Service Manual - Genie liftmanuals.gogenielift.com/Parts And Service Manuals/data...Part No. 43037 Genie Z-34/22 IC Service Manual - First Edition Table of Contents v Introduction

Service Manual Part No. 43037

Rev B

January 2007

(from serial number 100 to 1186)

Genie Z-34/22 IC Part No. 43037

Service Manual - First Edition

ii

Introduction

Genie North AmericaTelephone (206) 881-1800Toll Free 800 536-1800 in U.S.A.Toll Free 800 426-8089 in CanadaFax (206) 883-3475E-mail: [email protected]://www.genielift.com

Genie EuropeTelephone (44) 0636-813943Fax (44) 0636-815270http://www.genielift.com

Important

Read, understand and obey the safety rules andoperating instructions in the appropriateGenie Z-34/22 IC Operator’s Manual beforeattempting any maintenance or repair procedure.

This manual provides detailed scheduledmaintenance information for the machine ownerand user. It also provides troubleshooting andrepair procedures for qualified serviceprofessionals.

Basic mechanical, hydraulic and electricalskills are required to perform most procedures.However, several procedures require specializedskills, tools, lifting equipment and a suitableworkshop. In these instances, we stronglyrecommend that maintenance and repair beperformed at an authorized Genie dealerservice center.

Genie Industries has endeavored to deliver thehighest degree of accuracy possible. However,continuous improvement of our products is a Geniepolicy. Therefore product specificationsare subject to change without notice.

Readers are encouraged to notify Genie of errorsand send in suggestions for improvement. Allcommunications will be carefully considered forfuture printings of this and other manuals. Pleasewrite to the technical publications team in care ofGenie Industries, PO Box 97030, Redmond WA98073-9730 USA.

If you have any questions, please call GenieIndustries.

®

Copyright © 1997 by Genie Industries

43037 Rev B January 2007First Printing, Second Printing

Genie® is a registered trademarkof Genie Industries. Registered 2009987

Printed on recycled paper

Printed in U.S.A.

Part No. 43037 Genie Z-34/22 IC


iii

DangerFailure to obey the instructions and safety rulesin this manual and the appropriateGenie Z-34/22 IC Operator’s Manual will result indeath or serious injury.

Many of the hazards identified in theoperator’s manual are also safety hazardswhen maintenance and repair proceduresare performed.

Do Not Perform MaintenanceUnless:

You are trained and qualified to performmaintenance 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, liftingequipment and a suitable workshop.

Safety Rules



SAFETY RULES

Workplace SafetyBe sure to keep sparks, flames andlighted tobacco away from flammable andcombustible materials like battery gases

and engine fuels. Always have an approved fireextinguisher within easy reach.

Be sure that all tools and working areasare properly maintained and ready foruse. Keep work surfaces clean and free of

debris that could get into machine components andcause damage.

Be sure that your workshop or work areais properly ventilated and well lit.

Be sure any forklift, overhead crane orother lifting or supporting device is fullycapable of supporting and stabilizing the

weight to be lifted. Use only chains or straps thatare in good condition and of ample capacity.

Be sure that fasteners intended for onetime use (i.e., cotter pins and self-lockingnuts) are not reused. These components

may fail if they are used a second time.

Be sure to properly dispose of old oil orother fluids. Use an approved container.Please be environmentally safe .

Personal SafetyAny person working on or around a machine mustbe aware of all known safety hazards. Personalsafety and the continued safe operation of themachine should be your top priority.

Read each procedure thoroughly. Thismanual and the decals on the machine,use signal words to identify the following:

Indicates the presence of a hazardthat will cause death or seriousinjury.

Indicates the presence of a hazardthat may cause death or seriousinjury.

Indicates the presence of a hazardthat will or may cause seriousinjury or damage to the machine.

Indicates special operation ormaintenance information.

Be sure to wear protective eye wear andother protective clothing if the situationwarrants it.

Be aware of potential crushing hazardssuch as moving parts, free swinging orunsecured components when lifting or

placing loads. Always wear approved steel-toedshoes.

iv



Table of Contents

v

Introduction

Important Information ...................................................................................................... ii

Section One Safety Rules

General Safety Rules .................................................................................................... iii

Section Two Specifications

Machine Specifications ............................................................................................. 2 - 1

Performance Specifications ...................................................................................... 2 - 2

Hydraulic Specifications............................................................................................ 2 - 2

Bolt Torque Specifications ........................................................................................ 2 - 4

Kubota WG-750 Engine Specifications ..................................................................... 2 - 5

Kubota D-905 Engine Specifications ........................................................................ 2 - 7

Section Three Scheduled Maintenance Inspections

Introduction ............................................................................................................... 3 - 1

Table A ..................................................................................................................... 3 - 2

Table B ..................................................................................................................... 3 - 3

