clean, fresh grease.
2 Block the non-steer wheels and place a lifting
jack of ample capacity under the steer axle.
3 Raise the machine 6 inches / 15 cm and place
blocks under the drive chassis for support.
2 Place the large inner bearing into the rear
of the hub.
3 Install a new bearing grease seal into the hub
by pressing it evenly into the hub until it is flush.
Crushing damage. The machine
may fall if not properly supported.
4 Remove the lug nuts. Remove the tire and
wheel assembly.
Always replace the bearing grease
seal when removing the hub.
4 Slide the hub onto the yoke spindle.
Component damage. Do not
apply excessive force or damage
to the lip of the seal may occur.
5 Remove the dust cap, cotter pin and castle nut.
6 Pull the hub off the spindle. The washer and
outer bearing should fall loose from the hub.
7 Place the hub on a flat surface and gently pry
the bearing seal out of the hub. Remove the
rear bearing.
5 Fill the hub cavity with clean, fresh grease.
6 Place the outer bearing into the hub.
7 Install the washer and castle nut.
8 Tighten the castle nut to 158 ft-lbs / 214 Nm to
seat the bearings.
Rotate the hub by hand while
torquing the castle nut to make
sure the bearings seat properly.
9 Loosen the castle nut one full turn and then
torque to 35 ft-lbs / 47 Nm.
10 Install a new cotter pin. Bend the cotter pin
to lock it in.
Always use a new cotter pin when
installing a castle nut.
11 Install the dust cap, then the tire and wheel
assembly. Torque the wheel lug nuts to
specification. Refer to Section 2, Specifications.
4 - 56
Z-34/22 IC
Part No. 119987
June 2007
Section 5 • Schematics
Schematics
About This Section
There are two groups of schematics in this section.
An illustration legend precedes each group of
drawings.
Electrical Schematics
Observe and Obey:
Electrocution hazard. Contact with
electrically charged circuits could
result in death or serious injury.
Remove all rings, watches and
other jewelry.
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 a
damaged or malfunctioning machine.
Hydraulic Schematics
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.
Repair any machine damage or malfunction
before operating the machine.
Before Troubleshooting:
Read, understand and obey the safety rules
and operating instructions printed in the
appropriate Genie Z-34/22 IC Operator's
Manual on your machine.
Be sure that all necessary tools and test
equipment are available and ready for use.
General Repair Process
Identify
symptoms
Malfunction
discovered
Troubleshoot
problem
still exists
Return to
service
Part No. 119987
Z-34/22 IC
problem
solved
Inspect
and test
Perform
repair
5-1
Section 5 • Schematics
June 2007
Electrical Symbols Legend
REV A
TB17
15AMP.
FS1
GRN/BLK
Foot switch
BLK
ORG/BLK-1
Circuit breaker
PLAT
Wire color
with cable
number
GRND
Key switch
Solenoid or
relay coil
Ground
supression
circuit
Terminal
NO
Limit switch
TB21
Water temperature
switch, normally open
Horn button
normally open
LS3
Horn or alarm
BLK #21
P4
HORN
NC
Quick disconnect
terminal
Spark plug
KS1
WTS1 N.O.
TB20
RED
BLK
OPS1 N.C.
P1
LS2
NC
L1 DE
Light
T-circuits connect
at terminal
red Emergency
Stop button
normally closed
Limit switch
normally closed
held open
LS1
NO
Oil pressure switch,
normally closed
VAC
CR4
T-circuits
connect
Auxiliary pump
Relay contact
normally open
RED
GRN
BLK/RED
BP1
+
TS6
LIFT
+
_
A
B
X
R
-
12V
Battery
L
R
Gauge
Toggle switch DPDT
HM
STEER
R
RIGHT
PWR
GND
FWD
REV
BRK REL
OFF LIMIT
D C
DRIVE
Diode
Resistor
Toggle switch SPDT
Rotary OEM
flow control
LEFT
Circuits crossing
no connection
Vacuum switch
normaly open
250
TS3
ENGINE
START
AUX.
PUMP
Limit switch
normally open
held closed
WHT
Connection
no terminal
Tilt sensor
DP1
Hour meter
L
Drive control
5-2
Z-34/22 IC
Part No. 119987
June 2007
Section 5 • Schematics
Hydraulic Symbols Legend
REV A
N.O.
COM
Pressure gauge
N.C.
Double acting
cylinder
Pressure switch
0.035
Orifice with size
Solenoid operated
proportional valve
Filter
Brake
Check valve
Solenoid operated 2 pos.,
3 way, directional valve
Fixed displacement
pump
Variable orifice or
shut off valve
Relief valve
Solenoid operated 3 pos.,
4 way, directional valve
(D01)
Flow divider combiner
Bi-directional motor
Priority
flow divider
Pilot operated flow
control valve
Bi-directional, variable
displacement pump
Sequencing valve
Solenoid operated
dump valve
Shuttle valve
2-speed,
bi-directional motor
Counterbalance valve
E
Pump prime mover
engine or motor
Part No. 119987
Differential
sensing valve
Z-34/22 IC
5-3
Section 5 • Schematics
5-4
June 2007
Z-34/22 IC
Part No. 119987
TURNTABLE
ROTATE
WHT/BLK-3
WHT-3
TB22
RIGHT
BLK/RED-1
BLK
RED
RIGHT
LEFT
SWING
BLK/RED
RED/WHT#23-E.H.
BLK#R1-E.H.
RED#27-E.H.
WHT/BLK#5-E.H.
WHT#4-E.H.
WNT/RED#26 E.H.
BLK/WHT
WHT/BLK#25 E.H.
WHT
BLK#R5-E.H.
BLK/RED#R4-E.H.
BLK/WHT#41-E.H.
STA.
IND.
EXCT.
BAT. +
REGULATOR
BAT.
_
GND
-
RED
BLK
LEFT
HIGH RPM
HIGH RPM
FUNCTION
ENABLE
BLU/WHT-1
GLOW
PLUG
ENGINE
START
AUXILIARY
POWER
RED/BLK#28-E.H.
RED/WHT#23-E.H.
BLK/RED
ORG/BLK#41-E.H.
WHT#21-E.H.
WTS1
NO
ENGINE SPEED
GLOW
PLUG
BLK-1
RED-1
RED/BLK-1
WHT-2
BLK/RED-3
TB34
ORG/BLK-1
TB24
RED-E.H.
CR4
CR8
CR1
RED
7 KEY PWR.
8 KEY BYPASS
9 IGN./FUEL ON
RED#20-E.H.
REV A
Electrical Schematic - Diesel Models
(from serial number 1187 to 1546)
ORG/BLK
1
WHT
TURNTABLE ROTATE RIGHT
ES34D1E
TURNTABLE ROTATE LEFT
RPM CUTOUT COIL
RELAY
RPM COIL
GLOW PLUG RELAY
FLASHING BEACONS
WATER TEMPERATURE
SENDER
OIL PRESSURE SENDER
HOUR METER
STARTER MOTOR
FUEL SOLENOID
AUXILIARY POWER
RELAY
AUXILIARY PUMP
LEVEL SENSOR
HORN RELAY
HORN
RPM SOLENOID
GLOW PLUGS
ALTERNATOR
Part No. 119987
Z-34/22 IC
5-5
HM
STARTER
AUX
PUMP
BATTERY
8
PR1
NO
NO
TS20
RED
10A
CR3
CR3
PR1
CR5
CR5
CR4
CR8
TB5
CR2
CR2
NO
TB21
10 ENG. FAULT
CR1
NO
OPS1
NC
7
RED
TB20
5
FB
6
5 GROUND
6 BATTERY
IGNITION/
START
MODULE
3 START INPUT
4 AUX. ON
CB1
TS19
TS17
TS16
TS15
TS6
TS5
TS3
TS2
TS1
TB35
1 START RELAY
2 TACHOMETER
TB9
TB41
TB33
TB27
TB28
TB23
ENGINE
START
P3
HORN
RED
4
RED
BLK-2
CB2
PLAT
RED
RED
3
KS1
P1
10A
AUXILIARY
POWER
2
WHT-FS
TS27
RED
FS1
P2
N
M
L
K
J
I
H
G
F
E
D
C
B
A
June 2007
Section 5 • Schematics
LIFT/DRIVE
SELECT (OPTION)
RED
GRND
TB4
GND
+
-
BP1
1
ORG/BLK
WHT-FS
HIGH
LOW
DRIVE ENABLE
RED/WHT
RED
250
PLATFORM
LEVEL
PLATFORM
ROTATE
UP
JIB BOOM
DOWN
BRN-JIB
RIGHT
LEFT
UP
DOWN
PRIMARY
BOOM
BRN-2
BLU/RED-3
WHT-1
BLU/WHT-3
WHT/BLK-1
WHT/RED-1
BLU-1
BLU/BLK-1
RED/WHT-1
ORG-1
WHT/RED-3
ORG-3
ORG/BLK-3
BLK-3
BLK/WHT-3
RED-3
RED/BLK-3
BLU-3
4
GRN-1
GRN/BLK-1
UP
JIB BOOM
DOWN
RIGHT
PLATFORM ROTATE
LEFT
GRN/BLK-3
GRN-3
UP
PLATFORM LEVEL
DOWN
EXTEND
PRIMARY BOOM
RETRACT
SECONDARY
BOOM
UP
PRIMARY BOOM
DOWN
UP
DOWN
BLK-6
WHT-5
RED-5
WHT/BLK#31-E.H.
WHT/RED#32-E.H.
BLU#36-E.H.
BLU/BLK#37-E.H.
RED/WHT#25-E.H.
WHT/RED-E.H.
RED-6
ORG#14-E.H.
ORG/BLK#15-E.H.
BLK#7-E.H.
BLK/WHT#8-E.H.
RED#1-E.H.
RED/BLK#2-E.H.
BLU#10-E.H.
BLU/BLK#11-E.H.
BRN-5
BLK-5
WHT-8
WHT-6
WHT-7
BRN-8
BRN-6
BRN-7
GROUND
SECONDARY BOOM DWN
SECONDARY BOOM UP
PRIMARY BOOM DWN
PRIMARY BOOM UP
PRIMARY BOOM RETRACT
PRIMARY BOOM EXTEND
PLATFORM LEVEL DWN
PLATFORM LEVEL UP
PLATFORM ROTATE
JIB BOOM
BOOM FLOW CONTROL
BOOM EXTEND LIMIT SWITCH
BOOM UP LIMIT SWITCH
SECONDARY BOOM UP LIMIT SWITCH
MOTOR STROKE
STEER RIGHT
STEER LEFT
DRIVE EDC
DRIVE ENABLE LIMIT SWITCH
8
DECENT ALARM (OPTIONAL)
5-6
Z-34/22 IC
Part No. 119987
7
WHT#12-E.H.
LS4
NO
LS2
NO
LS1
NC
D.E.
EXTEND
PRIMARY
RETRACT BOOM
UP
DOWN
3
BLU/BLK-3
TB12
A3
6
NC
NO
TB13
TB30
TB31
TB32
TB37 TB36
TB29
LS3
TB40
PLATFORM LEVEL
CUT-OUT (OPTION)
TB6
R1
L1
R
SECONDARY
BOOM
CR9
CR10
ROTARY
OEM
A
+
FLOW
CONTROL X
UP
4
RED
2
TS14
1
2
3
4
5
6
7
8
TS13
1
2
3
4
5
6
7
8
9
10
HORSE
POWER
LIMITER
BOARD
DOWN
LS2
NC
CR9
CR10
BLK-JIB
TB44
TB17
TB15
TB8
TB2
TB11
WHT-JIB
BLU-JIB
TB43
TB18
TB14
TB7
TB1
5
TB10
ORG-JIB
TS26
TS25
TS24
TS23
TS22
TS21
DP1
TS11
TS10
TS9
TS8
TS7
R2
RED
Electrical Schematic - Diesel Models
(from serial number 1187 to 1546)
REV A
A
B
C
D
E
F
G
H
I
J
K
L
M
N
Section 5 • Schematics
June 2007
RED
RED
RED
RED
GND
GND
June 2007
Section 5 • Schematics
Electrical Schematic - Diesel Models
(from serial number 1187 to 1546)
WHT/BLK-3
WHT-3
BLK/RED-1
FUNCTION ENABLE
HIGH RPM
BLK
RIGHT
LEFT
TURNTABLE
ROTATE
BLK/RED#R3
ORG/BLK-EH
BLK/RED
RED/WHT#23-MH
RED/BLK#28-MH
RED#27-EH
TB4
RED-EH
WHT/BLK#5-CH
WHT#4-CH
GRN/WHT
BLK/WHT
WHT-EH
WHT-EH
WHT
BLK#R1-EH
BLK#R5-MH
BLK/RED#R4-EH
BLK/WHT#R8-EH
IND.
STA.
BAT.
+
EXCT.
HM
REGULATOR
BAT.
_
GND
_
RIGHT
TURNTABLE
ROTATE
LEFT
RED
ENGINE RPM
GRN/WHT-1
START
GLOW
PLUG
BLK/WHT-1
BLK-1
RED
AUXILIARY
PUMP
IGN./FUEL ON
TS20
RED
KEY BYPASS
9
ON
RED-1
KEY PWR.
8
AC GENERATOR
GLOW
PLUG
START
AUXILIARY
PUMP
RED/BLK-1
CR1
WHT#21-EH
REV A
Electrical Schematic - Diesel Models
(from serial number 1547 to 1996)
WHT-FS
WHT
ES34D1G
TURNTABLE ROTATE RIGHT
TURNTABLE ROTATE LEFT
RPM COIL
CUTOUT RELAY
RPM COIL
AC GENERATOR
OPTION
GLOW PLUG RELAY
FLASHING BEACON
WATER TEMPERATURE
SWITCH
OIL PRESSURE
SWITCH
HOUR METER
STARTER MOTOR
FUEL SOLENOID
AUXILIARY
PUMP RELAY
AUXILIARY PUMP
LEVEL SENSOR
HORN
RELAY
HORN
RPM SOLENOID
GLOW PLUG
ALTERNATOR
Part No. 119987
Z-34/22 IC
5-7
WTS1
OPS1
STARTER
AUX
PUMP
BATTERY
7
TB5
RED#CB1-EH
8
CR4
AUX. ON
CR4
CR8
+12V
7
WHT-2
BLK/RED-3
RED
CR8
START INPUT
CR3
PR1
CR5
FB
6
10 ENG. FAULT
CR2
TACHOMETER
LO
RED
GROUND
6
RED
4
TB35
START RELAY
2
TB45
1
ORG/BLK
3
TB23
TB9
TB34
TB33
TB27
TB28
RED
4
TS19
TS17
TS16
TS15
FS-HI
2
HI
RED
+
TS6
TS15
TS3
TS2
TS1
IGNITION/
START
MODULE
CB1
PLAT
RED
RED
P3
BLK-2
HORN
5
10A
5
GRND
10A
3
P1
CB2
TB22
KS1
FS1
RED
P2
1
N
M
L
K
J
I
H
G
F
E
D
C
B
A
June 2007
Section 5 • Schematics
BLK
RED
TS5
A1
TB21
GND
+
RED
RED
WHT
BP1
DRIVE ENABLE
DOWN
UP
LEFT
RIGHT
DOWN
UP
ORG
MOTOR STROKE
JIB BOOM
PLATFORM
ROTATE
PLATFORM
LEVEL
PRIMARY
BOOM
BLU/WHT-3
BLK-8
PLATFORM
LEVEL
PLATFORM
ROTATE
JIB BOOM
WHT-8
DOWN
UP
GRN/BLK-3
LEFT
RIGHT
GRN/BLK-1
GRN-1
SECONDARY
GRN-3
UP
DOWN
EXTEND
WHT-6
PRIMARY
BOOM
PRIMARY
BOOM
RETRACT
UP
DOWN
TB50
SECONDARY
BOOM
BLK-6
ORG-6
WHT-5
BRN-5
BLK-5
WHT #30-EH
WHT/BLK #31-EH
WHT-7
WHT/RED #32-CH
BLU/BLK#11-MH
BLU#10-MH
RED/BLK#2-MH
RED#1-MH
BLK/WHT#8-MH
BLK#7-MH
ORG/BLK#15-MH
ORG#14-MH
RED-6
WHT/RED-MH
BLK-7
RED/WHT#25-CH
BLU/BLK #37-MH
BLU#36-MH
WHT/RED
RED-5
6
LS3
BRN-2
BLU/RED-3
ORG/RED-3
WHT-1
WHT/BLK-1
WHT/RED-1
BLU-1
BLU/BLK-1
RED/WHT-1
ORG-1
WHT/RED-3
ORG-3
ORG/BLK-3
BLK-3
BLK/WHT-3
RED-3
RED/BLK-3
UP
DOWN
TB12
+
A
B
5
LS2
GROUND
SECONDARY
BOOM DOWN
SECONDARY
BOOM UP
PRIMARY
BOOM DOWN
PRIMARY
BOOM UP
PRIMARY BOOM
RETRACT
PRIMARY BOOM
EXTEND
PLATFORM
LEVEL DOWN
PLATFORM
LEVEL UP
PLATFORM ROTATE LEFT
PLATFORM ROTATE RIGHT
JIB DOWN
JIB UP
FLOW CONTROL
LIMIT SWITCHES
MOTOR STROKE
STEER RIGHT
STEER LEFT
TRAVEL ALARM
OPTION
BRAKE RELEASE
DRIVE REVERSE
DRIVE FORWARD
DRIVE ENABLE
LIMIT SWITCH
8
DECENT ALARM
OPTION
5-8
Z-34/22 IC
Part No. 119987
A2
2
TB13
TB16
TB30
TB31
TB32
TB36
DRIVE
ENABLE
LIGHT
PRIMARY
BOOM
RETRACT
EXTEND
DOWN
UP
BLU-3
BLU/BLK-3
SWITCH SHOWN WITH BOOM ROTATED PAST EITHER NON-STEER WHEEL.