Table C ..................................................................................................................... 3 - 5

Table D ..................................................................................................................... 3 - 6

Maintenance Inspection Report ................................................................................ 3 - 7

Section Four Scheduled Maintenance Procedures

Introduction ............................................................................................................... 4 - 1

A-1 Inspect the Operator’s and Safety Manuals .................................................... 4 - 2

A-2 Inspect the Decals and Placards ..................................................................... 4 - 2

A-3 Inspect for Damage, Loose or Missing Parts .................................................. 4 - 3

A-4 Check the Engine Oil Level ............................................................................. 4 - 3

A-5 Check the Engine Coolant Level ..................................................................... 4 - 4

A-6 Check for Fuel Leaks ...................................................................................... 4 - 4

A-7 Check the Hydraulic Oil Level ......................................................................... 4 - 5

A-8 Check for Hydraulic Leaks .............................................................................. 4 - 5



TABLE OF CONTENTS

vi

Section Four Scheduled Maintenance Procedures, continued

A-9 Check the Tire Pressure ................................................................................. 4 - 6

A-10 Test the Platform and Ground Controls ........................................................... 4 - 6

A-11 Test the Auxiliary Power Operation ................................................................. 4 - 7

A-12 Test the Tilt Sensor ......................................................................................... 4 - 8

A-13 Test the Limit Switches ................................................................................... 4 - 8

A-14 Perform 30 Day Service ................................................................................ 4 - 10

A-15 Clean the Air Filter Element .......................................................................... 4 - 10

A-16 Drain the Fuel Filter/Water Separator - Kubota Diesel Models ...................... 4 - 11

A-17 Check the Engine Belt .................................................................................. 4 - 12

A-18 Replace the Engine Oil and Filter .................................................................. 4 - 12

B-1 Check the Radiator ....................................................................................... 4 - 14

B-2 Check the Engine Choke - Kubota Gasoline/LPG Models ............................ 4 - 14

B-3 Check the Exhaust System ........................................................................... 4 - 15

B-4 Check the Battery ......................................................................................... 4 - 15

B-5 Inspect the Electrical Wiring .......................................................................... 4 - 16

B-6 Inspect the Tires and Wheels (including lug nut torque) ................................ 4 - 16

B-7 Confirm the Proper Brake Configuration ....................................................... 4 - 17

B-8 Check the Oil Level in the Torque Hubs ........................................................ 4 - 17

B-9 Check the Glow Plugs - Kubota Diesel Models ............................................. 4 - 18

B-10 Check and Adjust the Engine RPM ............................................................... 4 - 18

B-11 Test the Key Switch ...................................................................................... 4 - 20

B-12 Test the Emergency Stop Buttons ................................................................ 4 - 20

B-13 Test the Ground Control Override ................................................................. 4 - 21

B-14 Test the Platform Self-leveling ...................................................................... 4 - 21

B-15 Test the Service Horn ................................................................................... 4 - 22

B-16 Test the Foot Switch ..................................................................................... 4 - 22

B-17 Test the Engine Idle Select ........................................................................... 4 - 23

B-18 Test the Fuel Select - Kubota Gasoline/LPG Models .................................... 4 - 24

B-19 Test the Drive Enable System....................................................................... 4 - 24

B-20 Test the Drive Brakes ................................................................................... 4 - 25

B-21 Test the Drive Speed - Stowed Position ........................................................ 4 - 26



TABLE OF CONTENTS

vii

Section Four Scheduled Maintenance Procedures, continued

B-22 Test the Drive Speed - Raised or Extended Position .................................... 4 - 26

B-23 Test the Alarm Package - Optional Equipment ............................................. 4 - 27

B-24 Perform Hydraulic Oil Analysis ...................................................................... 4 - 28

B-25 Replace the Diesel Fuel Filter/Water Separator Element -Kubota Diesel Models ................................................................................... 4 - 29

C-1 Check the Primary Boom Wear Pads ........................................................... 4 - 30

C-2 Check the Turntable Rotation Bearing Bolts ................................................. 4 - 30

C-3 Check the Free-wheel Configuration ............................................................. 4 - 31

C-4 Grease the Turntable Rotation Bearing and Worm Drive Gear ..................... 4 - 32

C-5 Replace the Torque Hub Oil .......................................................................... 4 - 33

C-6 Replace the Hydraulic Filters ........................................................................ 4 - 33

C-7 Replace the Gasoline Fuel Filter - Kubota Gasoline/LPG Models ................. 4 - 34

C-8 Clean or Replace the Distributor Cap and Rotor -Kubota Gasoline/LPG Models ....................................................................... 4 - 35

C-9 Replace the Spark Plugs - Kubota Gasoline/LPG Models ............................. 4 - 36

C-10 Check and Adjust the Air/LPG Mixture - Kubota Gasoline/LPG Models ........ 4 - 37

C-11 Replace the Engine Air Filter ........................................................................ 4 - 38

C-12 Check and Adjust the Ignition Timing - Kubota Gasoline/LPG Models .......... 4 - 39

C-13 Check and Adjust the Engine Valve Clearance -Kubota Gasoline/LPG Models ....................................................................... 4 - 39

C-14 Bleed the Platform Rotator ............................................................................ 4 - 39

D-1 Test or Replace the Hydraulic Oil .................................................................. 4 - 40

D-2 Change or Recondition the Engine Coolant .................................................. 4 - 41

D-3 Change the Fuel Lines .................................................................................. 4 - 42



TABLE OF CONTENTS

viii

Section Five Troubleshooting Flow Charts

Introduction ............................................................................................................... 5 - 1

1 Engine Will Not Crank Over - Kubota Gasoline/LPG Models .......................... 5 - 3

2 Engine Cranks Over But Will Not Start - Kubota Gasoline/LPG Models .......... 5 - 5

2A Engine Cranks Over But Will Not Start OR Engine Runs While CrankingThen Dies - Kubota Gasoline/LPG Models...................................................... 5 - 7

2B Engine Runs While Cranking Then Dies - Kubota Gasoline/LPG Models ..... 5 - 10

3 Engine Cranks Over But Will Not Start - Kubota Diesel Models .................... 5 - 11

4 Engine Will Not Start On LPG, But Will Start On Gasoline -Kubota Gasoline/LPG Models ....................................................................... 5 - 14

5 Engine Choke Inoperative - Kubota Gasoline/LPG Models ........................... 5 - 16

6 Engine Glow Plugs Inoperative - Kubota Diesel Models ................................ 5 - 19

7 Engine Will Not Start On Gasoline, But Will Start On LPG -Kubota Gasoline/LPG Models ....................................................................... 5 - 21

8 Engine High Idle Inoperative - Kubota Gasoline/LPG Models ....................... 5 - 23

9 Engine Low Idle Inoperative - Kubota Gasoline/LPG Models ........................ 5 - 25

10 Engine High Idle Inoperative - Kubota Diesel Models .................................... 5 - 26

11 Engine Low Idle Inoperative - Kubota Diesel Models .................................... 5 - 28

12 All Functions Inoperative, Engine Starts and Runs ....................................... 5 - 29

13 All Lift and Steer Functions Inoperative, Drive Function Operational ............. 5 - 30

14 Ground Controls Inoperative, Platform Controls Operate Normally ............... 5 - 31

15 Platform Controls Inoperative, Ground Controls Operate Normally ............... 5 - 32

16 Primary Boom Up Function Inoperative ........................................................ 5 - 33

17 Primary Boom Down Function Inoperative .................................................... 5 - 36

18 Secondary Boom Up Function Inoperative .................................................... 5 - 39

19 Secondary Boom Down Function Inoperative ............................................... 5 - 42



TABLE OF CONTENTS

Section Five Troubleshooting Flow Charts, continued

20 Primary Boom Extend Function Inoperative .................................................. 5 - 45

21 Primary Boom Retract Function Inoperative .................................................. 5 - 48

22 Turntable Rotate Left Function Inoperative ................................................... 5 - 51

23 Turntable Rotate Right Function Inoperative ................................................. 5 - 54

24 All Platform Leveling Functions Inoperative .................................................. 5 - 57

25 Platform Level Up Function Inoperative ........................................................ 5 - 58

26 Platform Level Down Function Inoperative .................................................... 5 - 61

27 Platform Rotate Left Function Inoperative ..................................................... 5 - 64

28 Platform Rotate Right Function Inoperative ................................................... 5 - 67

29 Jib Boom Up Function Inoperative ................................................................ 5 - 70

30 Jib Boom Down Function Inoperative ............................................................ 5 - 73

31 Steer Left Function Inoperative ..................................................................... 5 - 76

32 Steer Right Function Inoperative ................................................................... 5 - 77

33 All Drive Functions Inoperative, All Other Functions Operate Normally ......... 5 - 78

34 Drive Forward or Reverse Function Inoperative ............................................ 5 - 81

35 Traction Function Inoperative ........................................................................ 5 - 82

36 Machine Will Not Drive At Full Speed............................................................ 5 - 83

37 Machine Drives At Full Speed With Platform Raised or Extended ................. 5 - 84

38 Drive Enable System Is Malfunctioning ......................................................... 5 - 85

39 Auxiliary Functions Inoperative ..................................................................... 5 - 86

ix



TABLE OF CONTENTS

x

Section Six Schematics

Introduction ............................................................................................................... 6 - 1

Electrical Symbols Legend ....................................................................................... 6 - 2

Hydraulic Symbols Legend ....................................................................................... 6 - 3