3
TB49
LS2
3
LS1
BOOM
EXTEND
PLATFORM LEVEL
CUT-OUT (CE VERSION ONLY)
D C
+
CR9
TS13
SECONDARY
BOOM
RED
TB37
TB29
CR9
CR10
CR10
TB44
TB17
TB15
TB8
TB2
TB11
PRIMARY
TB43
TB18
TB14
TB7
TB1
TB10
LIFT
DOWN
TB6
RED
TB40
DP1
L
L1 +
DRIVE
HIGH
L
R
A
B
X
R
LOW
R
R
2
ORG/RED
BRN
+
_
PWR
GND
FWD
REV
BRK REL
OFF LIMIT
ROTARY
OEM
A
+
FLOW
CONTROL X
UP
BRN-JIB
4
LS4
TS26
TS25
TS24
TS23
TS22
TS21
WHT-JIB
3
BLK-JIB
ORG
BLU-JIB
ORG-JIB
TS14
TS12
TS11
TS10
TS9
TS8
TS7
STEER
RED
Electrical Schematic - Diesel Models
(from serial number 1547 to 1996)
REV A
C
D
E
F
G
H
I
J
K
L
M
N
Section 5 • Schematics
June 2007
WHT-FS
1
JP1 (REMOVE FOR CE VERSION)
A3
7
GND
GND
NOTES:
2 SWITCH SHOWN WITH BOOM EXTENDED.
1. ALL LIMIT SWITCHES SHOWN WITH BOOM IN STOWED POSITION EXCEPT AS NOTED.
June 2007
Section 5 • Schematics
Electrical Schematic - Diesel Models
(from serial number 1547 to 1996)
WHT/BLK-3
WHT-3
BLK/RED-1
RED
FUNCTION ENABLE
HIGH RPM
BLK
RIGHT
LEFT
TURNTABLE
ROTATE
BLK/RED#R3
WHT
WHT
WHT
RED#27-EH
RED/BLK#28-MH
RED/WHT#23-MH
BLK/RED
ORG/BLK-EH
BRN
WNT/RED-EH
WHT/BLK-EH
BLK#R5-MH
WHT/BLK#5-CH
WHT#4-CH
GRN/WHT
BLK/WHT
WHT-EH
WHT-EH
BRN
WHT
BLK#R1-EH
CR4
BLK/RED#R4-EH
BLK/WHT#R8-EH
IND.
STA.
BAT.
+
EXCT.
HM
REGULATOR
BAT.
_
GND
_
RIGHT
TURNTABLE
ROTATE
LEFT
RED
ENGINE RPM
GRN/WHT-1
GLOW
PLUG
BLK/WHT-1
BLK-1
START
RED
IGN./FUEL ON
ON
WHT-2
KEY BYPASS
9
TS54
RED/BLK-1
RED-1
RED
BLK/RED-3
8
AC GENERATOR
GLOW
PLUG
START
AUXILIARY
PUMP
RED
BLK-2
TB4
RED-EH
REV A
Electrical Schematic - Diesel Models
(from serial number 1997 to 3241)
RED
1
WHT-FS
WHT
ES34D1L
TURNTABLE ROTATE RIGHT
TURNTABLE ROTATE LEFT
RPM COIL
CUTOUT RELAY
RPM COIL
AC GENERATOR
OPTION
GLOW PLUG RELAY
VOLT METER GAUGE
WATER TEMPERATURE GAUGE
OIL PRESSURE GAUGE
WATER TEMPERATURE
SWITCH
OIL PRESSURE
SWITCH
HOUR METER
STARTER MOTOR
FUEL SOLENOID
AUXILIARY
PUMP RELAY
AUXILIARY PUMP
LEVEL SENSOR
FLASHING BEACON
OPTION
HORN
RELAY
HORN
RPM SOLENOID
GLOW PLUG
ALTERNATOR
Part No. 119987
WTS1
OPS1
KEY PWR.
CR8
+12V
START INPUT
CR3
PR1
CR5
CR1
WHT#21-EH
CR4
TACHOMETER
LO
TS62
Added after serial
number 2266
FS-HI
HI
RED
BATTERY
7
TB5
RED#CB1-EH
CR8
6
FB
AUX. ON
TB35
START RELAY
2
IGNITION/
START
MODULE
GROUND
6
10A
4
TB45
1
TB23
TB9
TB34
TB33
TB27
TB28
4
TS12
TS47
TS6
TS2
TS1
TS56
TS52
TS51
AUXILIARY
PUMP
3
STARTER
AUX
PUMP
7
RED
RED
5
RED
CB1
Z-34/22 IC
5-9
+
3
ORG/BLK
RED
8
GRND
10A
PLAT
P1
CB2
TB22
KS1
P3
10 ENG. FAULT
CR2
5
HORN
2
FS1
RED
P2
N
M
L
K
J
I
H
G
F
E
D
C
B
A
June 2007
Section 5 • Schematics
BLK
TS4
A1
TB21
GND
+
WHT
BP1
DP1
ORG
MOTOR STROKE
JIB BOOM
PLATFORM
ROTATE
PLATFORM
LEVEL
BLU/WHT-3
BRN-2
BLU/RED-3
ORG/RED-3
WHT-1
WHT/BLK-1
WHT/RED-1
BLU-1
BLU/BLK-1
RED/WHT-1
ORG-1
WHT/RED-3
ORG-3
ORG/BLK-3
BLK-3
BLK/WHT-3
BLK-8
LS4
PLATFORM
LEVEL
PLATFORM
ROTATE
JIB BOOM
WHT-8
DOWN
UP
GRN/BLK-3
LEFT
RIGHT
GRN/BLK-1
GRN-1
SECONDARY
GRN-3
UP
DOWN
EXTEND
WHT-6
PRIMARY
BOOM
PRIMARY
BOOM
RETRACT
UP
DOWN
UP
TB50
SECONDARY
BOOM
BLK-6
ORG-6
WHT-5
RED-5
BRN-5
BLK-5
WHT #30-EH
WHT/BLK #31-EH
WHT-7
WHT/RED #32-CH
WHT/RED
BLU#36-MH
BLU/BLK #37-MH
RED/WHT#25-CH
BLK-7
WHT/RED-MH
RED-6
ORG#14-MH
ORG/BLK#15-MH
BLK#7-MH
BLK/WHT#8-MH
RED#1-MH
RED/BLK#2-MH
BLU#10-MH
BLU/BLK#11-MH
GROUND
DRIVE ENABLE LIMIT SWITCH
DRIVE FORWARD
DRIVE REVERSE
BRAKE RELEASE
TRAVEL ALARM
OPTION
STEER LEFT
STEER RIGHT
MOTOR STROKE
LIMIT SWITCHES
FLOW CONTROL
JIB UP
JIB DOWN
PLATFORM ROTATE RIGHT
PLATFORM ROTATE LEFT
PLATFORM
LEVEL UP
PLATFORM
LEVEL DOWN
PRIMARY BOOM
EXTEND
PRIMARY BOOM
RETRACT
PRIMARY
BOOM UP
PRIMARY
BOOM DOWN
SECONDARY
BOOM UP
SECONDARY
BOOM DOWN
DECENT ALARM
OPTION
5 - 10
Z-34/22 IC
Part No. 119987
DRIVE ENABLE
DOWN
UP
LEFT
RIGHT
DOWN
UP
PRIMARY
BOOM
RED-3
RED/BLK-3
4
DOWN
7
GND
8
NOTES:
DRIVE
ENABLE
LIGHT
PRIMARY
BOOM
RETRACT
EXTEND
DOWN
UP
BLU-3
TB12
+
LS3
6
A2
2
A
B
3
BLU/BLK-3
SWITCH SHOWN WITH BOOM ROTATED PAST EITHER NON-STEER WHEEL.
3
TB49
LS2
TB13
TB16
TB30
TB31
TB32
TB36
3
LS1
BOOM
EXTEND
PLATFORM LEVEL
CUT-OUT (CE VERSION ONLY)
D C
+
CR9
CR10
TS14
SECONDARY
BOOM
RED
TB37
TB29
CR9
CR10
LIFT
DOWN
TB6
RED
TB40
L
R
L1 +
DRIVE
HIGH
L
R
2
A
B
X
R
LOW
R
ORG/RED
BRN
+
_
PWR
GND
FWD
REV
BRK REL
OFF LIMIT
ROTARY
OEM
A
+
FLOW
CONTROL X
UP
BRN-JIB
5
TB44
TB17
TB15
TB8
TB2
TB11
PRIMARY
TB43
TB18
TB14
TB7
TB1
TB10
WHT-JIB
TS58
TS57
TS59
TS63
TS61
TS60
BLK-JIB
ORG
BLU-JIB
ORG-JIB
TS15
TS8
TS7
TS9
TS13
TS11
TS10
1
RED
RED
STEER
RED
Electrical Schematic - Diesel Models
(from serial number 1997 to 3241)
REV A
C
D
E
F
G
H
I
J
K
L
M
N
Section 5 • Schematics
June 2007
WHT-FS
JP1 (REMOVE FOR CE VERSION)
LS2
A3
GND
1. ALL LIMIT SWITCHES SHOWN WITH BOOM IN STOWED POSITION EXCEPT AS NOTED.
2 SWITCH SHOWN WITH BOOM EXTENDED.
June 2007
Section 5 • Schematics
Electrical Schematic - Diesel Models
(from serial number 1997 to 3241)
RIGHT
SWING
WHT/BLK-3
WHT-3
BLK/RED-1
ENGINE SPEED
HIGH RPM
BLU/RED-1
BLU/WHT-1
LP
GAS
FUEL
RIGHT
LEFT
SWING
BLK/RED
RED/WHT#23-E.H.
RED/BLK#R6-E.H.
WHT
WHT/BLK#25 E.H.
WNT/RED#26 E.H.
BLK/WHT
BLU/WHT#R6-E.H.
BLU/WHT#R6-E.H.
BLU/RED#R7-E.H.
WHT/BLK#5-E.H.
WHT#4-E.H.
CR3
NO
LEFT
ENGINE SPEED
FUEL
BLK/WHT-1
BLK
WHT#21-E.H.
BLK#R1-E.H.
RED#27-E.H.
+
BAT.
+
STA.
IND.
BLK/WHT#R8-E.H.
BLK/RED#R4-E.H.
BLK#R5-E.H.
-
ORG/BLK#41-E.H.
BLK/RED
RED/WHT#23-E.H.
RED/BLK#28-E.H.
COIL
HIGH RPM
LP
GAS
ENGINE
CHOKE
ENGINE
CHOKE
ENGINE
START
AUXILIARY
POWER
RED
NO
CR4
EXCT.
REGULATOR
GND
BAT.
_
TURNTABLE ROTATE RIGHT
TURNTABLE ROTATE LEFT
RPM COIL
RPM CUTOUT COIL RELAY
FLASHING BEACONS
FUEL RELAY
FUEL RELAY
LPG SOLENOID
ANTI-DIESEL VALVE
FUEL PUMP
CHOKE RELAY
OIL PRESSURE SENDER
WATER TEMPERATURE SENDER
HOUR METER
IGNITION SYSTEM
STARTER MOTOR
AUXILIARY POWER RELAY
AUXILIARY PUMP
LEVEL SENSOR
HORN RELAY
HORN
RPM SOLENOID
CHOKE SOLENOID
ALTERNATOR
Part No. 119987
WTS1
NO
HM
CR7
NO
RED-E.H.
G
FB
CR6
WHT#21-E.H.
DISTRIBUTOR
BLK-1
RED-1
RED#20-E.H.
CR8
BATTERY
8
TB24
5
OPS1
NC
STARTER
AUX
PUMP
ENGINE
START
AUXILIARY
POWER
RED/BLK-1
RED
TB5
VAC
CR2
NO
CR1
NO
TB4
TB21
RED
10 AMP.
CR7 CR3
CR6
PR1
NO
CR5
NO
CR4
CR8
WHT-2
BLK/RED-3
CB1
RED
TB39
RED
BLK/RED
TB28
TB35
TB41
TB38
TB34
TB33
TB27
TB23
TS18
TS17
TS16
TS20
ORG/BLK-1
TB9
4
RED
BLK-2
TS15
TS6
TS5
TS4
LIFT/DRIVE
SELECT (OPTION)
TS3
TS2
TS1
TS19
3
START RELAY
TACHOMETER
START INPUT
AUX. ON
IGN./START
GROUND
MODULE
BATTERY
KEY PWR.
KEY BYPASS
IGN./FUEL ON
ENG. FAULT
RED
6
Z-34/22 IC
5 - 11
BLK
RED
WHT-FS
1
1
2
3
4
5
6
7
8
9
10
TB20
GRND
10 AMP.
TB22
KS1
PLAT
P1
RED
RED
CB2
P3
HORN
2
WHT-FS
RED
FS1
P2
N
M
L
K
J
I
H
G
F
E
D
C
B
A
June 2007
Section 5 • Schematics
REV A
Electrical Schematic - Gasoline/LPG Models
(from serial number 1187 to 1546)
ORG/BLK
TS27
GND
7
ES34GP1E
+
-
BP1
1
WHT-FS
RED
DRIVE ENABLE
RED/WHT
RED
250
BRN-2
BLU/RED-3
WHT-1
BLU/WHT-3
WHT/BLK-1
WHT/RED-1
BLU-1
BLU/BLK-1
RED/WHT-1
GRN-1
GRN/BLK-1
UP
JIB BOOM
DOWN
RIGHT
PLATFORM ROTATE
LEFT
GRN/BLK-3
GRN-3
UP
PLATFORM LEVEL
DOWN
BLK-6
WHT-5
RED-5
WHT/BLK#31-E.H.
WHT/RED#32-E.H.
BLU#36-E.H.
BLU/BLK#37-E.H.
RED/WHT#25-E.H.
WHT/RED-E.H.
RED-6
ORG#14-E.H.
ORG/BLK#15-E.H.
BLK#7-E.H.
BLK/WHT#8-E.H.
RED#1-E.H.
RED/BLK#2-E.H.
BLU#10-E.H.
BLU/BLK#11-E.H.
BRN-5
BLK-5
WHT-8
WHT-6
WHT-7
BRN-6
BRN-8
7
BRN-7
GROUND
SECONDARY BOOM DWN
SECONDARY BOOM UP
PRIMARY BOOM DWN
PRIMARY BOOM UP
PRIMARY BOOM RETRACT
PRIMARY BOOM EXTEND
PLATFORM LEVEL DWN
PLATFORM LEVEL UP
PLATFORM ROTATE
JIB BOOM
BOOM FLOW CONTROL
BOOM EXTEND LIMIT SWITCH
BOOM UP LIMIT SWITCH
SECONDARY BOOM UP LIMIT SWITCH
MOTOR STROKE
STEER RIGHT
STEER LEFT
DRIVE EDC
DRIVE ENABLE LIMIT SWITCH
8
DECENT ALARM (OPTIONAL)
5 - 12
Z-34/22 IC
Part No. 119987
WHT#12-E.H.
LS4
NO
LS2
NO
LS1
NC
HIGH
ORG-1
WHT/RED-3
ORG-3
ORG/BLK-3
EXTEND
PRIMARY BOOM
RETRACT
UP
PRIMARY BOOM
DOWN
UP
SECONDARY
BOOM
TB12
A3
6
NC
NO
TB13
TB30
TB31
TB32
TB37 TB36
TB29
LS3
TB40
PLATFORM LEVEL
CUT-OUT (OPTION)
4
DOWN
TB44
TB17
TB6
R1
LOW
UP
JIB BOOM
DOWN
BRN-JIB
PLATFORM
ROTATE
PLATFORM
LEVEL
BLK-3
BLK/WHT-3
RED-3
RED/BLK-3
BLU-3
CR9
CR10
RIGHT
LEFT
UP
DOWN
PRIMARY
BOOM
EXTEND
PRIMARY
RETRACT BOOM
UP
DOWN
3
BLU/BLK-3
4
RED
D.E.
SECONDARY
BOOM
BLK-JIB
L1
R
A
B
2
ROTARY
OEM
A
+
FLOW
CONTROL X
UP
BLU-JIB
TS14
1
2
3
4
5
6
7
8
TS13
1
2
3
4
5
6
7
8
9
10
HORSE
POWER
LIMITER
BOARD
DOWN
LS2
NC
CR9
CR10
WHT-JIB
5
TB43
TB18
TB14
TB7
TB1
TB10
TB15
TB8
TB2
TB11
ORG-JIB
TS26
TS25
TS24
TS23
TS22
TS21
DP1
TS11
TS10
TS9
TS8
TS7
R2
RED
Electrical Schematic - Gasoline/LPG Models
(from serial number 1187 to 1546)
REV A
C
D
E
F
G
H
I
J
K
L
M
N
Section 5 • Schematics
June 2007
ORG/BLK
RED
RED
RED
GND
GND
June 2007
Section 5 • Schematics
Electrical Schematic - Gasoline/LPG Models
(from serial number 1187 to 1546)
LEFT
ENGINE
SPEED
TURNTABLE
ROTATE
RED
AC GENERATOR
FUEL
SELECT
WHT/BLK-3
WHT-3
BLK/RED-1
FUEL
SELECT
LOW RPM
FUNCTION ENABLE
HIGH RPM
GRN/WHT-1
BLU/RED-1
BLU/WHT-1
GAS
LP
BLK/WHT-1
CHOKE
ENGINE
START
BLK
RIGHT
LEFT
TURNTABLE
ROTATE
BLK/RED#R3
GRN/WHT
WHT#21-EH
BLK#R1-EH
RED#27-EH
TB27
WHT
WHT-EH
WHT-EH
BLK/WHT#R8
BLU/WHT#R6-EH
BLU/WHT#R6-EH
BLU/RED#R7-EH
WHT/BLK#5-CH
WHT#4-CH
CR3
CR7 CR3
CR6
TS20
RED
TB5
WHT
RED
AUXILIARY
POWER
TB21
RIGHT
ON
GAS
LP
CHOKE
RED-1
RED/BLK#28-MH
COIL
RED/WHT#23-MH
BLK/RED
CR8
+
EXCT.
BAT.
+
STA.
IND.
BLK/WHT#R8-EH
BLK/RED#R4-EH
BLK#R5-MH
-
ORG/BLK-EH
RED-EH
G
CR7
WHT#21-EH
HM
OPS1 WTS1
REGULATOR
GND
BAT.