Electrical Schematic - Diesel Models(before serial number 869) ....................................................................................... 6 - 5

Electrical Schematic - Diesel Models(from serial number 869 to 1186) .............................................................................. 6 - 7

Electrical Schematic - Gasoline/LPG Models(before serial number 869) ....................................................................................... 6 - 9

Electrical Schematic - Gasoline/LPG Models(from serial number 869 to 1186) ............................................................................ 6 - 11

Ground Control Box Wiring Diagram - Diesel Models(before serial number 869) ..................................................................................... 6 - 13

Ground Control Box Wiring Diagram - Diesel Models(from serial number 869 to 1186) ............................................................................ 6 - 14

Ground Control Box Wiring Diagram - Gasoline/LPG Models(before serial number 869) ..................................................................................... 6 - 15

Ground Control Box Wiring Diagram - Gasoline/LPG Models(from serial number 869 to 1186) ............................................................................ 6 - 16

Platform Control Box Wiring Diagram - Diesel Models ............................................ 6 - 17

Platform Control Box Wiring Diagram - Gasoline/LPG Models ................................ 6 - 18

Hydraulic Schematic, 2WD Models (before serial number 674) .............................. 6 - 19

Hydraulic Schematic, 2WD Models (from serial number 674 to 1029) .................... 6 - 21

Hydraulic Schematic, 2WD Models (from serial number 1030 to 1186) .................. 6 - 23

Hydraulic Schematic, 4WD Models (before serial number 674) .............................. 6 - 25

Hydraulic Schematic, 4WD Models (from serial number 674 to 1029) .................... 6 - 27

Hydraulic Schematic, 4WD Models (from serial number 1030 to 1186) .................. 6 - 29



TABLE OF CONTENTS

xi

Section Seven Repair Procedures

Introduction ............................................................................................................... 7 - 1

Platform Controls

1-1 Horsepower Limiter Board .............................................................................. 7 - 2

1-2 Diodes............................................................................................................. 7 - 4

1-3 Foot Switch ..................................................................................................... 7 - 5

1-4 Toggle Switches .............................................................................................. 7 - 6

Platform Components

2-1 Platform .......................................................................................................... 7 - 7

2-2 Platform Leveling Slave Cylinder .................................................................... 7 - 7

2-3 Platform Rotator .............................................................................................. 7 - 8

Jib Boom Components

3-1 Jib Boom ....................................................................................................... 7 - 10

3-2 Jib Boom Lift Cylinder ................................................................................... 7 - 11

3-3 Jib Boom / Platform Rotate Manifold Components(before serial number 1030) .......................................................................... 7 - 12

3-4 Jib Boom / Platform Rotate Manifold Components(after serial number 1029) ............................................................................. 7 - 13

Primary Boom Components

4-1 Plastic Cable Track ....................................................................................... 7 - 14

4-2 Primary Boom ............................................................................................... 7 - 14

4-3 Primary Boom Lift Cylinder ........................................................................... 7 - 17

4-4 Extension Cylinder ........................................................................................ 7 - 18

4-5 Platform Leveling Master Cylinder ................................................................ 7 - 19

Secondary Boom Components

5-1 Secondary Boom .......................................................................................... 7 - 23

5-2 Secondary Boom Lift Cylinder ....................................................................... 7 - 26



xii

TABLE OF CONTENTS

Section Seven Repair Procedures, continued

Kubota D-905 Engine

6-1 Timing Adjustment ........................................................................................ 7 - 27

6-2 Glow Plugs .................................................................................................... 7 - 27

6-3 Engine RPM .................................................................................................. 7 - 27

6-4 Flex Plate ...................................................................................................... 7 - 27

6-5 Water Temperature and Oil Pressure Gauges .............................................. 7 - 28

Kubota WG-750 Engine

7-1 Choke Adjustments ....................................................................................... 7 - 29

7-2 Timing Adjustment ........................................................................................ 7 - 29

7-3 Carburetor Adjustment .................................................................................. 7 - 29

7-4 RPM Adjustment ........................................................................................... 7 - 29

7-5 Flex Plate ...................................................................................................... 7 - 29

7-6 Water Temperature and Oil Pressure Gauges .............................................. 7 - 30

7-7 Vacuum Switch ............................................................................................. 7 - 31

Ground Controls

8-1 Control Relays .............................................................................................. 7 - 32

8-2 Toggle Switches, See 1-4, Toggle Switches ................................................. 7 - 33

8-3 Wago® Components ...................................................................................... 7 - 33

Hydraulic Pumps

9-1 Auxiliary Pump .............................................................................................. 7 - 34

9-2 Lift/Steer Pump ............................................................................................. 7 - 34

9-3 Drive Hydraulic Pump ................................................................................... 7 - 35

Function Manifolds

10-1 Function Manifold Components ..................................................................... 7 - 38