_
TURNTABLE ROTATE RIGHT
TURNTABLE ROTATE LEFT
RPM RELAY
GENERATOR OPTION
RPM CUTOUT COIL RELAY
FUEL RELAY
FUEL RELAY
LPG SOLENOID
ANTI-DIESEL VALVE
FUEL PUMP
CHOKE RELAY
WATER TEMPERATURE SWITCH
OIL PRESSURE SWITCH
POWER RELAY
HOUR METER
IGNITION SYSTEM
START RELAY
STARTER MOTOR
AUXILIARY POWER RELAY
AUXILIARY PUMP
LEVEL SENSOR
FLASHING BEACON
HORN RELAY
HORN
RPM SOLENOID
CHOKE SOLENOID
ALTERNATOR
Part No. 119987
ENGINE
START
AUXILIARY
POWER
RED/BLK-1
7 KEY PWR.
10A
CR4
+12V
CR2
CR1
CR6
FB
RED
8 KEY BYPASS
9 IGN./FUEL ON
10 ENG. FAULT
RED#CB1-EH
DISTRIBUTOR
6
Z-34/22 IC
5 - 13
ORG/BLK
TB38
TB35
3 START INPUT
4 AUX. ON
TB45
1 START RELAY
2 TACHOMETER
TB23
TB9
4
WHT-2
TS15
TB34
TB33
TB28
TS19
TS18
TS17
TS16
BLK/RED-3
3
PR1
CR5
CR4
CR8
RED
2
TB39
RED
7
GRND
10A
HI
TB4
5
RED
TS5
BLK-2
A1
FS-HI
LO
TS15
TS6
TS4
TS3
TS2
TS1
IGNITION/
START
MODULE
5 GROUND
6 BATTERY
RED
CB1
PLAT
RED
TB22
KS1
P1
CB2
+
P3
HORN
RED
FS1
P2
N
M
L
K
J
I
H
G
F
E
D
C
B
A
June 2007
Section 5 • Schematics
REV A
Electrical Schematic - Gasoline/LPG Models
(from serial number 1547 to 1996)
BLK
WHT-FS
WHT
RED
1
GND
8
ES34GP1J
+
_
WHT
ORG
MOTOR STROKE
JIB BOOM
PLATFORM
ROTATE
PLATFORM
LEVEL
BLU/WHT-3
BRN-2
BLU/RED-3
ORG/RED-3
WHT-1
WHT/BLK-1
WHT/RED-1
WHT-8
JIB BOOM
PLATFORM
ROTATE
PLATFORM
LEVEL
WHT-6
BLK-6
5
ORG-6
WHT-5
RED-5
BRN-5
BLK-5
WHT #30-EH
WHT/BLK #31-EH
WHT-7
WHT/RED #32-CH
WHT/RED
BLU#36-MH
BLU/BLK #37-MH
RED/WHT#25-CH
BLK-7
WHT/RED-MH
RED-6
ORG#14-MH
ORG/BLK#15-MH
BLK#7-MH
BLK/WHT#8-MH
RED#1-MH
RED/BLK#2-MH
BLU#10-MH
BLU/BLK#11-MH
7
GND
GROUND
DRIVE ENABLE
LIMIT SWITCH
DRIVE FORWARD
DRIVE REVERSE
BRAKE RELEASE
TRAVEL ALARM
OPTION
STEER LEFT
STEER RIGHT
MOTOR STROKE
LIMIT SWITCHES
FLOW CONTROL
JIB UP
JIB DOWN
PLATFORM ROTATE RIGHT
PLATFORM ROTATE LEFT
PLATFORM
LEVEL UP
PLATFORM
LEVEL DOWN
PRIMARY BOOM
EXTEND
PRIMARY BOOM
RETRACT
PRIMARY
BOOM UP
PRIMARY
BOOM DOWN
SECONDARY
BOOM UP
SECONDARY
BOOM DOWN
DECENT ALARM
OPTION
5 - 14
Z-34/22 IC
Part No. 119987
BLU-1
BLK-8
DOWN
UP
GRN/BLK-3
LEFT
RIGHT
GRN/BLK-1
GRN-1
SECONDARY
GRN-3
UP
DOWN
EXTEND
PRIMARY
BOOM
PRIMARY
BOOM
RETRACT
UP
DOWN
UP
TB50
SECONDARY
BOOM
8
NOTES:
LS3
6
A2
2
BLU/BLK-1
RED/WHT-1
ORG-1
WHT/RED-3
ORG-3
ORG/BLK-3
BLK-3
BLK/WHT-3
RED-3
RED/BLK-3
4
DOWN
TB12
+
3
LS1
BOOM
EXTEND
PLATFORM LEVEL
CUT-OUT (CE VERSION ONLY)
TB13
TB16
TB30
TB31
TB32
DRIVE ENABLE
DOWN
UP
LEFT
RIGHT
DOWN
UP
PRIMARY
BOOM
PRIMARY
BOOM
RETRACT
EXTEND
DOWN
UP
BLU-3
BLU/BLK-3
SWITCH SHOWN WITH BOOM ROTATED PAST EITHER NON-STEER WHEEL.
3
TB49
LS2
STEER
SECONDARY
BOOM
RED
+
CR9
LIFT
DOWN
TB6
RED
TB40
TB36
CR9
D C
UP
BRN-JIB
TB37
TB29
CR10
CR10
TB44
TB17
TB15
TB8
TB2
TB11
PRIMARY
TB43
TB18
TB14
TB7
TB1
TB10
LS4
TS26
TS25
TS24
TS23
TS22
TS21
WHT-JIB
DP1
L
L1 +
DRIVE
HIGH
L
R
2
A
B
X
R
TS13
ROTARY
OEM
A
+
FLOW
CONTROL X
R
+
_
PWR
GND
FWD
REV
BRK REL
OFF LIMIT
LOW
R
ORG/RED
BRN
BP1
A
B
3
BLK-JIB
ORG
BLU-JIB
ORG-JIB
TS14
TS12
TS11
TS10
TS9
TS8
TS7
1
RED
RED
DRIVE
ENABLE
LIGHT
RED
Electrical Schematic - Gasoline/LPG Models
(from serial number 1547 to 1996)
REV A
C
D
E
F
G
H
I
J
K
L
M
N
Section 5 • Schematics
June 2007
WHT-FS
JP1 (REMOVE FOR CE VERSION)
LS2
A3
GND
2 SWITCH SHOWN WITH BOOM EXTENDED.
1. ALL LIMIT SWITCHES SHOWN WITH BOOM IN STOWED POSITION EXCEPT AS NOTED.
June 2007
Section 5 • Schematics
Electrical Schematic - Gasoline/LPG Models
(from serial number 1547 to 1996)
LEFT
TURNTABLE
ROTATE
ENGINE
SPEED
AC GENERATOR
FUEL
SELECT
WHT/BLK-3
WHT-3
BLK/RED-1
LOW RPM
FUNCTION ENABLE
HIGH RPM
GRN/WHT-1
BLU/RED-1
BLU/WHT-1
FUEL
SELECT
TURNTABLE
ROTATE
TB35
RIGHT
LEFT
BLK/RED#R3
GRN/WHT
WHT
WHT
WHT
TB27
WHT
BRN
WHT-EH
WHT-EH
WHT/BLK-EH
WNT/RED-EH
BRN
BLK/WHT#R8
BLU/WHT#R6-EH
BLU/WHT#R6-EH
BLU/RED#R7-EH
WHT/BLK#5-CH
WHT#4-CH
CR7 CR3
CR6
RIGHT
ON
GAS
LP
GAS
LP
BLK/WHT-1
CHOKE
ENGINE
START
BLK
WHT#21-EH
-
BLK#R5-MH
+
BLK/RED#R4-EH
BLK/WHT#R8-EH
BAT.
+
STA.
IND.
CR8
EXCT.
REGULATOR
GND
BAT.
_
TURNTABLE ROTATE RIGHT
TURNTABLE ROTATE LEFT
RPM RELAY
GENERATOR OPTION
RPM CUTOUT COIL RELAY
FUEL RELAY
FUEL RELAY
LPG SOLENOID
ANTI-DIESEL VALVE
FUEL PUMP
CHOKE RELAY
VOLT METER GAUGE
WATER TEMPERATURE GAUGE
OIL PRESSURE GAUGE
WATER TEMPERATURE SWITCH
OIL PRESSURE SWITCH
POWER RELAY
HOUR METER
IGNITION SYSTEM
START RELAY
STARTER MOTOR
AUXILIARY POWER RELAY
AUXILIARY PUMP
LEVEL SENSOR
FLASHING BEACON
OPTION
HORN RELAY
HORN
RPM SOLENOID
CHOKE SOLENOID
ALTERNATOR
Part No. 119987
HM
OPS1 WTS1
STARTER
AUX
PUMP
BLK#R1-EH
RED#27-EH
RED/BLK#28-MH
COIL
RED/WHT#23-MH
BLK/RED
ORG/BLK-EH
RED-EH
G
CR7
CR6
WHT#21-EH
DISTRIBUTOR
TB5
WHT
RED#CB1-EH
TB21
TS62
RED
7 KEY PWR.
10A
CHOKE
ENGINE
START
RED-1
RED/BLK-1
RED
CR4
+12V
WHT-2
BLK/RED-3
5 GROUND
6 BATTERY
RED
RED
ORG/BLK
CR3
PR1
CR5
CR4
CR8
8 KEY BYPASS
9 IGN./FUEL ON
10 ENG. FAULT
CR2
CR1
TB39
TS54
TS53
TS56
TS52
TB38
TB34
TB33
TB28
TB45
1 START RELAY
2 TACHOMETER
TB23
TB9
4
TS51
AUXILIARY
POWER
3
FB
6
Z-34/22 IC
5 - 15
RED
HI
RED
2
IGNITION/
START
MODULE
3 START INPUT
4 AUX. ON
CB1
PLAT
RED
TS4
BLK-2
A1
FS-HI
LO
TS47
TS12
TS3
TS6
TS2
TS1
AUXILIARY
POWER
TB4
5
GND
7
GRND
10A
TB22
KS1
P1
CB2
+
P3
HORN
WHT-FS
WHT
1
RED
FS1
P2
N
M
L
K
J
I
H
G
F
E
D
C
B
A
June 2007
Section 5 • Schematics
REV A
Electrical Schematic - Gasoline/LPG Models
(from serial number 1997 to 3241)
BLK
RED
8
ES34GP1L
+
_
WHT
BP1
ORG
MOTOR STROKE
JIB BOOM
PLATFORM
ROTATE
PLATFORM
LEVEL
WHT-FS
BLU/WHT-3
BRN-2
BLU/RED-3
ORG/RED-3
WHT-1
WHT/BLK-1
WHT/RED-1
BLU-1
BLK-8
PLATFORM
LEVEL
PLATFORM
ROTATE
JIB BOOM
WHT-8
DOWN
UP
GRN/BLK-3
LEFT
RIGHT
GRN/BLK-1
GRN-1
SECONDARY
GRN-3
UP
DOWN
WHT-6
5
BLK-6
ORG-6
WHT-5
RED-5
BRN-5
BLK-5
WHT #30-EH
WHT/BLK #31-EH
WHT-7
WHT/RED #32-CH
WHT/RED
BLU#36-MH
BLU/BLK #37-MH
RED/WHT#25-CH
BLK-7
WHT/RED-MH
RED-6
ORG#14-MH
ORG/BLK#15-MH
BLK#7-MH
BLK/WHT#8-MH
RED#1-MH
RED/BLK#2-MH
BLU#10-MH
BLU/BLK#11-MH
7
GND
GROUND
PLATFORM ROTATE RIGHT
JIB DOWN
JIB UP
FLOW CONTROL
LIMIT SWITCHES
MOTOR STROKE
STEER RIGHT
STEER LEFT
TRAVEL ALARM
OPTION
BRAKE RELEASE
DRIVE REVERSE
DRIVE FORWARD
DRIVE ENABLE LIMIT SWITCH
8
PLATFORM ROTATE LEFT
PLATFORM
LEVEL UP
PLATFORM
LEVEL DOWN
PRIMARY BOOM
EXTEND
PRIMARY BOOM
RETRACT
PRIMARY
BOOM UP
PRIMARY
BOOM DOWN
SECONDARY
BOOM UP
SECONDARY
BOOM DOWN
DECENT ALARM
OPTION
NOTES:
3
LS3
5 - 16
Z-34/22 IC
Part No. 119987
BLU/BLK-1
RED/WHT-1
ORG-1
WHT/RED-3
ORG-3
ORG/BLK-3
EXTEND
PRIMARY
BOOM
PRIMARY
BOOM
RETRACT
UP
DOWN
UP
TB50
SECONDARY
BOOM
TB12
+
TB13
TB16
TB30
TB31
TB32
TB36
A
B
6
A2
2
DP1
L
DRIVE ENABLE
DOWN
UP
LEFT
RIGHT
DOWN
UP
BLK-3
BLK/WHT-3
RED-3
RED/BLK-3
4
DOWN
TB49
LS2
STEER
PRIMARY
BOOM
PRIMARY
BOOM
RETRACT
EXTEND
DOWN
BLU-3
BLU/BLK-3
TB6
RED
TB40
L
R
L1 +
DRIVE
HIGH
SECONDARY
BOOM
SWITCH SHOWN WITH BOOM ROTATED PAST EITHER NON-STEER WHEEL.
3
UP
DOWN
RED
LS1
BOOM
EXTEND
PLATFORM LEVEL
CUT-OUT (CE VERSION ONLY)
LIFT
+
CR9
D C
UP
BRN-JIB
TB37
TB29
CR9
CR10
CR10
TB44
TB17
TB15
TB8
TB2
TB11
PRIMARY
TB43
TB18
TB14
TB7
TB1
TB10
LS4
TS58
TS57
TS59
TS63
TS61
TS60
WHT-JIB
TS14
ROTARY
OEM
A
+
FLOW
CONTROL X
R
2
A
B
X
R
LOW
R
ORG/RED
BRN
+
_
PWR
GND
FWD
REV
BRK REL
OFF LIMIT
3
BLK-JIB
ORG
BLU-JIB
ORG-JIB
TS15
TS8
TS7
TS9
TS13
TS11
TS10
1
RED
RED
DRIVE
ENABLE
LIGHT
RED
Electrical Schematic - Gasoline/LPG Models
(from serial number 1997 to 3241)
REV A
C
D
E
F
G
H
I
J
K
L
M
N
Section 5 • Schematics
June 2007
JP1 (REMOVE FOR CE VERSION)
LS2
A3
GND
2 SWITCH SHOWN WITH BOOM EXTENDED.
1. ALL LIMIT SWITCHES SHOWN WITH BOOM IN STOWED POSITION EXCEPT AS NOTED.
June 2007
Section 5 • Schematics
Electrical Schematic - Gasoline/LPG Models
(from serial number 1997 to 3241)
Section 5 • Schematics
June 2007
Ground Control Box Wiring Diagram - Diesel Models
(from serial number 1187 to 1546)
Section 5 • Schematics
June 2007
Ground Control Box Wiring Diagram - Diesel Models
(from serial number 1187 to 1546)
A
B
C
D
REV A
E
F
G
H
I
J
K
M
VOLTAGE
COOLANT TEMP.
OIL PRESSURE
BLK-7
WHT/RED-26A
BRN (GROUND)
WHT-23A
RED-27A
RD-4-ISM
GRN-17A
3
GRN/BLK-18A
TS25
39
38
BLU/BLK-1
37
34
BLK-1
33
BK-3-ISM
WHT/RED-1
32
WT/RD-E.H.
BRAKE
WHT/BLK-1
31
WT/BK-E.H.
E.D.C.
WHT-1
30
R/W-1
29
RD/WT-E.H.
RED/BLK-1
28
RD/BK-M.H.
RED-1
27
RED-E.H.
RED-S.P.
AUX. PWR.
ORG/BLK-41D
GRN/BLK-44A
BLK-33B
26
WT/RD-E.H.
WT/RD-S.P.
WATER TEMP. SENDER
25
WT/BK-E.H.
WT/BK-S.P.
OIL PRESSURE SENDER
24
WHT-E.H.
WHT-E.H.
WHT-SP-DB
RED-S.P.
12V BATT. SUPPLY
18
GR/BK-S.P.
PLAT. ROT. R.
GRN-3
ORG/RED-3
17
GRN-S.P.
PLAT. ROT. L.
BLK-6
ORG/BLK-3
15
ORG/BLK-M.H.
OG/BK-S.P.
PLAT. LEVEL DN.
BLK-6
ORG-3
14
ORG-M.H.
ORG-S.P.
PLAT. LEVEL. UP
BLU/RED-3
BLU/WHT-3
13
RED-R2-30
WHT-TB23B
BLK/WHT-34A
WHT-R2-86
WHT-24D
ENGINE/MANIFOLD
HARNESS
7
DRV. ENA. LT.
12
WHT-E.H.
BLU/BLK-3
11
BLU/BLK-M.H.
BLU/BK-S.P.
SEC. BOOM DN
BLU-3
10
BLU-M.H.
BLU-S.P.
SEC. BOOM UP
DRV. ENA.
BLK/RED-3
9
BLK/WHT-3
8
BLK/WHT-M.H.
BK/WT-S.P.
BOOM RETRACT
BLK-3
7
BLK-M.H.
BLK-S.P.
BOOM EXTEND
HORN
WHT/RED-3
6
W/R-M.H.
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
RED/WHT-3
RED/BLK-3
3
2
RED/BLK-M.H.
RD/BK-S.P.
PRI. BOOM DOWN
RED-3
1
RED-M.H.
TS23
BOOM EXTEND/RETRACT TOGGLE SWITCH
TS24
PLATFORM LEVEL TOGGLE SWITCH
TS25
PLATFORM ROTATE TOGGLE SWITCH
TS26
JIB UP/DOWN TOGGLE SWITCH
CB1
CIRCUIT BREAKER, CONTROLS, 10A
CB2
CIRCUIT BREAKER, ENGINE, 10A
HM
HOUR METER
R1
RESISTOR, 5 OHM, BOOM FUNCTIONS
EH
ENGINE HARNESS
MH
MANIFOLD HARNESS
ORG-TB14B
ORG/BLK-TB15B
RED-6
CR10
CR9
RED-S.P.
PRI. BOOM UP
1
START RELAY
2
TACHOMETER
3
START INPUT
4
AUX. ON
5
GROUND
6
BATTERY
7
KEY PWR.
8
KEY BYPASS
BRN-GRD
ORG/BLK-E.H.
ORG-E.H.
PLATFORM LEVEL CUT-OUT OPTION
RD/WT-S.P.
A
B
IGNITION/
START
MODULE
9
IGN./FUEL ON
10
ENG. FAULT
RED-6 ISM
WHT-9 ISM
RED-CB2
PRIMARY BOOM UP/DOWN TOGGLE SWITCH
16
C
RED-27D
SECONDARY BOOM UP/DOWN TOGGLE SWITCH
TS22
WARNING SENDER
RED-E.H.
BRN-GRD.-R4-85
TS21
2WD/4WD
TILT ALARM
21
D
BLK-R1-86
BLK/RED-35A
E.D.C.
20
BK/RD-CR5
GRN-43A
BLK-33A
START
GLOW PLUG
PWR. TO PLAT.
IGNITION PWR.
BLK-5
RED-20A
RED-R1#30
BLK-S.P.
KEYSWITCH PWR.
WHT-5
CABLE
#3
RPM
BLK-S.P.
CABLE
#2
ORG/BLK-15A
BK/RD-S.P.
BK/WT-S.P.
22
(OPT)
ORG-14A
STEER RIGHT
BLK-2
TS16
CB1
BLU-M.H.
BLK/RED-1
BLK/WHT-1
GRN/BLK-3
WHT/BLK-5A
STEER LEFT
36
RED/BLK-2A
WHT-4A
GAS
35
19
TS21
L.P.