10-2 Valve Adjustments - Function Manifold ......................................................... 7 - 42



xiii

Section Seven Repair Procedures, continued

Fuel and Hydraulic Tanks

11-1 Fuel Tank ...................................................................................................... 7 - 45

11-2 Hydraulic Tank .............................................................................................. 7 - 45

Turntable Rotation Components

12-1 Rotation Hydraulic Motor ............................................................................... 7 - 46

2WD Steering Axle Components

13-1 Yoke and Hub ............................................................................................... 7 - 47

13-2 Steering Cylinder .......................................................................................... 7 - 48

13-3 Tie Rod ......................................................................................................... 7 - 48

4WD Steering Axle Components

14-1 Yoke and Hub ............................................................................................... 7 - 49

14-2 Steering Cylinder .......................................................................................... 7 - 50

14-3 Tie Rod ......................................................................................................... 7 - 50

Brake and 2 Speed Manifold

15-1 Brake and 2 Speed Manifold Components .................................................... 7 - 51

Non-steering Axle Components

16-1 Drive Motor ................................................................................................... 7 - 52

16-2 Torque Hub ................................................................................................... 7 - 52

2WD Drive Manifold

17-1 2WD Drive Manifold Components ................................................................. 7 - 54

17-2 Valve Adjustments ........................................................................................ 7 - 55

4WD Drive Manifold

18-1 4WD Drive Manifold Components ................................................................. 7 - 56

18-2 Valve Adjustments ........................................................................................ 7 - 58

TABLE OF CONTENTS



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Part No. 43037 Genie Z-34/22 IC 2 - 1

Section 2 - SpecificationsService Manual - First Edition

Specifications

Machine Specifications

Stowed dimensions

Length 18 ft 6 in 5.6 m

Width 5 ft 8 in 1.7 m

Height, maximum 6 ft 7 in 2 m

Machine Weight See Serial Plate(Machine weights vary with option configurations)

Ground clearance2WD models 5.75 in 14.6 cm4WD models 6.5 cm 16.5 cm

Operational dimensions

Height, platform maximum 34 ft 8 in 10.6 m

Height, working maximum 40 ft 8 in 12.4 m

Horizontal reach, maximum 22 ft 4 in 6.8 m

Turntable tailswing 0

Wheelbase 6 ft 2 in 1.9 m

Minimum turning circle, 13 ft. 1 in 4 moutside

Minimum turning circle, 5 ft. 8 in 1.7 minside

Turntable rotation 355° 355°

Platform rotation 180° 180°

Fluid capacities

Fuel tank capacity 12 gallons45.4 liters

Hydraulic tank capacity 18 gallons68.1 liters

Hydraulic system capacity 22 gallons(including tank) 83.3 liters

Torque hubs 17 ounces0.5 liters

Tires and wheels Rough terrain Industrial

Tire size 10-16.5 NHS 9-14.5 LT

Tire ply rating Tread 6Sidewall 6

Tire contact area 77.8 sq in. 43.5 sq in502 cm. 280 sq cm

Overall tire diameter 30.5 in. 28 in77.5 cm. 37 cm

Wheel diameter 16.5 in. 14.5 in42 cm. 45 cm

Wheel width 10 in. 7 in25.4 cm. 18 cm

Wheel lugs - 4WD 9 @ 5/8-18

Wheel lugs - 2WDFront 8 @ 5/8-18 8 @ 5/8-18Rear 9 @ 5/8-18 9 @ 5/8-18

Tire pressure2WD 45 psi 100 psi

3.1 bar 6.89 bar4WD 45 psi

3.1 bar

Lug nut torque 125 ft-lbs 169.5 Nm

Platform dimensions

Length 56 in142 cm

Width 30 in76 cm

Maximum capacity 500 lbs227 kg

Continuous improvement of our products is aGenie policy. Product specifications aresubject to change without notice.

2 - 2 Genie Z-34/22 IC Part No. 43037

Section 2 - Specifications Service Manual - First Edition

Performance Specifications

Drive speeds (maximum) 2WD 4WD

Boom stowed, high range 4.5 mph 4.0 mph7.2 km/h 6.4 km/h

40 ft/6.1 sec 40 ft/6.8 sec12.2 m/6.1 sec 12.2 m/6.8 sec

Boom raised or extended 0.6 mph 0.6 mph1km/h 1km/h

40 ft/40 sec 40 ft/40 sec12.2 m/40 sec 12.2 m/40 sec

Gradeability (stowed) 37 % 45 %

Boom function speeds, maximumfrom platform controls (with 500 lbs in platform)