BLU/BK-M.H.
BLU-1
GRN/WHT-3
CABLE
#1
LIMIT SWITCH
BLK-CR5
BLU/BLK-11A
6
BLU/RED-1
BLU/WHT-1
PULSE PICKUP
WHT-6
WHT-S.P.
TS26
CB2
42
ENGINE GLOW PLUG TOGGLE SWITCH
ENGINE RPM TOGGLE SWITCH
TURNTABLE ROTATE TOGGLE SWITCH
23
(OPT)
TS19
ORG/RED-1
WHT-CR2
BLU-10A
TS20
JIB UP
RED-CR17
TS22
TS17
GRN-S.P.
WHT-2
CABLE
#5
4
43
RED-1A
TS24
_
GRN-1
TS17
TS19
TS20
RD/WT-M.H.
WHT/RED-3A
R1
HM
ENGINE START TOGGLE SWITCH
JIB DOWN
WT-10-ISM
BLK-7A
+
AUXILIARY TOGGLE SWITCH
TS16
GR/BK-S.P.
CABLE
#6
BLK/WHT-8A
TS23
TS15
44
WHT-8
RED-5
TS15
GROUND
GRN/BLK-1
OG/BK-E.H.
NC
NC
GROUND
BRN-8
41
BLK-CR3
NO
BRN-E.H.
BRN
40
KS1
NO
BRN
46
ORG-1
BK/RD-CR3
BK/WT-CR8
CABLE
#7
P1
47
ORG/BLK-1
BLK-22A
KEY SWITCH
45
WHT-7
WHT/BLK-25A
EMERGENCY STOP BUTTON
KS1
BRN-2
OG/BK-2ISM
CABLE
#8
WHT-21A
2
P1
GRN/WHT-1
BRN-6
BRN-5
N
DESCRIPTION
LABEL
1
5
L
BLK/RED-35D
BRN-5 ISM
BLK/RED-R4-E.H.
BLK-33D
CR1
CR2
CR3
CR4
BLK-1-ISM
BLK-R1-E.H.
BLK-R5-M.H.
WHT-21D
CR5
BLK/WHT-R8-E.H.
CR8
8
BLK-22D
BLK/RED-9D
BLK/WHT-34D
ES34D5E
5 - 17
Z-34/22 IC
Part No. 119987
June 2007
Section 5 • Schematics
Ground Control Box Wiring Diagram - Diesel Models
(from serial number 1547 to 1985)
REV A
M
L
K
J
I
VOLTAGE
SPARE WIRE LIST
GRN/WHT-1
ORG/RED-1
ORG/BLK-1
GRN/WHT-3
RED/WHT-3
*
H
OIL PRESSURE
G
F
E
BRN-5
1 - PLATFORM LEVEL CUTOUT
2 - FLASHING BEACON
3 - DESCENT ALARM
4 - AC GENERATOR
WHT/RED-EH
BRN-2
WHT-6
BLK-7
BRN-GND. STUD
[
WHT/BLK-EH
WHT-23A
KS1
BLK/RED-CR3
GRN/WHT-EH
GRN/WHT-TB45
GRN/WHT-TB35
BLK/RED-SP
NO
NO
BLU/WHT-1
BLK/RED-CR3
BLK/WHT-CR8
BLK-ISM-3
WHT/RED-CH
(LS1)
TS15
CABLE
9
RED-27A
AC GENERATOR
HIGH RPM
GRN-17A
(OPTION)
GRN/BLK-18A
RED-ISM-4
BLK/WHT-8A
BLK-7A
TS25
TS23
WHT/RED-6A
CABLE
6
BLK-CR5
WHT-CR2
(LS2)
RED-1A
HM
RED-5
RED/BLK-2A
-
TS24
TS22
BLU-10A
A2
TS26
ORG/BLK-TB15B
CABLE
5
ORG/BLK-3
ORG-3
BLU/RED-3
BLU/WHT-3
BLU/BLK-3
BLU-3
BLK/RED-CR5
BLK/RED-3
BLK/WHT-3
BLK-3
WHT/RED-3
WHT/BLK-3
WHT-3
RED/BLK-3
(LS3)
BLU/BLK-11A
TS21
TS17
9
TS16
(OPT.)
WHT-4A
CABLE
1
WHT/BLK-1
WHT-1
RED/WHT-1
RED/BLK-1
RED-1
[OPTION 2]
WHT-2
BLK-2
*
*
WHT-5
BLK-5
[
OPTION 3]
+
RED-6
10
[
OPTION 3]
RED-3
D
WHT/BLK-5A
CB1
CB2
ORG-6
ORG/BLK-CR10
ORG-CR10
ORG/BLK-SP
ORG-SP
GRN-43A
PLATFORM LEVEL DOWN
PLATFORM LEVEL UP
PLATFORM LEVEL CUTOUT (CE VERSION ONLY)
JIB UP
L.P.
GAS
BLU/BLK-MH
BLU-MH
BLK/RED-SP
BLK/WHT-SP
BLK-SP
WHT/RED-SP
*
WHT/BLK-EH
WHT-EH
RED/WHT-CH
RED/BLK-MH
RED-SP
RED/WHT-MH
WHT-SP
BLK-SP
WHT-SP
STEER RIGHT
STEER LEFT
HIGH RPM
DRIVE REVERSE
DRIVE FORWARD
HIGH/LOW DRIVE
TILT ALARM
AUXILIARY PUMP
KEYSWITCH POWER
KEYSWITCH POWER
+12V TO PLATFORM
IGNITION POWER
GRN/BLK-SP
GRN-SP
PLAT. ROTATE RIGHT
PLAT. ROTATE LEFT
DRIVE ENABLE RELAY
ORG/BLK-SP
ORG-SP
PLAT. LEVEL DOWN
PLAT. LEVEL UP
DRIVE ENABLE LIGHT
WHT
FOOTSWITCH
SEC. BOOM DOWN
BLU/BLK-SP
BLU-SP
2
CHOKE
START
BRAKE RELEASE
SEC. BOOM UP
HORN
BOOM RETRACT
BOOM EXTEND
BOOM FUNCTION F.C.
BLK/WHT-SP
BLK-SP
WHT/RED-SP
WHT/BLK-SP
WHT-SP
RED/BLK-SP
TURN. ROTATE LEFT
TURN. ROTATE RIGHT
PRIMARY BOOM DOWN
RED-SP
PRIMARY BOOM UP
3
4
A
B
[* SEE OPTIONAL WIRING]
ORG/BLK-EH
GRN/BLK-44A
BLK-33D
ORG-14A
RED-27D
ORG/BLK-15A
WHT/RED-32A
BLK/WHT-34A
BLK-33A
CONTROL RELAY I.D.
ES34D6J
GENERATOR OPTION
JIB DOWN
OFF-LIMIT SPEED
C
BLK-CR1
CABLE
2
BRN-CR4
RED-CR1 (12GA)
CR1-ENGINE START
CR2-ENGINE RUN
CR3-RPM CUTOUT
CR4-HIGH RPM
CR5-HORN
CR8-CHOKE
GRN/BLK-SP
GRN-SP
TS20
RED-EH (12GA)
15
14
1
GROUND
LS2-LS4 JUNCTION
LS1-LS2 JUNCTION
WHT #12
ORG-MH
TS19
ORG/BLK-3
ORG-3
*
27 RED-EH
23
23 WHT-ISM-7
22
21 WHT-EH
18
17
16
15 ORG/BLK-MH *
14 ORG-MH *
13
12
11 BLU/BLK-MH
10 BLU-MH
9
8 BLK/WHT-MH
7 BLK-MH
6 WHT/RED-MH
5 WHT/BLK-MH
4 WHT-MH
2 RED/BLK-MH
1 RED-MH
BRN-52C
ORG/BLK-MH
A
GROUND
52
52 BRN-GND. STUD
50
49
37
36
35
34
33
32
31
30
29
28
BLU/BLK-1
BLU-1
BLK/RED-1
BLK/WHT-1
BLK-1
WHT/RED-1
GRN/BLK-3
GRN-3
ORG/RED-3
+
ORG-TB14B
B
45
44
43
40
39
38
GRN/BLK-1
GRN-1
ORG-1
BLU/RED-1
CABLE
7
NC
45
35
OPTION 3]
BLK-8
(LS4)
P1
NC
BRN [OPTION 1]
BRN [OPT. 2/3]
WHT-8
BLK-6
CABLE
8
BLK-22A
*AC GENERATOR OPTION
C
COOLANT TEMPERATURE
OPTION NUMBERS
WHT-21A
GRN/WHT-1
BLK/RED-1
D
WHT-7
N
RED-CR8
CABLE
3
WHT-TB23B
BLK/RED-35A
GRN/BLK-CR2
WHT-EH
LABEL
START RELAY
2
TACHOMETER
3
START INPUT
4
AUX. ON
5
GROUND
6
BATTERY
7
KEY PWR.
8
KEY BYPASS
9
IGN./FUEL ON
10
ENG. FAULT
5
IGNITION/START
MODULE
6
DESCRIPTION
P1
KS1
TS15
TS16
TS17
TS18
EMERGENCY STOP BUTTON
KEY SWITCH
AUXILIARY TOGGLE SWITCH
ENGINE START TOGGLE SWITCH
ENGINE CHOKE TOGGLE SWITCH
TS19
TS20
TS21
TS22
FUNCTION ENABLE/ENGINE RPM TOGGLE SWITCH
TURNTABLE ROTATE TOGGLE SWITCH
SECONDARY BOOM UP/DOWN TOGGLE SWITCH
PRIMARY BOOM UP/DOWN TOGGLE SWITCH
TS23
TS24
BOOM EXTEND/RETRACT TOGGLE SWITCH
PLATFORM LEVEL TOGGLE SWITCH
TS25
TS26
CB1
CB2
HM
EH
MH
CH
PLATFORM ROTATE TOGGLE SWITCH
JIB UP/DOWN TOGGLE SWITCH
SP
CR
ISM
A2
1
ENGINE/MANIFOLD/
CHASSIS HARNESS
BLK/RED-35D
GRN/BLK-ISM-9
WHT (14GA)
RED-SP (12GA)
1
2
3
4
BRN-ISM-5
BLK-ISM-1
7
BLK/RED-EH (14GA)
BLK-EH (14GA)
WHT-21D
BLK/WHT-EH (14GA)
BLK/RED-MH (14GA)
5
CIRCUIT BREAKER, ENGINE, 10A
CIRCUIT BREAKER, CONTROLS, 10A
8
BLK/WHT-34D
BLK-22D
HOUR METER
ENGINE HARNESS
MANIFOLD HARNESS
CHASSIS HARNESS
RED-ISM-6
8
BLK/RED-9D
SWITCH PANEL
CONTROL RELAY
IGNITION/START MODULE
BRAKE RELEASE/TRAVEL ALARM (OPT.)
BRN-SP
BRN-OPT. 4
BRN-EH
BRN-52B
CONTROL BOX GROUND
Part No. 119987
Z-34/22 IC
5 - 18
June 2007
Section 5 • Schematics
Ground Control Box Wiring Diagram - Diesel Models
(from serial number 1547 to 1985)
Section 5 • Schematics
June 2007
Ground Control Box Wiring Diagram - Diesel Models
(from serial number 1986 to 3241)
Section 5 • Schematics
June 2007
Ground Control Box Wiring Diagram - Diesel Models
(from serial number 1986 to 3241)
A
B
C
VOLTAGE
1
D
OIL PRESSURE
REV A
E
F
G
H
WHT/RED-EH
[
WHT-7
WHT-21A
BRN-2
WHT-6
BLK-7
BRN-GND.
WHT/BLK-EH
2
WHT-23A
(LS4)
WHT/RED-32A
P1
KS1
CABLE
7
TS51
+
OPTION 3]
BLK-8
BLU/WHT-1
BLK/RED-CR3
BLK/WHT-CR8
BLK-ISM-3
RED-27A
NC
WHT/RED-CH
CABLE
9
(OPTION)
RED
RED-ISM-4
RED
3
RED-EH 12GA
BRN
CB2
RED-CR1 12GA
CB1
CABLE
6
(LS2)
BLK-CR5
WHT-CR2
HM
_
R
BLK-7A
ORG/BLK-15A
*
*
WHT-5
BLK-5
[
OPTION 3]
ORG/BLK-3
ORG-3
BLU/RED-3
BLU/WHT-3
BLU/BLK-3
BLU-3
BLK/RED-CR5
BLK/RED-3
BLK/WHT-3
BLK-3
WHT/RED-3
WHT/BLK-3
WHT-3
RED/BLK-3
D
CABLE
5
U
(LS3)
E
ORG-14A
4
GRN-17A
TS61
TS58
D
TS57
GRN/BLK-18A
D
L
TS56
U
TS52
R
CABLE
1
U
TS60
TS54
[
OPTION 3]
D
1
BLU-10A
N
SPARE WIRE LIST
GROUND
GRN/WHT-1
ORG/RED-1
ORG/BLK-1
GRN/WHT-3
RED/WHT-3
LS2-LS4 JUNCTION
LS1-LS2 JUNCTION
GRN/BLK-SP
GRN-SP
GENERATOR OPTION
JIB DOWN
ORG/BLK-EH
BLK-33D
RED-1A
RED-27D
RED/BLK-2A
GRN-43A
BRN-CR4
GRN/BLK-44A
RED-CR8
BLK/WHT-34A
BLK-33A
BLK/RED-35A
6
OPTION NUMBERS
*
1 - PLATFORM LEVEL CUTOUT
2 - FLASHING BEACON
3 - DESCENT ALARM
4 - AC GENERATOR
JIB UP
L.P.
GAS
BLU/BLK-MH
BLU-MH
BLK/RED-SP
BLK/WHT-SP
BLK-SP
WHT/RED-SP
*
1
WHT/BLK-EH
WHT-EH
RED/WHT-CH
RED/BLK-MH
RED-SP
RED/WHT-MH
WHT-SP
BLK-SP
WHT-SP
STEER RIGHT
STEER LEFT
HIGH RPM
CHOKE
START
BRAKE RELEASE
BLK/RED-CR3
TILT ALARM
AUXILIARY PUMP
KEYSWITCH POWER
KEYSWITCH POWER
GRN/WHT-1
BLK/RED-1
45
GRN/WHT-EH
GRN/WHT-TB35
AC GENERATOR
35
GRN/WHT-TB45
BLK/RED-SP
HIGH RPM
+12V TO PLATFORM
IGNITION POWER
PLAT. ROTATE RIGHT
PLAT. ROTATE LEFT
DRIVE ENABLE RELAY
ORG/BLK-SP
ORG-SP
PLAT. LEVEL DOWN
PLAT. LEVEL UP
DRIVE ENABLE LIGHT
WHT
FOOTSWITCH
SEC. BOOM DOWN
BLU/BLK-SP
BLU-SP
*AC GENERATOR OPTION
DRIVE REVERSE
DRIVE FORWARD
HIGH/LOW DRIVE
GRN/BLK-SP
GRN-SP
SEC. BOOM UP
HORN
BOOM RETRACT
BOOM EXTEND
BOOM FUNCTION F.C.
BLK/WHT-SP
BLK-SP
WHT/RED-SP
WHT/BLK-SP
WHT-SP
RED/BLK-SP
TURN. ROTATE LEFT
TURN. ROTATE RIGHT
PRIMARY BOOM DOWN
RED-SP
PRIMARY BOOM UP
ORG-TB14B
ORG/BLK-TB15B
RED-6
10
9
A
B
BRN-52C
After serial number 2267
BLK-CR1
CABLE
2
BLU/BLK-11A
CABLE
3
WHT-TB23B
GRN/BLK-CR2
WHT-EH
8
M
WHT #12
R
WHT-4A
7
L
GROUND
DENOTES TEST PORT
EMERGENCY STOP BUTTON
KEY SWITCH
AUXILIARY TOGGLE SWITCH
ENGINE START TOGGLE SWITCH
TS54
TS56
TS57
TS58
TS59
TS60
TS61
TS62
FUNCTION ENAB./ENGINE RPM TOGGLE SWITCH
ENGINE GLOW PLUG TOGGLE SWITCH
PLATFORM ROTATE TOGGLE SWITCH
JIB UP/DOWN TOGGLE SWITCH
PLATFORM LEVEL TOGGLE SWITCH
SECONDARY BOOM UP/DOWN TOGGLE SWITCH
PRIMARY BOOM UP/DOWN TOGGLE SWITCH
TURNTABLE ROTATE TOGGLE SWITCH
RED-SP (12GA)
TS63
BOOM EXTEND/RETRACT TOGGLE SWITCH
BLK/RED-MH (14GA)
CB1
CB2
HM
EH
MH
CIRCUIT BREAKER, ENGINE, 10A
CIRCUIT BREAKER, CONTROLS, 10A
HOUR METER
ENGINE HARNESS
MANIFOLD HARNESS
CH
SP
CR
ISM
CHASSIS HARNESS
SWITCH PANEL
CONTROL RELAY
IGNITION/START MODULE
A2
BRK. REL./TRAVEL ALARM (OPT.)
ORG-MH
ORG-6
1
START RELAY
2
TACHOMETER
3
START INPUT
ORG/BLK-3
ORG-3
4
AUX. ON
5
GROUND
6
BATTERY
7
KEY PWR.
8
KEY BYPASS
CONTROL RELAY I.D.
9
IGN./FUEL ON
10
ENG. FAULT
CR1-ENGINE START
CR2-ENGINE RUN
CR3-RPM CUTOUT
CR4-HIGH RPM
CR5-HORN
CR8-CHOKE
15
14
ORG/BLK-CR10
ORG-CR9
ORG/BLK-SP
ORG-SP
PLATFORM LEVEL DOWN
PLATFORM LEVEL UP
PLATFORM LEVEL CUTOUT (CE VERSION ONLY)
IGNITION/START
MODULE
DESCRIPTION
P1
KS1
TS51
TS52
ORG/BLK-MH
[* SEE OPTIONAL WIRING]
U
LABEL
K
OFF-LIMIT SPEED
C
WHT/BLK-5A
L
*
27 RED-EH
23
23 WHT-ISM-7
22
21 WHT-EH
18
17
16
15 ORG/BLK-MH *
14 ORG-MH *
13
12
11 BLU/BLK-MH
10 BLU-MH
9
8 BLK/WHT-MH
7 BLK-MH
6 WHT/RED-MH
5 WHT/BLK-MH
4 WHT-MH
2 RED/BLK-MH
1 RED-MH
RED-3
TS62
D
5
WHT/BLK-1
WHT-1
RED/WHT-1
RED/BLK-1
RED-1
[OPTION 2]
WHT-2
BLK-2
RED-5
WHT/RED-6A
TS59
TS63
37
36
35
34
33
32
31
30
29
28
BLU/BLK-1
BLU-1
BLK/RED-1
BLK/WHT-1
BLK-1
WHT/RED-1
GRN/BLK-3
GRN-3
ORG/RED-3
BLK/WHT-8A
+
52
52 BRN-GND. STUD
50
49
45
44
43
40
39
38
GRN/BLK-1
GRN-1
ORG-1
BLU/RED-1
(LS1)
A2
NO
BRN [OPTION 1]
BRN [OPT. 2/3]
WHT-8
BLK-6
CABLE
8
BLK-22A
NO
J
COOLANT TEMPERATURE
BRN-5
NC
I
ENGINE/MANIFOLD/
CHASSIS HARNESS
BLK/RED-35D
GRN/BLK-ISM-9
WHT (14GA)
CR1
CR2
CR3
CR4
BRN-ISM-5
BLK-ISM-1
BLK/RED-EH (14GA)
BLK-EH (14GA)
WHT-21D
BLK/WHT-EH (14GA)
BLK/WHT-34D
BLK-22D
RED-ISM-6
CR5
CR8
BLK/RED-9D
BRN-SP
BRN-OPT. 4
BRN-EH
BRN-52B
CONTROL BOX GROUND
ES34D6L
5 - 19
Z-34/22 IC
Part No. 119987
June 2007
Section 5 • Schematics
Ground Control Box Wiring Diagram Gasoline/LPG Models
(from serial number 1187 to 1546)
REV A
N
M
L
K
J
I
H
F
E
D
COOLANT TEMPERATURE
GAUGE
OIL PRESSURE
GAUGE
VOLTAGE
GAUGE
G
WHT/RED-26A
BRN (GROUND)
WHT-21A
C
BRN-6
47
BRN
BRN-E.H.
GROUND
BRN-5
BRN-2
46
BRN
BRN-8
GROUND
GRN/WHT-1
45
GRN/BLK-1
44
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.
WHT-7
ORG-1
40
WHT-8
WHT-6
LIMIT SWITCH
BLU/RED-1
39
BU/RD-S.P.
L.P.
BLU/WHT-1
38
BU/WT-S.P.
GAS
BLU/BLK-1
37
BU/BK-M.H.
BLU-1
36
BLU-M.H.
BK/RD-CR3
BLK/RED-1
35
BLK/WHT-CR8
BLK/WHT-1
34
BLK-1
33
BK-3-ISM
WHT/RED-1
32
WT/RD-E.H.
BRAKE
WHT/BLK-1
31
WT/BK-E.H.
E.D.C.
WHT-1
30
R/W-1
29
RD/WT-E.H.
RED/BLK-1
28
RD/BK-M.H.
RED-1
27
RED-E.H.
RED-S.P.
AUILIARY POWER
26
WT/RD-E.H.
WT/RD-S.P.
WATER TEMP. SENDER
25
WT/BK-E.H.
WT/BK-S.P.
OIL PRESSURE SENDER
24
WHT-E.H.
BLU/RED-CR7
BU/WT-CR6
WHT/BLK-25A
WHT-23A
CABLE #7
P1
NC
KS1
NO
RED-5
NO
TS15
NC
RED-27A
RD-4-ISM
GRN-17A
GRN/BLK-18A
CABLE #6
BLK/WHT-8A
WT-10-ISM
BLK-7A
TS23
TS25
+
RD/WT-M.H.
WHT/RED-3A
BLK-CR5
R1
RED-1A
HM
TS24
BLU-10A
CR10
CR9
TS21
TS20
ORG-E.H.
TS19
CB2
12V BATTERY SUPPLY
GRN/WHT-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
BLK-6
ORG/BLK-3
15
ORG/BLK-M.H.
OG/BK-S.P.
PLATFORM LEVEL DOWN
BLK-6
ORG-M.H.
ORG-S.P.
PLATFORM LEVEL UP
ORG-3
14
WHT-5
BLU/RED-3
13
BLK-5
BLU/WHT-3
12
WHT-E.H.
BLU/BLK-3
11
BLU/BLK-M.H.
BU/BK-S.P.
SECONDARY BOOM DOWN
BLU-3
10
BLU-M.H.
BLU-S.P.
SECONDARY BOOM UP
BLK/RED-3
9
BLK/WHT-3
8
BLK/WHT-M.H.
BK/WT-S.P.
BOOM RETRACT
BLK-3
7
BLK-M.H.
BLK-S.P.
BOOM EXTEND
WHT/RED-3
6
W/R-M.H.
WT/RD-S.P.
BOOM FUNCTION FLOW CONTROL
WHT/BLK-3
5
WHT/BLK-M.H.
WT/BK-S.P.
TURNTABLE ROTATE LEFT
WHT-3
4
WHT-M.H.
WHT-S.P.
TURNTABLE ROTATE RIGHT
RED/WHT-3
3
RED/BLK-3
2
RED/BLK-M.H.
RD/BK-S.P.
PRIMARY BOOM DOWN
RED-3
1
RED-M.H.
RED-S.P.
PRIMARY BOOM UP
CABLE #2
CB1
GRN-43A
D
4
DRIVE ENABLE LIGHT
DRIVE ENABLE
HORN
5
RD/WT-S.P.
C
A
B
GRN/BLK-44A
BLK-R1-86
ORG-14A
ORG/BLK-15A
RED-R1#30
ORG/BLK-41D
CABLE #3
BLK-33B
RED-27D
BLU/WHT-38A
BRN-GRD -R4-85
BLU/RED-39A
RED-R2-30
BLK/WHT-34A
BLK-33A
LABEL
DESCRIPTION
P1
EMERGENCY STOP BUTTON
KS1
KEY SWITCH
TS15
WHT-24D
ENGINE/
MANIFOLD
HARNESS
ENGINE START SWITCH
TS17
ENGINE CHOKE SWITCH
TS18
ENGINE FUEL SELECT SWITCH
TS19
TS20
ENGINE RPM SWITCH
TURNTABLE ROTATE SWITCH
SECONDARY BOOM UP/DOWN SWITCH
PRIMARY BOOM UP/DOWN SWITCH
BLK-R1-E.H.
BOOM EXTEND/RETRACT SWITCH
TS24
PLATFORM LEVEL SWITCH
BLK-R5-M.H.
TS25
PLATFORM ROTATE SWITCH
CIRCUIT BREAKER, CONTROLS, 10A
CB2
CIRCUIT BREAKER, ENGINE, 10A
HM
HOUR METER
AUX. ON
5
GROUND
6
BATTERY
7
KEY PWR.
6
IGN./START
MODULE
KEY BYPASS
9
IGN./FUEL ON
10
ENG. FAULT
BLK/RED-R4-E.H.
BLK/RED-35D
CR2
CR3
7
CR4
WHT-21D
BLU/WHT-R6-E.H.
CR5
RESISTOR, 5 OHM, BOOM FUNCTIONS
BLK-22D
EH
ENGINE HARNESS
BLK/RED-9D
MH
MANIFOLD HARNESS
R1
4
BLK-1-ISM
TS21
JIB UP/DOWN SWITCH
START INPUT
CR1
TS23
TS26
TACHOMETER
3
BRN-5 ISM
TS22
CB1
START RELAY
2
RED-6 ISM
WHT-9 ISM
RED-CB2
AUXILIARY SWITCH
TS16
1
8
WHT-R2-86
BLK/RED-35A
ES34GP5F
KEYSWITCH POWER
IGNITION POWER
CABLE #1
3
WARNING SENDER
WHT-S.P.
POWER TO PLATFORM
RED-20A
PLATFORM LEVEL CUT-OUT OPTION
TILT ALARM
RED-S.P.
WHT/BLK-5A
ORG/BLK-E.H.
2WD/4WD
RED-E.H.
WHT-4A
BRN-GRD
E.D.C.
20
TS16
TS18
ENGINE START
RED-CR17
BK/RD-CR5
TS17
GLOW PLUG
BLK-S.P.
WHT-SP-DB
(OPT)
BLU/BLK-11A
TS26
2
RPM
BLK-S.P.
(OPT)
RED-6
BLK-2
22
STEER RIGHT
BK/RD-S.P.
WHT-E.H.
TS22
ORG/BLK-TB15B
23
STEER LEFT
21
CABLE #5
-
WHT-2
1
PULSE PICKUP
WHT-CR2
RED/BLK-2A
ORG-TB14B
A
BLK-7
CABLE #8
BLK-22A
B
Part No. 119987
CR6
BLU/RED-R7-E.H.
CR7
BLK/WHT-R8-E.H.
CR8
8
BLU/WHT-38D
BLU/RED-39D
Z-34/22 IC
BLK/WHT-34D
5 - 20
June 2007
Section 5 • Schematics
Ground Control Box Wiring Diagram Gasoline/LPG Models
(from serial number 1187 to 1546)
Section 5 • Schematics
Ground Control Box Wiring Diagram Gasoline/LPG Models
(from serial number 1547 to 1985)
June 2007
Section 5 • Schematics
June 2007
Ground Control Box Wiring Diagram Gasoline/LPG Models
(from serial number 1547 to 1985)
A
B
C
VOLTAGE
REV A
D
OIL PRESSURE
E
F
G
H
BRN-5
BRN-GND. STUD
[
WHT-7
WHT/RED-EH
BRN-2
WHT-6
BLK-7
WHT-21A
WHT/BLK-EH
CABLE
8
BLK-22A
WHT-23A
(LS4)
P1
CABLE
7
NC
KS1
NO
NO
WHT-8
BLK-6
OPTION 3]
BLK-8
GRN/BLK-1
GRN-1
ORG-1
BLU/RED-CR7
BLU/RED-1
BLU/WHT-CR6
BLU/WHT-1
BLK/RED-CR3
BLK/WHT-CR8
BLK-ISM-3
WHT/RED-CH
CABLE
9
RED-27A
GRN-17A
(OPTION)
GRN/BLK-18A
RED-ISM-4
BLK/WHT-8A
BLK-7A
TS25
TS23
WHT/RED-6A
CABLE
6
(LS2)
BLK-CR5
WHT-CR2
RED-1A
HM
RED-5
*
*
-
TS24
BLU-10A
A2
TS26
4
CABLE
5
TS22
WHT-5
BLK-5
[
OPTION 3]
(LS3)
BLK/RED-CR5
BLU/BLK-11A
+
TS21
TS17
TS16
(OPT.)
WHT-4A
TS18
CABLE
1
[
BLU/BLK-1
BLU-1
BLK/RED-1
BLK/WHT-1
BLK-1
WHT/RED-1
WHT/BLK-1
WHT-1
RED/WHT-1
RED/BLK-1
RED-1
[OPTION 2]
WHT-2
BLK-2
K
L
OPTION 3]
ORG/BLK-3
ORG-3
BLU/RED-3
BLU/WHT-3
BLU/BLK-3
BLU-3
BLK/RED-3
BLK/WHT-3
BLK-3
WHT/RED-3
WHT/BLK-3
WHT-3
RED/BLK-3
RED-3
D
WHT/BLK-5A
GROUND
SPARE WIRE LIST
GROUND
GRN/WHT-1
ORG/RED-1
ORG/BLK-1
GRN/WHT-3
RED/WHT-3
LS2-LS4 JUNCTION
LS1-LS2 JUNCTION
44
43
40
39
38
GRN/BLK-SP
GRN-SP
37
36
35
34
33
32
31
30
29
28
BLU/BLK-MH
BLU-MH
BLK/RED-SP
BLK/WHT-SP
BLK-SP
WHT/RED-SP
GENERATOR OPTION
JIB DOWN
M
OPTION NUMBERS
*
1 - PLATFORM LEVEL CUTOUT
2 - FLASHING BEACON
3 - DESCENT ALARM
4 - AC GENERATOR
OFF-LIMIT SPEED
L.P.
GAS
BLU/WHT-SP
*
STEER RIGHT
STEER LEFT
HIGH RPM
CHOKE
START
BRAKE RELEASE
C
*AC GENERATOR OPTION
DRIVE REVERSE
WHT/BLK-EH
WHT-EH
DRIVE FORWARD
HIGH/LOW DRIVE
RED/WHT-CH
RED/BLK-MH
RED-SP
RED/WHT-MH
BLK/RED-CR3
TILT ALARM
AUXILIARY PUMP
KEYSWITCH POWER
KEYSWITCH POWER
WHT-SP
BLK-SP
WHT-SP
GRN/WHT-EH
45
35 GRN/WHT-TB45
GRN/WHT-1
BLK/RED-1
5
CB1
CB2
PLAT. ROTATE RIGHT
PLAT. ROTATE LEFT
DRIVE ENABLE RELAY
ORG/BLK-SP
ORG-SP
PLAT. LEVEL DOWN
PLAT. LEVEL UP
DRIVE ENABLE LIGHT
WHT
FOOTSWITCH
SEC. BOOM DOWN
BLU/BLK-SP
BLU-SP
SEC. BOOM UP
HORN
BOOM RETRACT
BOOM EXTEND
BOOM FUNCTION F.C.
BLK/WHT-SP
BLK-SP
WHT/RED-SP
WHT/BLK-SP
WHT-SP
RED/BLK-SP
CABLE
2
GRN/BLK-44A
TURN. ROTATE LEFT
TURN. ROTATE RIGHT
PRIMARY BOOM DOWN
RED-SP
PRIMARY BOOM UP
ORG-TB14B
RED-6
10
9
A
B
BRN-52C
RED-27D
ORG/BLK-15A
BRN-CR4
RED-CR1 (12GA)
WHT/RED-32A
BLK/WHT-34A
BLU/WHT-38A
6
RED-CR2
CABLE
3
BLU/RED-39A
GRN/BLK-CR2
BLK-33A
WHT-EH
BLK/RED-35A
LABEL
7
8
EMERGENCY STOP BUTTON
KEY SWITCH
AUXILIARY TOGGLE SWITCH
ENGINE START TOGGLE SWITCH
ENGINE CHOKE TOGGLE SWITCH
ENGINE FUEL SELECT TOGGLE SWITCH
TS19
TS20
TS21
TS22
FUNCTION ENABLE/ENGINE RPM TOGGLE SWITCH
TURNTABLE ROTATE TOGGLE SWITCH
SECONDARY BOOM UP/DOWN TOGGLE SWITCH
PRIMARY BOOM UP/DOWN TOGGLE SWITCH
TS23
TS24
BOOM EXTEND/RETRACT TOGGLE SWITCH
PLATFORM LEVEL TOGGLE SWITCH
TS25
TS26
CB1
CB2
HM
EH
MH
CH
PLATFORM ROTATE TOGGLE SWITCH
JIB UP/DOWN TOGGLE SWITCH
SP
CR
ISM
A2
5 - 21
1
START RELAY
2
TACHOMETER
3
START INPUT
ORG/BLK-3
ORG-3
4
AUX. ON
5
GROUND
6
BATTERY
ENGINE/MANIFOLD/
CHASSIS HARNESS
7
KEY PWR.
8
KEY BYPASS
CONTROL RELAY I.D.
9
IGN./FUEL ON
10
ENG. FAULT
CR1-ENGINE START
CR2-ENGINE RUN
CR3-RPM CUTOUT
CR4-HIGH RPM
CR5-HORN
RED-ISM-6
WHT (14GA)
1
RED-SP (12GA)
2
3
15
14
ORG/BLK-CR10
ORG-CR10
ORG/BLK-SP
ORG-SP
PLATFORM LEVEL DOWN
PLATFORM LEVEL UP
CR6-FUEL PUMP (GAS)
CR7-LPG SOLENOID
CR8-CHOKE
BLK/RED-35D
GRN/BLK-ISM-9
4
BRN-ISM-5
BLK-ISM-1
BLK/RED-EH (14GA)
WHT-21D
BLK-EH (14 GA)
BLU/WHT-EH
BLK/RED-MH (14GA)
5
BLK/WHT-EH (14GA)
BLU/RED-EH
6
7
8
BLK/WHT-34D
CIRCUIT BREAKER, ENGINE, 10A
CIRCUIT BREAKER, CONTROLS, 10A
BLK-22D
HOUR METER
ENGINE HARNESS
MANIFOLD HARNESS
CHASSIS HARNESS
BLK/RED-9D
SWITCH PANEL
CONTROL RELAY
IGNITION/START MODULE
BRAKE RELEASE/TRAVEL ALARM (OPT.)
Z-34/22 IC
ORG-MH
PLATFORM LEVEL CUTOUT (CE VERSION ONLY)
IGNITION/START
MODULE
DESCRIPTION
P1
KS1
TS15
TS16
TS17
TS18
ORG/BLK-MH
ORG-6
BLK-CR1
ORG/BLK-EH
BLK-33D
ORG-14A
HIGH RPM
ORG/BLK-TB15B
[* SEE OPTIONAL WIRING]
GRN-43A
AC GENERATOR
BLK/RED-SP
IGNITION POWER
TS20
RED-EH (12GA)
GRN/WHT-TB35
+12V TO PLATFORM
GRN/BLK-SP
GRN-SP
WHT #12
TS19
N
JIB UP
BLU/RED-SP
27 RED-EH
23
23
22
21 WHT-EH
18
17
16
15 ORG/BLK-MH *
14 ORG-MH *
13
12
11 BLU/BLK-MH
10 BLU-MH
9
8 BLK/WHT-MH
7 BLK-MH
6 WHT/RED-MH
5 WHT/BLK-MH
4 WHT-MH
2 RED/BLK-MH
1 RED-MH
GRN/BLK-3
GRN-3
ORG/RED-3
+
RED/BLK-2A
52
52 BRN-GND. STUD
50
49
45
*
BRN [OPTION 1]
BRN [OPT. 2/3]
(LS1)
TS15
NC
3
J
COOLANT TEMPERATURE
1
2
I
BLU/WHT-38D
BLU/RED-39D
BRN-SP
BRN-OPT. 4
BRN-EH
BRN-52B
CONTROL BOX GROUND
ES34GP6H
Part No. 119987
June 2007
Section 5 • Schematics
Ground Control Box Wiring Diagram Gasoline/LPG Models
(from serial number 1986 to 3241)
REV A
N
M
L
K
J
I
VOLTAGE
H
OIL PRESSURE
G
F
E
D
C
*
GRN/WHT-3
RED/WHT-3
OPTION NUMBERS
WHT-21A
1 - PLATFORM LEVEL CUTOUT
2 - FLASHING BEACON
3 - DESCENT ALARM
4 - AC GENERATOR
WHT/RED-EH
BRN-GND.