Jib boom up 24 to 30 seconds

Jib boom down 15 to 21 seconds

Primary boom up 16 to 22 seconds

Primary boom down 28 to 34 seconds

Primary boom extend 24 to 30 seconds

Primary boom retract 14 to 20 seconds

Secondary boom up 16 to 22 seconds

Secondary boom down 29 to 35 seconds

Turntable rotate - 355° 100 to 106 seconds

Platform rotate - 160° 4 to 7 seconds

SPECIFICATIONS

Hydraulic Specifications

Hydraulic fluid Dexron equivalent

Drive pump

Type: bi-directional variabledisplacement piston pump

Displacement 1.71 cu inper revolution 28 cc

Displacement @ 3000rpm 22 gpm(2500 psi/172 bar) 83.3 L/min

Hydraulic tank 25 micron with 5 psisuction line filter ( .34 bar) bypass

Drive manifold

Motor shift/brake relief pressure 210 psi14.5 bar

4WD front motor 7 gpmflow regulators 26.5 L/min

4WD rear motor 14 gpmflow regulators 53 L/min

2WD rear motor 22 gpmflow regulators 83.3 L/min

Front drive motors - 4WD models

Displacement per revolution 1.52 cu in25 cc

Rear drive motors

Displacement per revolution 2.8 cu in46 cc

Function pump

Type: Fixed displacement gear pump

Displacement 0.24 cu inper revolution 4 cc

Hydraulic tank 10 micron with 25 psireturn line filter (1.7 bar) bypass

Part No. 43037 Genie Z-34/22 IC 2 - 3


Function manifold

Function relief 3200 psivalve pressure 220.7 bar

Boom down relief 1400 psiFunction relief 96.6 bar

Secondary boom down relief 1600 psivalve pressure 110.3 bar

Primary boom extend relief 1800 psivalve pressure 124.1 bar

Turntable rotate relief pressure 1750 psi(before serial number 674) 120.7 bar(replaced by counterbalance valvesafter serial number 673)

Auxiliary pump

Type Fixed displacement gear pump

Displacement 0.5 gpm1.9 L/min

Auxiliary pump 3400 psirelief pressure 234.5 bar

SPECIFICATIONS

2 - 4 Genie Z-34/22 IC Part No. 43037


24

32

20

28

18

24

16

24

14

20

Torque - Dry

inch-pounds

Torque - Dry

foot-pounds

Torque - Dry

Newton meters

Torque - Dry

inch-pounds

Torque - Dry

foot-pounds

Torque - Dry

Newton meters

43

49

96

120

17

19

30

35

50

55

75

90

110

120

150

170

260

300

430

470

640

700

5

6

11

14

23

28

41

48

68

75

102

122

149

163

204

231

353

407

583

637

868

949

60

68

144

168

25

25

45

50

70

80

110

120

150

170

220

240

380

420

600

660

900

1000

7

8

16

19

34

34

61

68

95

109

149

163

204

231

298

326

515

570

814

895

1221

1356

Size Threads SAE Grade 5 Bolts SAE Grade 8 Bolts per inch

Bolt Torque Specifications

13

20

12

18

11

18

10

16

9

14

8

12

No. 10

1/4 inch

5/16 inch

3/8 inch

7/16 inch

1/2 inch

9/16 inch

5/8 inch

3/4 inch

7/8 inch

1 inch

Torque specifications for lubricated bolts are 25% less than dry torque specifications for each bolt size.

These bolt torque specifications are for general use only. Specification may vary depending on application of bolt.

SPECIFICATIONS

Part No. 43037 Genie Z-34/22 IC 2 - 5



Displacement 42.21 cu in0.74 liters

Number of cylinders 3

Bore & stroke 2.68 x 2.68 inches68 x 68 mm

HorsepowerGross intermitent 24.5 @ 3600 rpm

Firing order 1 - 2 - 3

Low idle 1600 rpm

High idle 3000 rpm

Governor centrifugal ballmechanical

Compression ratio 9:1

Compression pressure (approx.) 128 to 185 psi8.8 to 12.7 bar

Pressure (psi) of lowest cylinder must be at least 90%of highest cylinder

Valve clearances, cold 0.0057 to 0.0072 inches0.145 to 0.085 mm

Lubrication system

Oil pressure 28 to 64 psi(operating temp. @ 3850 rpm) 1.9 to 4.4 bar

Oil capacity 3.9 quarts(including filter) 3.25 liters

Oil viscosity requirements 10W-30

Use oils meeting API classification SF (labeled SF/CCor SF/CD) for improved wear protection.