WHT/BLK-EH
CABLE
8
BLK-22A
WHT-23A
BRN [OPTION 1]
BRN [OPT. 2/3]
P1
A2
GRN/WHT-1
45
35
BLK/RED-1
KS1
GRN/WHT-EH
GRN/WHT-TB45
GRN/WHT-TB35
BLK/RED-SP
NO
NO
RED-27A
NC
AC GENERATOR
GRN/BLK-1
45
44
BRN
RED-EH 12GA
RED-CR1 12GA
CB1
CB2
BLU/RED-SP
BLU/WHT-CR6
BLU/WHT-1
BLU/WHT-SP
L.P.
GAS
BLU/BLK-1
37
BLU/BLK-MH
STEER RIGHT
BLU-MH
STEER LEFT
BLK/RED-SP
BLK/WHT-SP
BLK-SP
HIGH RPM
*
*
R
ORG-TB14B
D
E
U
ORG/BLK-TB15B
WHT-5
CABLE
5
BLK-5
[
OPTION 3]
(LS3)
ORG-14A
RED-6
10
TS56
9
TS58
TS52
TS61
TS57
D
D
U
U
GRN/BLK-18A
L
R
CABLE
1
BRN-52C
ORG/BLK-MH
ORG-MH
TS53
TS60
[
OPTION 3]
32
31
WHT-1
30
RED/WHT-1
29
RED/BLK-1
RED-1
[OPTION 2]
28
L
TILT ALARM
AUXILIARY PUMP
RED/BLK-MH
RED-SP
RED/WHT-MH
WHT-EH
WHT-SP
KEYSWITCH POWER
KEYSWITCH POWER
BLK-SP
+12V TO PLATFORM
WHT-SP
IGNITION POWER
PLAT. ROTATE RIGHT
GRN/BLK-SP
GRN-3
ORG/RED-3
17
GRN-SP
PLAT. ROTATE LEFT
DRIVE ENABLE
ORG/BLK-3
15
ORG/BLK-MH *
ORG/BLK-SP
PLAT. LEVEL DOWN
ORG-3
14
ORG-MH *
ORG-SP
BLU/RED-3
BLU/WHT-3
13
PLAT. LEVEL UP
DRIVE ENABLE LIGHT
WHT
FOOTSWITCH
SEC. BOOM DOWN
16
12
BLU/BLK-3
11
BLU/BLK-MH
BLU/BLK-SP
BLU-3
10
BLU-MH
BLU-SP
SEC. BOOM UP
HORN
BLK/RED-3
9
BLK/WHT-3
8
BLK/WHT-MH
BLK/WHT-SP
BOOM RETRACT
BLK-3
7
BLK-MH
BLK-SP
WHT/RED-3
6
WHT/RED-MH
WHT/RED-SP
BOOM EXTEND
BOOM FUNCTION F.C.
WHT/BLK-3
5
WHT/BLK-MH
WHT/BLK-SP
TURN. ROTATE RIGHT
WHT-3
4
2
WHT-MH
WHT-SP
RED/BLK-3
RED/BLK-MH
RED/BLK-SP
TURN. ROTATE LEFT
PRIMARY BOOM DOWN
RED-3
1
RED-MH
RED-SP
PRIMARY BOOM UP
C
3
4
A
B
WHT #12
DENOTES TEST PORT
ORG/BLK-CR10
ORG/BLK-SP
PLATFORM LEVEL DOWN
14
WHT-4A
ORG-3
ORG-CR9
ORG-SP
PLATFORM LEVEL UP
BLU-10A
BLU/BLK-11A
BLK-CR1
CABLE
2
ORG/BLK-EH
BLK-33D
RED-1A
RED-27D
RED/BLK-2A
GRN-43A
BRN-CR4
GRN/BLK-44A
RED-CR2
BLK/WHT-34A
BLU/WHT-38A
BLU/RED-39A
BLK-33A
CABLE
3
BLK/RED-35A
GRN/BLK-CR2
WHT-EH
1
START RELAY
2
TACHOMETER
3
START INPUT
4
AUX. ON
5
GROUND
6
BATTERY
7
KEY POWER
8
KEY BYPASS
[* SEE OPTIONAL WIRING]
5
IGNITION/START
MODULE
9
IGN./FUEL ON
10
ENGINE FAULT
6
DESCRIPTION
CONTROL RELAY I.D.
P1
EMERGENCY STOP BUTTON
CR1-ENGINE START
CR2-ENGINE RUN
CR3-RPM CUTOUT
KS1
KEY SWITCH
TS51
AUXILIARY TOGGLE SWITCH
TS52
ENGINE START TOGGLE SWITCH
TS53
FUEL SELECT TOGGLE SWITCH
TS54
TS56
FUNCTION ENAB./ENGINE RPM TOGGLE SWITCH
ENGINE CHOKE TOGGLE SWITCH
RED-SP (12GA)
TS57
PLATFORM ROTATE TOGGLE SWITCH
BLK-ISM-1
TS58
TS59
TS60
TS61
JIB UP/DOWN TOGGLE SWITCH
PLATFORM LEVEL TOGGLE SWITCH
SECONDARY BOOM UP/DOWN TOGGLE SWITCH
PRIMARY BOOM UP/DOWN TOGGLE SWITCH
TS62
TURNTABLE ROTATE TOGGLE SWITCH
TS63
BOOM EXTEND/RETRACT TOGGLE SWITCH
CR4-HIGH RPM
CR5-HORN
CR6-FUEL PUMP (GAS)
DRIVE FORWARD
HIGH/LOW DRIVE
RED/WHT-CH
U
15
LABEL
DRIVE REVERSE
WHT/BLK-EH
WHT-EH
22
21
18
START
BRAKE RELEASE
WHT/RED-SP
RED-EH
2
GLOW PLUG
R
ORG/BLK-3
PLATFORM LEVEL CUTOUT (CE VERSION ONLY)
CR7-LPG SOLENOID
CR8-CHOKE
27
23
23
WHT/BLK-5A
D
*
33
WHT/BLK-1
D
TS62
TS54
ORG-6
BLK/RED-CR5
GRN-17A
OFF-LIMIT SPEED
34
WHT-2
BLK-2
RED-5
WHT/RED-6A
TS59
TS63
35
GRN/BLK-3
ORG/BLK-15A
-
36
BLK/RED-1
BLK/WHT-1
BLK-1
WHT/RED-1
BLK-CR5
WHT-CR2
BLK-7A
JIB UP
39
38
BLK/WHT-8A
HM
GRN-SP
43
40
RED-ISM-4
(LS2)
LS1-LS2 JUNCTION
GENERATOR OPTION
JIB DOWN
BLU/RED-1
WHT/RED-CH
CABLE
6
GRN/BLK-SP
ORG-1
(OPTION)
RED
*
GRN-1
BLU-1
1
GROUND
LS2-LS4 JUNCTION
BLU/RED-CR7
CABLE
9
RED
BRN-GND. STUD
BLK-8
(LS1)
HIGH RPM
+
[
BLK/RED-CR3
BLK/WHT-CR8
BLK-ISM-3
CABLE
7
TS51
+
NC
*AC GENERATOR OPTION
WHT-8
BLK-6
52
50
49
OPTION 3]
GROUND
52
BRN-2
WHT-6
BLK-7
(LS4)
WHT/RED-32A
BLK/RED-CR3
WHT-7
GRN/WHT-1
ORG/RED-1
ORG/BLK-1
A
COOLANT TEMPERATURE
BRN-5
SPARE WIRE LIST
B
CB1
CIRCUIT BREAKER, ENGINE, 10A
CB2
CIRCUIT BREAKER, CONTROLS, 10A
HM
EH
HOUR METER
ENGINE HARNESS
MH
MANIFOLD HARNESS
CH
CHASSIS HARNESS
SP
SWITCH PANEL
CR
ISM
A2
CONTROL RELAY
IGNITION/START MODULE
BRAKE RELEASE/TRAVEL ALARM (OPT.)
ENGINE/MANIFOLD/
CHASSIS HARNESS
RED-ISM-6
BLK/RED-35D
GRN/BLK-ISM-9
WHT (14GA)
1
2
3
4
BRN-ISM-5
7
BLK/RED-EH (14GA)
BLK-EH (14 GA)
WHT-21D
BLK/RED-MH (14GA)
BLU/WHT-EH
5
BLK/WHT-EH (14GA)
BLU/RED-EH
6
7
8
BLK/WHT-34D
BLK-22D
BLK/RED-9D
BLU/WHT-38D
8
BLU/RED-39D
BRN-SP
BRN-EH
BRN-OPT. 4
BRN-52B
CONTROL BOX GROUND
ES34GP5L
Part No. 119987
Z-34/22 IC
5 - 22
June 2007
Section 5 • Schematics
Ground Control Box Wiring Diagram Gasoline/LPG Models
(from serial number 1986 to 3241)
Section 5 • Schematics
June 2007
Platform Control Box Wiring Diagram - Diesel Models
(from serial number 1187 to 1546)
Section 5 • Schematics
June 2007
Platform Control Box Wiring Diagram - Diesel Models
(from serial number 1187 to 1546)
A
B
C
D
REV A
E
F
G
H
I
J
K
L
M
N
1
SPARE WIRES
TS1
TS14
GRN/WHT#45-1
RED-JIB
ORG/RED-3
ORG/RED#42-1
LABEL DESCRIPTION
RED/BLK-1
TS6
L1
NO
P3
TS9
NC
110
CABLE
#3
TS7
NC
TS8
P2
3
TILT
ALARM
2
F.S.
CABLE
#2
TS12
TS10
TS11
4
-
X
R
EMERGENCY STOP BUTTON
HORN BUTTON
DP1
DRIVE CONTROLLER
BP1
BOOM FUNCTION SPEED CONTROLLER
TS1
AUXILIARY TOGGLE SWITCH
TS2
START TOGGLE SWITCH
TS3
GLOW PLUG TOGGLE SWITCH
TS5
RPM TOGGLE SWITCH
TS6
TURNTABLE ROTATE TOGGLE SWITCH
TS7
SECONDARY BOOM UP/DOWN TOGGLE SWITCH
TS8
PRIMARY BOOM UP/DOWN TOGGLE SWITCH
TS9
EXTEND/RETRACT TOGGLE SWITCH
TS10
PLATFORM LEVEL TOGGLE SWITCH
TS11
PLATFORM ROTATE TOGGLE SWITCH
TS12
JIB UP/DOWN TOGGLE SWITCH
TS13
DRIVE HIGH/LOW OUTPUT TOGGLE SWITCH
TS14
DRIVE ENABLE TOGGLE SWITCH
R2
250 OHM RESISTER
L1
DRIVE ENABLE LIGHT
JIB
CABLE
#1
+
BP1
A
P2
P3
8
1
2
4
3
5
7
9
8
10
DP1
6
7
TS13
6
BRN-2
5
ORG#40-1
4
TS2
3
R2
2
250
1
WHT-FS
ORG/BLK#41-1
5
TS5
HORSE POWER LIMITER
TS3
BRN#2-HPL
WHT#1-HPL
6
RED#10-HPL
7
BLU/WHT-3
RED/WHT#29-1
WHT/BLK-3
WHT-3
BLU/BLK-3
BLU-3
Part No. 119987
GRN/BLK#44-1
Z-34/22 IC
GRN#43-1
5 - 23
RED/WHT-3
REMOVE THIS WIRE WHEN LOAD SENSE OPTION IS REQUIRED.
BLK/RED#35-1
RED-F.S.
BLK/WHT#34-1
BLK#33-1
WHT/RED-3
ORG/BLK-3
ORG-3
RED/BLK-3
RED-3
GRN/BLK-3
GRN-3
BLK/WHT-3
BLK-3
BLU/RED-3
WHT/RED#32-1
WHT#30-1
WHT/BLK#31-1
BLU#36-1
BLU/BLK#37-1
WHT-2
BLK-2
BLK-F.S.
BLK/RED-3
RED#27-1
BRN-JIB
BLUE-JIB
ORG-JIB
WHT-JIB
BLK-JIB
8
ES34D3E
June 2007
Section 5 • Schematics
Platform Control Box Wiring Diagram - Diesel Models
(from serial number 1547 to 1996)
REV A
N
M
L
K
J
I
H
G
F
E
D
C
B
A
NOTES:
1
1
REMOVE JUMPER JP1 FOR CE VERSION.
2
REMOVE THIS WIRE WHEN LOAD SENSE OPTION IS REQUIRED.
WHT
WHT
TS15
SPARE WIRES
TS1
L1
GRN/WHT-1
2
ORG/RED-1
ORG/BLK-1
BLU/RED-1
BLU/WHT-1
TS12
GRN/WHT-3
RED/WHT-3
R
L
L
A1
R
TS7
U
D
TS9
NO
P3
WHT
3
RED
RED
CABLE
#3
U
D
U
D
TS11
R
E
NC
NC
TS13
TS10
P2
F.S.
#2
ORG/RED
4
U
D
TS8
RED
BRN
A
LABEL
BRN-JIB
R
+
JIB
CABLE
#1
C
-
TS2
DP1
D
X
BP1
R
L
+
-
X
B
TS14
1
A
R
DESCRIPTION
BRN-2
BRN
TS4
TS6
P2
P3
DP1
BP1
TS1
TS2
TS4
TS6
TS7
TS8
TS9
TS10
TS11
TS12
EMERGENCY STOP BUTTON
HORN BUTTON
DRIVE CONTROLLER
BOOM FUNCTION SPEED CONTROLLER
AUXILIARY TOGGLE SWITCH
START ENGINE TOGGLE SWITCH
HIGH/LOW RPM TOGGLE SWITCH
GLOW PLUG TOGGLE SWITCH
PLATFORM ROTATE TOGGLE SWITCH
JIB UP/DOWN TOGGLE SWITCH
PLATFORM LEVEL TOGGLE SWITCH
SECONDARY BOOM UP/DOWN TOGGLE SWITCH
PRIMARY BOOM UP/DOWN TOGGLE SWITCH
TURNTABLE ROTATE TOGGLE SWITCH
TS13
TS14
TS15
A1
EXTEND/RETRACT TOGGLE SWITCH
DRIVE RANGE TOGGLE SWITCH
DRIVE ENABLE TOGGLE SWITCH
TILT ALARM
L1
DRIVE ENABLE LIGHT
5
6
RED
WHT
7
RED/BLK-1
BLU/WHT-3
WHT/BLK-3
ORG/RED-3
BLU/BLK-3
WHT-3
BLU-3
WHT/RED-3
BLK/RED-1
RED-FS
BLK/WHT-1
BLK-1
GRN/BLK-3
GRN-3
RED/WHT-1
GRN-1
RED/BLK-3
GRN/BLK-1
ORG-3
RED-3
ORG/BLK-3
BLK-3
BLK/WHT-3
ORG-1
BLU/RED-3
WHT/BLK-1
WHT/RED-1
WHT-1
BLU/BLK-1
BLU-1
WHT-FS
WHT-2
BLK-FS
BLK-2
BLK/RED-3
RED-1
BLUE-JIB
WHT-JIB
ORG-JIB
BLK-JIB
8
2
ES34D3J
Part No. 119987
Z-34/22 IC
5 - 24
June 2007
Section 5 • Schematics
Platform Control Box Wiring Diagram - Diesel Models
(from serial number 1547 to 1996)
Section 5 • Schematics
June 2007
Platform Control Box Wiring Diagram - Diesel Models
(from serial number 1997 to 3241)
Section 5 • Schematics
June 2007
Platform Control Box Wiring Diagram - Diesel Models
(from serial number 1997 to 3241)
A
B
C
D
REV A
E
F
G
H
I
J
K
L
M
N
NOTES:
1
1
REMOVE JUMPER JP1 FOR CE VERSION.
2
REMOVE THIS WIRE WHEN LOAD SENSE OPTION IS REQUIRED.
WHT
WHT
TS15
SPARE WIRES
GRN/WHT-1
L1
TS1
2
ORG/RED-1
ORG/BLK-1
BLU/RED-1
BLU/WHT-1
TS12
GRN/WHT-3
RED/WHT-3
A1
R
R
TS7
U
E
R
L
L
D
TS9
NO
P3
WHT
3
RED
RED
CABLE
#3
U
U
U
D
D
D
TS11
NC
NC
TS13
TS10
P2
F.S.
#2
ORG/RED
4
TS8
BRN
-
+
A
JIB
CABLE
#1
X
LABEL
BP1
R
RED
5
R
BRN-JIB
C
TS2
DP1
D
L
+
-
X
B
TS14
1
A
R
BRN-2
6
DESCRIPTION
BRN
TS4
TS6
P2
P3
DP1
BP1
TS1
TS2
TS4
TS6
TS7
TS8
TS9
TS10
TS11
TS12
EMERGENCY STOP BUTTON
HORN BUTTON
DRIVE CONTROLLER
BOOM FUNCTION SPEED CONTROLLER
AUXILIARY TOGGLE SWITCH
START ENGINE TOGGLE SWITCH
HIGH/LOW RPM TOGGLE SWITCH
GLOW PLUG TOGGLE SWITCH
PLATFORM ROTATE TOGGLE SWITCH
JIB UP/DOWN TOGGLE SWITCH
PLATFORM LEVEL TOGGLE SWITCH
SECONDARY BOOM UP/DOWN TOGGLE SWITCH
PRIMARY BOOM UP/DOWN TOGGLE SWITCH
TURNTABLE ROTATE TOGGLE SWITCH
TS13
TS14
TS15
A1
EXTEND/RETRACT TOGGLE SWITCH
DRIVE RANGE TOGGLE SWITCH
DRIVE ENABLE TOGGLE SWITCH
TILT ALARM
L1
DRIVE ENABLE LIGHT
RED
WHT
7
BLU/WHT-3
RED/BLK-1
WHT/BLK-3
ORG/RED-3
BLU/BLK-3
WHT-3
WHT/RED-3
BLU-3
BLK/RED-1
RED-FS
BLK-1
BLK/WHT-1
GRN/BLK-3
GRN-1
GRN-3
RED/WHT-1
RED/BLK-3
GRN/BLK-1
ORG-3
RED-3
ORG/BLK-3
BLK-3
BLK/WHT-3
BLU/RED-3
ORG-1
WHT/BLK-1
WHT/RED-1
WHT-1
BLU/BLK-1
BLU-1
WHT-FS
WHT-2
BLK-FS
BLK-2
BLK/RED-3
RED-1
ORG-JIB
BLUE-JIB
WHT-JIB
BLK-JIB
8
2
ES34D3L
5 - 25
Z-34/22 IC
Part No. 119987
June 2007
Section 5 • Schematics
Platform Control Box Wiring Diagram Gasoline/LPG Models
(from serial number 1187 to 1546)
REV A
N
M
L
K
J
I
H
G
F
E
D
C
B
A
1
SPARE WIRES
TS14
GRN/WHT#45-1
TS1
RED-JIB
ORG/RED-3
TILT
ALARM
ORG/RED#42-1
2
TS6
L1
NO
P3
RED/BLK-1
TS9
NC
R
DESCRIPTION
P2
EMERGENCY STOP BUTTON
P3
HORN BUTTON
DP1
DRIVE CONTROLLER
BP1
BOOM FUNCTION SPEED CONTROLLER
TS1
AUXILIARY SWITCH
TS2
START SWITCH
TS3
CHOKE SWITCH
TS4
FUEL SELECT SWITCH
TS5
RPM SWITCH
TS6
TURNTABLE ROTATE SWITCH
TS7
SECONDARY BOOM UP/DOWN SWITCH
TS8
PRIMARY BOOM UP/DOWN SWITCH
TS9
EXTEND/RETRACT SWITCH
TS10
PLATFORM LEVEL SWITCH
TS11
PLATFORM ROTATE SWITCH
TS12
JIB UP/DOWN SWITCH
TS13
DRIVE HIGH/LOW OUTPUT SWITCH
TS14
DRIVE ENABLE SWITCH
R2
250 OHM RESISTER
L1
DRIVE ENABLE LIGHT
WHT-FS
1
2
4
3
5
7
9
8
10
DP1
BRN-2
8
6
7
TS13
6
4
5
ORG/BLK#41-1
5
ORG#40-1
TS4
4
TS2
3
R2
2
250
1
3
JIB
CABLE
#1
X
BP1
-
F.S.
CABLE
#2
TS12
TS10
TS11
+
110
CABLE
#3
TS7
NC
TS8
P2
A
LABEL
TS5
HORSE POWER LIMITER
TS3
BRN#2-HPL
WHT#1-HPL
6
7
RED#10-HPL
BLU/WHT-3
RED/WHT#29-1
WHT/BLK-3
WHT-3
BLU/BLK-3
BLU-3
GRN/BLK#44-1
GRN#43-1
RED/WHT-3
BLU/WHT#38-1
BLU/RED#39-1
BLK/RED#35-1
BLK/WHT#34-1
BLK#33-1
RED-F.S.
WHT/RED-3
ORG/BLK-3
ORG-3
RED/BLK-3
RED-3
GRN/BLK-3
GRN-3
BLK/WHT-3
BLK-3
BLU/RED-3
WHT/RED#32-1
WHT#30-1
WHT/BLK#31-1
BLU#36-1
BLU/BLK#37-1
WHT-2
BLK-2
BLK-F.S.
BLK/RED-3
RED#27-1
BRN-JIB
BLUE-JIB
ORG-JIB
WHT-JIB
BLK-JIB
ES34GP3E
8
REMOVE THIS WIRE WHEN LOAD SENSE OPTION IS REQUIRED.
Part No. 119987
Z-34/22 IC
5 - 26
June 2007
Section 5 • Schematics
Platform Control Box Wiring Diagram Gasoline/LPG Models
(from serial number 1187 to 1546)
Section 5 • Schematics
June 2007
Platform Control Box Wiring Diagram Gasoline/LPG Models
(from serial number 1547 to 1996)
Section 5 • Schematics
June 2007
Platform Control Box Wiring Diagram Gasoline/LPG Models
(from serial number 1547 to 1996)
A
B
C
REV A
D
E
F
G
H
I
J
K
L
M
N
NOTES:
1
1
REMOVE JUMPER JP1 FOR CE VERSION.
2
REMOVE THIS WIRE WHEN LOAD SENSE OPTION IS REQUIRED.
WHT
TS14
TS1
2
SPARE WIRES
GRN/WHT-1
ORG/RED-1
ORG/BLK-1
GRN/WHT-3
RED/WHT-3
WHT
TS8
TS9
L1
NO
P3
WHT
RED
RED
3
A1
TS6
+
F.S.
TS12
TS11
JIB
A
BRN-JIB
CABLE
#1
+
BPI
-
TS13
ORG
BRN
TS4
L
X
DP1
R
110V AC
TS10
ORG/RED
5
C
#2
TS7
NC
R
RED
D
CABLE
#3
NC
P2
4
-
X
B
R
BRN-2
+
TS2
1
A
BRN
6
TS5
TS3
WHT
LABEL
DESCRIPTION
P2
EMERGENCY STOP BUTTON
P3
HORN BUTTON
DP1
DRIVE CONTROLLER
BP1
BOOM FUNCTION SPEED CONTROLLER
TS1
AUXILIARY TOGGLE SWITCH
TS2
START TOGGLE SWITCH
TS3
CHOKE TOGGLE SWITCH
TS4
FUEL SELECT TOGGLE SWITCH
TS5
RPM TOGGLE SWITCH
TS6
TURNTABLE ROTATE TOGGLE SWITCH
TS7
SECONDARY BOOM UP/DOWN TOGGLE SWITCH
TS8
PRIMARY BOOM UP/DOWN TOGGLE SWITCH
TS9
EXTEND/RETRACT TOGGLE SWITCH
TS10
PLATFORM LEVEL TOGGLE SWITCH
TS11
PLATFORM ROTATE TOGGLE SWITCH
TS12
JIB UP/DOWN TOGGLE SWITCH
TS13
DRIVE HIGH/LOW OUTPUT TOGGLE SWITCH
TS14
DRIVE ENABLE TOGGLE SWITCH
A1
TILT ALARM
L1
DRIVE ENABLE LIGHT
RED
7
RED/BLK-1
ORG/RED-3
BLU/WHT-3
WHT/BLK-3
WHT-3
BLU/BLK-3
GRN/BLK-1
BLU-3
GRN-1
BLU/WHT-1
BLK/WHT-1
BLU/RED-1
BLK/RED-1
RED-FS
WHT/RED-3
ORG/BLK-3
BLK-1
ORG-3
RED/BLK-3
2
5 - 27
RED-3
GRN-3
GRN/BLK-3
RED/WHT-1
BLK/WHT-3
BLK-3
BLU/RED-3
ORG-1
WHT/RED-1
WHT/BLK-1
WHT-1
BLU-1
WHT-FS
BLU/BLK-1
WHT-2
BLK-FS
BLK-2
BLK/RED-3
RED-1
BLUE-JIB
WHT-JIB
ORG-JIB
BLK-JIB
8
ES34GP3J
Z-34/22 IC
Part No. 119987
June 2007
Section 5 • Schematics
Platform Control Box Wiring Diagram Gasoline/LPG Models
(from serial number 1997 to 3241)
REV A
N
M
L
K
J
I
H
G
F
E
D
C
B
A
NOTES:
1
REMOVE JUMPER JP1 FOR CE VERSION.
2
REMOVE THIS WIRE WHEN LOAD SENSE OPTION IS REQUIRED.
1
WHT
WHT
TS15
SPARE WIRES
L1
TS1
2
+
TS7
TS12
GRN/WHT-1
ORG/RED-1
ORG/BLK-1
GRN/WHT-3
RED/WHT-3
R
L
L
A1
R
U
D
TS9
NO
P3
WHT
3
RED
RED
CABLE
#3
D
U
U
D
TS11
R
E
NC
NC
TS13
TS10
P2
F.S.
#2
ORG/RED
U
D
TS8
RED
X
-
+
JIB
R
CABLE
#1
BRN
A
RED
L
A
+
-
X
B
TS14
1
BRN-JIB
R
TS3
C
TS2
DP1
D
R
LABEL
DESCRIPTION
P2
EMERGENCY STOP BUTTON
P3
HORN BUTTON
DP1
DRIVE CONTROLLER
BP1
BOOM FUNCTION SPEED CONTROLLER
TS1
AUXILIARY TOGGLE SWITCH
TS2
START TOGGLE SWITCH
TS3
FUEL SELECT TOGGLE SWITCH
TS4
HIGH/LOW RPM TOGGLE SWITCH
TS6
CHOKE TOGGLE SWITCH
TS7
PLATFORM ROTATE TOGGLE SWITCH
TS8
JIB BOOM UP/DOWN TOGGLE SWITCH
TS9
PLATFORM LEVEL UP/DOWN TOGGLE SWITCH
TS10
SECONDARY BOOM UP/DOWN TOGGLE SWITCH
TS11
PRIMARY BOOM UP/DOWN TOGGLE SWITCH
TS12
TURNTABLE ROTATE TOGGLE SWITCH
BRN-2
BRN
TS4
TS6
TS13
EXTEND/RETRACT TOGGLE SWITCH
TS14
DRIVE RANGE TOGGLE SWITCH
TS15
DRIVE ENABLE TOGGLE SWITCH
A1
TILT ALARM
L1
DRIVE ENABLE LIGHT
4
5
6
7
BLU/WHT-3
RED/BLK-1
WHT/BLK-3
ORG/RED-3
BLU/BLK-3
WHT-3
WHT/RED-3
BLU-3
BLK/WHT-1
BLU/RED-1
BLU/WHT-1
BLK/RED-1
RED-FS
BLK-1
GRN/BLK-3
GRN-3
RED/WHT-1
GRN-1
RED/BLK-3
GRN/BLK-1
ORG-3
RED-3
ORG/BLK-3
BLK-3
BLK/WHT-3
ORG-1
BLU/RED-3
WHT/RED-1
WHT/BLK-1
WHT-1
BLU/BLK-1
BLU-1
WHT-FS
WHT-2
BLK-FS
BLK-2
BLK/RED-3
RED-1
BLUE-JIB
WHT-JIB
ORG-JIB
BLK-JIB
ES34GP3L
8
2
Part No. 119987
Z-34/22 IC
5 - 28
June 2007
Section 5 • Schematics
Platform Control Box Wiring Diagram Gasoline/LPG Models
(from serial number 1997 to 3241)
Section 5 • Schematics
June 2007
Generator Option Wiring Diagram
(from serial number 1547 to 1996)
1
TILT
ALARM
TS7
TS8
LABEL
DESCRIPTION
HORN BUTTON
EMERGENCY STOP BUTTON
DRIVE CONTROLLER
P2
DP1
AUXILIARY SWITCH
BOOM FUNCTION SPEED CONTROLLER
P3
TS1
GLOW PLUG SWITCH
START SWITCH
BP1
TS2
TS4
TS3
TURNTABLE ROTATE SWITCH
SECONDARY BOOM UP/DOWN SWITCH
RPM SWITCH
PRIMARY BOOM UP/DOWN SWITCH
TS5
TS8
TS7
PLATFORM LEVEL SWITCH
EXTEND/RETRACT SWITCH
TS6
TS10
TS9
JIB UP/DOWN SWITCH
PLATFORM ROTATE SWITCH
DRIVE HIGH/LOW OUTPUT SWITCH
TS11
TS13
AC GENERATOR SWITCH (OPTION)
DRIVE ENABLE SWITCH
TS12
TS14
JIB
DRIVE ENABLE LIGHT
TS15
F.S.
L1
110
CABLE
#1
BP1
CABLE
#2
RED
TS13
TS2
DPI
TS5
TS3
8
GRN/WHT-1
TS12
TS10
TS11
6
CABLE
#3
P2
NC
A
+
_
X
R
TS6
TS15
TS9
NC
5
Part No. 119987
Z-34/22 IC
5 - 29
R
B
X
_
+
A
7
L
R
C
D
L1
P3
NO
4
TS14
TS1
2
3
N
M
L
K
J
I
H
G
F
E
D
C
B
A
June 2007
Section 5 • Schematics
REV A
Generator Option Wiring Diagram
(from serial number 1547 to 1996)
Generator Option Wiring Diagram
(from serial number 1997 to 3241)
REV A
TS15
TS10
TS11
TS13
TS8
EMERGENCY STOP BUTTON
DESCRIPTION
P2
DRIVE CONTROLLER
HORN BUTTON
LABEL
DP1
P3
AUXILIARY SWITCH
BOOM FUNCTION SPEED CONTROLLER
RPM SWITCH
START ENGINE SWITCH
TS1
TS4
PLATFORM ROTATE SWITCH
JIB UP/DOWN SWITCH
GLOW PLUG SWITCH
TS8
SECONDARY BOOM SWITCH
PLATFORM LEVEL SWITCH
TS6
TS10
TURNTABLE ROTATE SWITCH
PRIMARY BOOM SWITCH
DRIVE RANGE SWITCH
PRIMARY BOOM EXTEND SWITCH
TS12
TS14
AC GENERATOR SWITCH (OPTION)
DRIVE ENABLE SWITCH
OVERLOAD LIGHT (OPTION)
DRIVE ENABLE LIGHT
TS15
TS13
TS11
TS9
TS7
TS2
BP1
6
TS47
TS47
L2
CABLE
#1
JIB
L1
F.S.
CABLE
#2
BP1
L2
TS2
DPI
TS14
TS4
TS6
5 - 30
Z-34/22 IC
Part No. 119987
5
+
RED
4
CABLE
#3
P2
NC
GRN/WHT-1
2
TILT
ALARM
TS12
TS7
TS9
P3
NC
7
R
B
X
+
A
L1
TS1
NO
L
R
C
D
A
+
_
X
R
A
B
C
D
E
F
G
H
I
J
K
L
M
N
Section 5 • Schematics
June 2007
1
3
8
June 2007
Section 5 • Schematics
Generator Option Wiring Diagram
(from serial number 1997 to 3241)
Section 5 • Schematics
June 2007
Load Sense Option Wiring Diagram
(from serial number 1187 to 1546)
Section 5 • Schematics
June 2007
Load Sense Option Wiring Diagram
(from serial number 1187 to 1546)
A
B
REV A
C
D
E
F
G
H
I
J
K
L
1
M
N
LOAD SENSOR
TS14
TS1
FUSE
RED/BLK
1
RED
2
2
BLK
3
3
WHT
4
YEL
1
2
TILT
5
RED/BLK
6
7
LOAD SENSE PCB
4
ALARM
TS6
L2
L1
NO
P3
DESCRIPTION
P2
EMERGENCY STOP BUTTON
P3
HORN BUTTON
8
3
LABEL
AUXILIARY SWITCH
TS2
START SWITCH
TS3
CHOKE SWITCH
TS4
FUEL SELECT SWITCH
TS5
RPM SWITCH
TS6
TURNTABLE ROTATE SWITCH
TS7
SECONDARY BOOM UP/DOWN SWITCH
TS8
PRIMARY BOOM UP/DOWN SWITCH
TS9
EXTEND/RETRACT SWITCH
TS10
PLATFORM LEVEL SWITCH
TS11
PLATFORM ROTATE SWITCH
11
TS1
12
F.S.
#2
RED/BLK
JIB
5
BRN
CABLE
#1
R
BRN
WHT
X
BP1
-
BOOM FUNCTION SPEED CONTROLLER
TS12
TS10
TS11
+
BP1
10
110V
CABLE
#3
NC
A
DRIVE CONTROLLER
9
TS7
TS8
TS9
NC
P2
4
DP1
TS12
JIB UP/DOWN SWITCH
TS13
DRIVE HIGH/LOW OUTPUT SWITCH
TS14
DRIVE ENABLE SWITCH
R2
250 OHM REGISTER
L1
DRIVE ENABLE LIGHT
L2
OVERLOAD LIGHT (OPTION)
RED/WHT
TS4
2
3
4
5
6
7
8
LOAD SENSE OPTION
10 9
TS5
CR11
TS3
7
BLK - F.S.
8
7 6
5
4 3
2 1
HORSE POWER LIMITER
DP1
TS13
BRN
RED/WHT
1
TS2
6
1 2 3 4
LOAD SENSE PCB
P2
1 2 3 4 5 6 7 8 9 10 11 12
FS1
RED/BLK
BLK
CR11
RED
WHT
WHT
CR11
3A
BRN
RED/BLK
8
ES34GP4E
5 - 31
Z-34/22 IC
Part No. 119987
June 2007
Section 5 • Schematics
Load Sense Option Wiring Diagram
(from serial number 1547 to 1996)
REV A
N
M
L
K
J
I
H
G
F
E
D
C
B
A
LOAD SENSOR
1
2
DESCRIPTION
LABEL
P3
HORN BUTTON
GLOW PLUG SWITCH
8
F.S.
#2
RED/WHT
JIB
FS1
RED/BLK
9 10 11 12
BRN
8
CABLE
#1
7
WHT
6
RED/BLK
5
L2
P2
6
RED
BLK
RED/BLK
4
RED/WHT
LOAD SENSE PCB
A
BP1
3
+
TS13
1 2
4
X _
12
5
TS12
TS10
TS11
R
3
4
11
110
CABLE
#3
NC
BRN
LOAD SENSE OPTION
1 2
YEL
3
10
TS7
TS8
TS9
OVERLOAD LIGHT (OPTION)
NC
L2
P2
DRIVE ENABLE SWITCH
DRIVE ENABLE LIGHT
WHT
9
DRIVE HIGH/LOW OUTPUT SWITCH
LOAD SENSE PCB
7
JIB UP/DOWN SWITCH
TS13
TS14
6
TS12
L1
5
PLATFORM ROTATE SWITCH
4
PLATFORM LEVEL SWITCH
TS11
3
EXTEND/RETRACT SWITCH
TS10
TS6
PRIMARY BOOM UP/DOWN SWITCH
TS9
+
SECONDARY BOOM UP/DOWN SWITCH
TS8
L2
TS7
L1
TURNTABLE ROTATE SWITCH
NO
RPM SWITCH
TS6
P3
TS5
TILT
ALARM
TS4
BLK
4
START SWITCH
TS3
3
TS2
RED
2
AUXILIARY SWITCH
1
TS1
2
DRIVE CONTROLLER
BOOM FUNCTION SPEED CONTROLLER
RED/BLK
1
DP1
BP1
FUSE
TS14
EMERGENCY STOP BUTTON
TS1
P2
CR11
WHT
WHT
CR11
3A
BRN
C
R
L
TS2
D
DPI
RED/BLK
7
BRN
A
+
_
X
B
R
BLK - FS
CR11
TS5
TS3
Part No. 119987
8
Z-34/22 IC
5 - 32
June 2007
Section 5 • Schematics
Load Sense Option Wiring Diagram
(from serial number 1547 to 1996)
June 2007
Section 5 • Schematics
Load Sense Option Wiring Diagram
(from serial number 1997 to 3241)
REV A
N
M
L
K
J
I
H
G
F
E
D
C
B
A
LOAD SENSOR
1
2
DESCRIPTION
LABEL
P2
EMERGENCY STOP BUTTON
P3
HORN BUTTON
TS8
JIB UP/DOWN SWITCH
TS9
PLATFORM LEVEL SWITCH
TS10
SECONDARY BOOM SWITCH
TS11
PRIMARY BOOM SWITCH
WHT-FS
C
OVERLOAD LIGHT (OPTION)
NC
L2
NO
DRIVE ENABLE LIGHT
+
AC GENERATOR SWITCH (OPTION)
L1
TS12
TS47
TS7
DRIVE ENABLE SWITCH
TS9
DRIVE RANGE SWITCH
TS15
L1
TS14
P3
TURNTABLE ROTATE SWITCH
PRIMARY BOOM EXTEND SWITCH
WHT
NO
TS12
TS13
RED/BLK
N
LOAD SENSE
OPTION
WH
T
3
ED
4
PLATFORM ROTATE SWITCH
3
GLOW PLUG SWITCH
TS7
2
TS6
GR
BRN
1
START ENGINE SWITCH
RPM SWITCH
1 2 3 4 5 6 7 8 9
TS2
TS4
_
AUXILIARY SWITCH
TS15
DRIVE CONTROLLER
BOOM FUNCTION SPEED CONTROLLER
TS1
TS1
DP1
BP1
R
BLK
RED/WHT
4
TS10
TS11
TS13
NC
CABLE
#3
P2
NC
TS8
5
#2
F.S.