Starter motor

Brush length, new 0.669 in17 mm

Brush length wear limit 0.453 in11.5 mm

Brush spring tension 50 to 91 ounces13.7 to 25.5 Newtons

Battery

Type 12V, Group 24

Quantity 1

Ampere hour 75AH

Cold cranking ampere 875A

Reserve capacity @ 25A rate 125 minutes

Fuel pump

Static pressure 2.84 psi0.19 bar

Minimum volume flow 1 pint(per minute) 500 cc

SPECIFICATIONS

2 - 6 Genie Z-34/22 IC Part No. 43037


Ignition System

Ignition spark advance 20° BTDC

Ignition coil primary 1.3 to 1.6Ωresistance @ 75°F / 24°C

Ignition coil secondary 10.7 to 14.5 kΩresistance @ 75°F / 24°C

Spark plug type NGKBCP4ES-11

Spark plug gap 0.039 to 0.043 inches1.0 to 1.1 mm

Engine coolant

Capacity 3.1 quarts2.9 liters

Alternator

Output 30A

Fan belt deflection 1/4 to 3/8 inch7 to 9 mm

Bolt torque specificationstorque torque

Bolt description (size) ft-lbs Nm

Head cover cap nuts (M6) 3 to 4 4 to 6

Head Bolts (M8) 29 to 33 37 to 42

Bearing case bolts 1 (M6) 9 to 12 13 to 16


Flywheel bolts (M10) 40 to 44 54 to 59

Connecting rod bolts (M6) 11 to 14 26 to 30

Rocker arm bracket nuts (M6) 7 to 8 10 to 11

Idle gear shaft nuts (M6) 7 to 8 10 to 11

Spark plug (M14) 14 to 18 20 to 24

Crankshaft bolt (M12) 72 to 79 98 to 108

SPECIFICATIONS

Part No. 43037 Genie Z-34/22 IC 2 - 7


Kubota D-905 Engine

Displacement 54.86 cu in0.90 liters

Number of cylinders 3

Bore and stroke 2.83 x 2.90 inches72 x 73.6 mm

HorsepowerGross intermitent 26 @ 3600 rpm

Firing order 1 - 2 - 3

Compression ratio 22:1

Compression pressure 412 to 469 psi28.4 to 32.3 bar

Low idle 1300 rpm

High idle 3000 rpm

Governor centrifugal mechanical

Valve clearance, cold 0.0057 to 0.0072 in0.145 to 0.185 mm

Engine coolant

Capacity 3.3 quarts3.1 liters

Lubrication system

Oil pressure 36 to 64 psi2.48 to 4.41 bar

Oil capacity 5.4 quarts(including filter) 5.1 liters

Oil viscosity 10W-30requirements

Engine oil should have properties of API classificationCC/SE, CD/SE, CC/SF or CD/SF grades.

Injection system

Injection pump make Bosch MD

Injection timing 13° to 25° BTDC

Injection pump pressure 1991 psi137 bar

Fuel requirement diesel number 2-D

AlternatorOutput 30A

Starter motor

Brush length, new 0.5188 in13 mm

Brush length, minimum 0.3346 in8.5 mm

Battery

Type 12V, Group 24

Quantity 1

Ampere hour 75AH

Cold cranking ampere 875A

Reserve capacity @ 25A rate 125 minutes

Fan belt deflection 1/4 to 3/8 inch7 to 9 mm

Bolt torque specificationstorque torque

Bolt description (size, grade) ft-lbs Nm

Head cover cap nuts (M7) 5 to 6 7 to 9

Head Bolts (M10) 47 to 50 64 to 69



Flywheel bolts (M10) 40 to 44 54 to 59

Connecting rod bolts (M8) 30 to 35 41 to 46

Rocker arm bracket nuts (M7) 16 to 19 22 to 26

Idle gear shaft nuts (M6) 7 to 8 10 to 11

Glow plugs (M10) 14 to 18 20 to 24

Nozzle holder assembly (M20) 36 to 50 49 to 69

Injection pipe 18 to 25 25 to 34retaining nuts (M12)

SPECIFICATIONS

2 - 8 Genie Z-34/22 IC Part No. 43037



Part No. 43037 Genie Z-34/22 IC 3 - 1

Section 3 - Scheduled Maintenance InspectionsService Manual - First Edition

Tools arerequired

New partsrequired

Warmengine

required

Coldengine

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Dealerservice

suggested

Scheduled Maintenance Inspections

Observe and Obey:

Maintenance inspections shall be completed bya person trained and qualified on themaintenance of this machine.

Scheduled maintenance inspections shall becompleted daily, quarterly, annually and every2 years as specified on the MaintenanceInspection Report.

Failure to properly complete eachinspection when required maycause death, serious injury orsubstantial machine damage.

Immediately tag and remove from service adamaged or malfunctioning machine.

Repair any machine damage or malfunctionbefore operating machine.

Keep records on all inspections for three years.

Machines that have been out of service for aperiod longer than 3 months must complete thequarterly inspection.

About This SectionThe Schedule

There are four types of maintenance inspectionsthat must be performed according to a schedule—daily, quarterly, annual and two year. To accountfor repeated procedures, the Maintenance Tablesand the Maintenance Inspection Report have beendivided into four subsections—A, B, C, D. Use thefollowing chart to determine which group(s) ofprocedures are required to perform a scheduledinspection.