CABLE
#1
JIB
+
R
BRN
P2
FS1
X -
+ A
BP1
L2
LOAD SENSE OPTION
RED-FS
6
TS47
BLK-FS
WHT-FS
NC.
C.
WHT
+
8
D C R L
TS2
RED/BLK
DPI
RED
NO.
RED/WHT
A +
-
X B R
WHT-FS
7
BRN
TS14
_
LOAD SENSE PCB
TS4
TS6
8
Part No. 119987
Z-34/22 IC
5 - 33
June 2007
Section 5 • Schematics
Load Sense Option Wiring Diagram
(from serial number 1997 to 3241)
Section 5 • Schematics
June 2007
Hydraulic Schematic, 2WD Models
(from serial number 1187 to 1546)
A
B
C
REV A
D
E
F
G
H
I
J
L
M
B
A
CHARGE PRESSURE
1
B
A
3500
PSI
2
K
AUXILIARY
PUMP
0.5 GPM
3500
PSI
LIFT/STEER
PUMP
3.0 GPM
M
E
320
PSI
3
T1
S1
S2
L1
DRIVE PUMP
P1
T3
5
PSI
25 PSI
4
HYDRAULIC TANK
CHARGE PRESSURE
5
A PORT
T2
T1
CP
6
T
B
250
PSI
M4
P
B PORT
A
AD
AC
0.025
inch
AA
7
RIGHT
REAR
BRAKE
M2
BRAKE
2 SPD
AB
8
BRAKE/2-SPEED
MANIFOLD
M3
D
C
TRACTION
MANIFOLD
0.070
inch
LEFT
REAR
BRAKE
M1
T3
5 - 34
Z-34/22 IC
Part No. 119987
STEERING
CYLINDER
N
June 2007
Section 5 • Schematics
Hydraulic Schematic, 2WD Models
(from serial number 1187 to 1546)
REV A
N
M
L
K
J
I
H
G
F
E
D
C
B
A
PLATFORM LEVEL SLAVE CYLINDER
1
SECONDARY BOOM
PRIMARY BOOM
JIB BOOM
PRIMARY BOOM EXTENSION
0.032 inch
2
TURNTABLE ROTATE
3000 PSI
8:1
PLATFORM ROTATE
5.9 CU. IN.
/REV
3
MASTER
T1
S1
S2
3000 PSI
1.5:1
P1
3000 PSI
3:1
2500 PSI
3:1
3000 PSI
3:1
2500 PSI
3:1
T3
4
S1
C1
S2
C2
M1
C3
M2
C4
C6
C5
C8
C7
E
G1
5
.8 GPM
P1
A
3200 PSI
F
G
B
0.025 inch
(from serial number
1187 to1891)
L
H
I
J
K
1600 PSI
1400 PSI
0.022 inch
(from serial number
1892 to1969)
1800 PSI
J1
3000 PSI
3:1
J2
6
PR1
PR2
1500 PSI
3:1
CE
C
M
D
N
O
X
0.052 inch
P
Q
R
S
T
U
V
CD
CB
CC
7
Y
0.028
inch
0.052 inch
P2
W
CA
0.3 GPM
CF
CG
(after serial number 1969)
0.1 GPM
T2
0.025 inch
T1
T3
8
T4
Part No. 119987
Z-34/22 IC
5 - 35
June 2007
Section 5 • Schematics
Hydraulic Schematic, 2WD Models
(from serial number 1187 to 1546)
Section 5 • Schematics
June 2007
Hydraulic Schematic, 2WD Models
(from serial number 1547 to 2900)
A
B
C
REV A
D
E
F
G
H
I
J
K
L
M
CHARGE PRESSURE
B
A
1
50
PSI
B
E
A
D
3500 PSI
GENERATOR OPTION
3 gpm
2
GEN
AUXILIARY
PUMP
0.5 GPM
3500 PSI
2000 PSI
T
FM
LIFT/STEER
PUMP
3 GPM
E
3
M
220 PSI
T1
S1
S2
L2
DRIVE PUMP
L1
P1
4
T3
25
PSI
HYDRAULIC TANK
CHARGE PRESSURE
5
A PORT
T2
T1
B
CP
6
170 PSI
M4
T
B PORT
P
A
A
AD
REAR
LEFT
AC
0.025
inch
B
AA
7
M2
BRAKE
AB
2 SPD
M3
8
BRAKE/2-SPEED
MANIFOLD
REAR
RIGHT
D
C
0.070
inch
B
TRACTION
MANIFOLD
A
M1
STEERING
T3
5 - 36
Z-34/22 IC
Part No. 119987
N
June 2007
Section 5 • Schematics
Hydraulic Schematic, 2WD Models
(from serial number 1547 to 2900)
REV A
N
M
L
K
J
I
H
G
F
E
D
C
B
A
PLATFORM LEVEL SLAVE CYLINDER
1
SECONDARY BOOM
PRIMARY BOOM
JIB BOOM
PRIMARY BOOM EXTENSION
0.032 inch
2
TURNTABLE ROTATE
3000 PSI
8:1
PLATFORM ROTATE
5.9 CU. IN.
/REV
MASTER
3
T1
S1
S2
3000 PSI
1.5:1
P1
3000 PSI
3:1
2500 PSI
3:1
3000 PSI
3:1
2500 PSI
3:1
T3
4
S1
C1
S2
C2
M1
C3
M2
C4
C6
C5
C8
C7
E
G1
.8 GPM
P1
5
A
3200 PSI
F
G
H
I
B
0.025 inch
(from serial number
1187 to1891)
L
J
K
1600 PSI
1400 PSI
0.022 inch
(from serial number
1892 to1969)
1800 PSI
6
J1
3000 PSI
3:1
J2
PR1
PR2
1500 PSI
3:1
CE
C
M
D
N
O
X
0.052 inch
P
Q
R
S
T
U
V
CD
Y
0.028
inch
0.052 inch
P2
W
CA
0.3 GPM
CF
CC
7
CG
(after serial number 1969)
0.1 GPM
T2
CB
0.025 inch
T1
T3
T4
8
Part No. 119987
Z-34/22 IC
5 - 37
June 2007
Section 5 • Schematics
Hydraulic Schematic, 2WD Models
(from serial number 1547 to 2900)
Section 5 • Schematics
June 2007
Hydraulic Schematic, 2WD Models
(from serial number 2901 to 3241)
A
B
C
REV A
D
E
F
G
H
I
J
K
L
M
CHARGE PRESSURE
B
A
1
50
PSI
B
E
A
D
3500 PSI
GENERATOR OPTION
3 gpm
GEN
2
AUXILIARY
PUMP
0.5 GPM
3500 PSI
2000 PSI
T
FM
LIFT/STEER
PUMP
3 GPM
E
3
M
220 PSI
T1
S1
S2
L2
DRIVE PUMP
L1
P1
T3
4
25
PSI
HYDRAULIC TANK
CHARGE PRESSURE
5
A PORT
T2
T1
B
CP
170 PSI
6
M4
T
B PORT
P
A
A
AD
REAR
LEFT
AC
0.025
inch
B
AA
M2
BRAKE
7
AB
2 SPD
M3
8
BRAKE/2-SPEED
MANIFOLD
REAR
RIGHT
D
0.070
inch
B
C
TRACTION
MANIFOLD
A
M1
STEERING
T3
5 - 38
Z-34/22 IC
Part No. 119987
N
June 2007
Section 5 • Schematics
Hydraulic Schematic, 2WD Models
(from serial number 2901 to 3241)
REV A
N
M
L
K
J
I
H
G
F
E
D
C
B
A
PLATFORM LEVELING
SLAVE CYLINDER
1
SECONDARY BOOM CYLINDER
PRIMARY BOOM CYLINDER
EXTENSION CYLINDER
JIB BOOM
0.032 inch
2
TURNTABLE ROTATE
3000 PSI
4.5:1
PLATFORM ROTATE
5.9 CU. IN. /REV
MASTER
CYLINDER
3
T1
S1
3000 PSI
1.5:1
S2
3000 PSI
3:1
2500 PSI
3:1
3000 PSI
1.5:1
2500 PSI
3:1
P1
T3
4
S1
S2
C1
C2
M1
C3
M2
C4
C5
C6
C8
C7
E
G1
1 GPM
5
P1
A
F
G
H
I
J
3200 PSI
K
L
B
1600 PSI
1600 PSI
2800 PSI
1500 PSI
3:1
3000 PSI
3:1
6
(removed
after serial
number 3215)
J1
C
M
D
N
P
X
0.052 inch
O
0.052 inch
Q
R
S
T
U
PR1
PR2
V
CG
Y
CH
P2
W
J2
0.028 inch
0.1 GPM
CI
7
0.3 GPM
CF
T2
T1
0.035 inch
T3
T4
8
Part No. 119987
Z-34/22 IC
5 - 39
June 2007
Section 5 • Schematics
Hydraulic Schematic, 2WD Models
(from serial number 2901 to 3241)
Section 5 • Schematics
June 2007
Hydraulic Schematic, 4WD Models
(from serial number 1187 to 1546)
A
B
C
REV A
D
E
F
G
H
I
J
K
L
B
A
CHARGE PRESSURE
1
B
A
3500 PSI
AUXILIARY
PUMP
0.5 GPM
3500 PSI
2
M
LIFT/STEER
PUMP
3.0 GPM
E
320 PSI
T1
S1
3
S2
L1
P1
DRIVE PUMP
T3
25
PSI
5
PSI
4
HYDRAULIC TANK
CHARGE PRESSURE
5
A PORT
B PORT
T2
M8
M4
T
250
PSI
B
A
CP
T1
P
6
AD
0.025
inch
REAR
RIGHT
AC
AA
M2
M6
FRONT
RIGHT
BRAKE
F
D
AB
2 SPD
E
7
M3
0.045
inch
BRAKE/2 SPEED
MANIFOLD
REAR
LEFT
G
M7
K
67%
FRONT
LEFT
0.052
inch
33%
0.052 inch C
M1
M5
H
I
P
T3
8
J
5 - 40
Z-34/22 IC
Part No. 119987
4WD
TRACTION
MANIFOLD
STEERING
M
N
June 2007
Section 5 • Schematics
Hydraulic Schematic, 4WD Models
(from serial number 1187 to 1546)
REV A
N
M
L
K
J
I
H
G
F
E
D
C
B
A
PLATFORM LEVEL SLAVE CYLINDER
1
SECONDARY BOOM
PRIMARY BOOM
JIB BOOM
PRIMARY BOOM EXTENSION
0.032 inch
2
TURNTABLE ROTATE
3000 PSI
8:1
PLATFORM ROTATE
5.9 CU. IN.
/REV
MASTER
3
T1
S1
S2
3000 PSI
1.5:1
P1
3000 PSI
3:1
2500 PSI
3:1
3000 PSI
3:1
2500 PSI
3:1
T3
S1
C1
S2
C2
M1
C3
M2
C4
C6
C5
4
C8
C7
E
G1
.8 GPM
P1
5
A
3200 PSI
F
G
B
0.025 inch
(from serial number
1187 to1891)
L
H
I
J
K
1600 PSI
1400 PSI
0.022 inch
(from serial number
1892 to1969)
1800 PSI
J1
3000 PSI
3:1
J2
PR1
6
PR2
1500 PSI
3:1
CE
C
M
D
N
O
X
0.052 inch
P
Q
R
S
T
U
V
CD
Y
CB
0.028
inch
0.052 inch
P2
W
CA
CF
0.1 GPM
T2
0.025 inch
CC
0.3 GPM
7
CG
(after serial number 1969)
T1
T3
T4
8
Part No. 119987
Z-34/22 IC
5 - 41
June 2007
Section 5 • Schematics
Hydraulic Schematic, 4WD Models
(from serial number 1187 to 1546)
Section 5 • Schematics
June 2007
Hydraulic Schematic, 4WD Models
(from serial number 1547 to 2900)
A
B
C
REV A
D
E
F
G
H
I
J
K
L
M
CHARGE PRESSURE
B
A
50
PSI
1
B
E
A
D
3500 PSI
GENERATOR OPTION
3 gpm
GEN
2
AUXILIARY
PUMP
0.5 GPM
3500 PSI
2000 PSI
T
M
FM
LIFT/STEER
PUMP
3.0 GPM
E
220 PSI
3
T1
S1
DRIVE PUMP
S2
L2
L1
P1
25
PSI
T3
4
HYDRAULIC TANK
CHARGE PRESSURE
A PORT
5
B PORT
T2
M8
M4
B
A
CP
T
T1
P
A
6
AD
0.025
inch
TOP
170 PSI
REAR
LEFT
AC
BOT
B
AA
M2
M5
BRAKE
F
D
AB
FRONT
RIGHT
2 SPD
E
M7
M3
7
0.045
inch
B
BRAKE/2-SPEED MANIFOLD
K
G
67%
REAR
RIGHT
0.052
inch
33%
TOP
C
0.052 inch
A
M1
FRONT
LEFT
BOT
M6
H
I
STEERING
CYLINDER
P
T3
8
5 - 42
J
Z-34/22 IC
Part No. 119987
TRACTION
MANIFOLD
N
June 2007
Section 5 • Schematics
Hydraulic Schematic, 4WD Models
(from serial number 1547 to 2900)
REV A
N
M
L
K
J
I
H
G
F
E
D
C
B
A
PLATFORM LEVEL SLAVE CYLINDER
1
SECONDARY BOOM
PRIMARY BOOM
JIB BOOM
PRIMARY BOOM EXTENSION
0.032 inch
2
TURNTABLE ROTATE
3000 PSI
8:1
PLATFORM ROTATE
5.9 CU. IN.
/REV
MASTER
3
T1
S1
S2
3000 PSI
1.5:1
P1
3000 PSI
3:1
2500 PSI
3:1
3000 PSI
3:1
2500 PSI
3:1
T3
4
S1
C1
S2
C2
M1
C3
M2
C4
C6
C5
C8
C7
E
G1
.8 GPM
P1
5
A
3200 PSI
F
G
H
I
B
0.025 inch
(from serial number
1187 to1891)
L
J
K
1600 PSI
1400 PSI
0.022 inch
(from serial number
1892 to1969)
1800 PSI
6
J1
3000 PSI
3:1
J2
PR1
PR2
1500 PSI
3:1
CE
C
M
D
N
O
X
0.052 inch
P
Q
R
S
T
U
V
CD
Y
CB
0.028
inch
0.052 inch
P2
W
CA
CF
0.1 GPM
T2
0.025 inch
0.3 GPM
CC
7
CG
(after serial number 1969)
T1
T3
T4
8
Part No. 119987
Z-34/22 IC
5 - 43
June 2007
Section 5 • Schematics
Hydraulic Schematic, 4WD Models
(from serial number 1547 to 2900)
Section 5 • Schematics
June 2007
Hydraulic Schematic, 4WD Models
(from serial number 2901 to 3241)
A
B
C
REV A
D
E
F
G
H
I
J
K
L
M
CHARGE PRESSURE
B
A
50
PSI
1
B
E
A
D
3500 PSI
GENERATOR OPTION
3 gpm
GEN
2
AUXILIARY
PUMP
0.5 GPM
3500 PSI
2000 PSI
T
M
FM
LIFT/STEER
PUMP
3.0 GPM
E
220 PSI
3
T1
S1
DRIVE PUMP
S2
L2
L1
P1
25
PSI
T3
4
HYDRAULIC TANK
CHARGE PRESSURE
A PORT
5
B PORT
T2
M8
M4
B
A
CP
T
T1
P
A
6
AD
0.025
inch
TOP
170 PSI
REAR
LEFT
AC
BOT
B
AA
M2
M5
BRAKE
F
D
AB
FRONT
RIGHT
2 SPD
E
M7
M3
7
0.045
inch
B
BRAKE/2-SPEED MANIFOLD
K
G
67%
REAR
RIGHT
0.052
inch
33%
TOP
C
0.052 inch
A
M1
FRONT
LEFT
BOT
M6
H
I
STEERING
CYLINDER
P
T3
8
5 - 44
J
Z-34/22 IC
Part No. 119987
TRACTION
MANIFOLD
N
O
June 2007
Section 5 • Schematics
Hydraulic Schematic, 4WD Models
(from serial number 2901 to 3241)
REV A
O
N
M
L
K
J
I
H
G
F
E
D
C
B
A
PLATFORM LEVELING
SLAVE CYLINDER
1
SECONDARY BOOM CYLINDER
PRIMARY BOOM CYLINDER
EXTENSION CYLINDER
JIB BOOM
0.032 inch
TURNTABLE ROTATE
3000 PSI
4.5:1
PLATFORM ROTATE
2
5.9 CU. IN. /REV
MASTER
CYLINDER
T1
3
S1
3000 PSI
1.5:1
S2
3000 PSI
3:1
2500 PSI
3:1
3000 PSI
1.5:1
2500 PSI
3:1
P1
T3
S1
S2
C1
C2
M1
C3
M2
C4
C5
C6
C8
C7
4
E
G1
1 GPM
P1
A
F
G
H
I
J
3200 PSI
K
5
L
B
1600 PSI
1600 PSI
2800 PSI
(removed
after serial
number 3215)
1500 PSI
3:1
3000 PSI
3:1
J1
C
M
D
N
P
X
0.052 inch
O
0.052 inch
Q
R
S
T
U
PR1
6
PR2
V
CG
Y
CH
P2
W
J2
0.1 GPM
0.028 inch
CI
7
0.3 GPM
CF
T2
T1
0.035 inch
T3
T4
8
Part No. 119987
Z-34/22 IC
5 - 45
June 2007
Section 5 • Schematics
Hydraulic Schematic, 4WD Models
(from serial number 2901 to 3241)
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.
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