Inspection Table or Checklist

Daily A

Quarterly A + B

Annual A + B + C

Two year A + B + C + D

Maintenance Tables

The maintenance tables contained in this sectionprovide summary information on the specificphysical requirements for each inspection.

Complete step-by-step instructions for eachscheduled maintenance procedure are provided insection 4, Scheduled Maintenance Procedures.

Maintenance Inspection Report

The maintenance inspection report containschecklists for each type of scheduled inspection.

Make copies of the Maintenance InspectionReport to use for each inspection. Storecompleted forms for three years.

3 - 2 Genie Z-34/22 IC Part No. 43037

Section 3 - Scheduled Maintenance Inspections Service Manual - First Edition

Tools arerequired

New partsrequired

Warmengine

required

Coldengine

required

Dealerservice

suggested

Table A

A-1 Inspect the Operator's and Safety Manuals

A-2 Inspect the Decals and Placards

A-3 Inspect for Damage, Loose or Missing Parts

A-4 Check the Engine Oil Level

A-5 Check the Engine Coolant Level

A-6 Check for Fuel Leaks

A-7 Check the Hydraulic Oil Level

A-8 Check for Hydraulic Leaks

A-9 Check the Tire Pressure

A-10 Test the Platform and Ground Controls

A-11 Test the Auxiliary Power Operation

A-12 Test the Tilt Sensor

A-13 Test the Limit Switches

A-14 Perform 30 Day Service

Every 50 hours, perform the following enginemaintenance procedure.

A-15 Clean the Air Filter Element

Maintenance Tables

Part No. 43037 Genie Z-34/22 IC 3 - 3


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Table A, continued

Every 100 hours, perform the following two enginemaintenance procedures.

A-16 Drain the Fuel Filter/Water Separator - Kubota Diesel Models

A-17 Check the Engine Belt


A-18 Replace the Engine Oil and Filter

Table B

B-1 Check the Radiator

B-2 Check the Engine Choke- Kubota Gasoline/LPG Models

B-3 Check the Exhaust System

B-4 Check the Battery

B-5 Inspect the Electrical Wiring

B-6 Inspect the Tires and Wheels(including lug nut torque)

B-7 Confirm the Proper Brake Configuration

B-8 Check the Oil Level in the Torque Hubs

B-9 Check the Glow Plugs- Kubota Diesel Models

B-10 Check and adjust the Engine RPM

MAINTENANCE TABLES

3 - 4 Genie Z-34/22 IC Part No. 43037


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Table B, continued

B-11 Test the Key Switch

B-12 Test the Emergency Stop Buttons

B-13 Test the Ground Control Override

B-14 Test the Platform Self-leveling

B-15 Test the Service Horn

B-16 Test the Foot Switch

B-17 Test the Engine Idle Select

B-18 Test the Fuel Select Operation- Kubota Gasoline/LPG Models

B-19 Test the Drive Enable System

B-20 Test the Drive Brakes

B-21 Test the Drive Speed - Stowed Position

B-22 Test the Drive Speed - Raised or ExtendedPosition

B-23 Test the Alarm Package - Optional Equipment

B-24 Perform Hydraulic Oil AnalysisSee D-1 Test or Replace the Hydraulic Oil


B-25 Replace the Diesel Fuel Filter/WaterSeparator Element - Kubota Diesel Models

MAINTENANCE TABLES

Part No. 43037 Genie Z-34/22 IC 3 - 5


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Table C

C-1 Check the Primary Boom Wear Pads

C-2 Check the Turntable Rotation Bearing Bolts

C-3 Check the Free-wheel Configuration

C-4 Grease the Turntable Rotation Bearingand Worm Drive Gear

C-5 Replace the Torque Hub Oil

C-6 Replace the Hydraulic Filters

C-7 Replace the Gasoline Fuel Filter- Kubota Gasoline/LPG Models

C-8 Clean or Replace the Distributor Capand Rotor - Kubota Gasoline/LPG Models

C-9 Replace the Spark Plugs- Kubota Gasoline/LPG Models

C-10 Check and Adjust the Air/LPG Mixture- Kubota Gasoline/LPG Models

C-11 Replace the Engine Air Filter

C-12 Check and Adjust the Ignition Timing- Kubota Gasoline/LPG Models

C-13 Check the Engine Valve Clearances- Kubota Gasoline/LPG Models

C-14 Bleed the Platform Rotator

MAINTENANCE TABLES

3 - 6 Genie Z-34/22 IC Part No. 43037


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required

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Table D

D-1 Test or Replace the Hydraulic Oil

D-2 Change or Recondition the Engine Coolant

D-3 Change the Fuel Lines

MAINTENANCE TABLES

Part No. 43037 Genie Z-34/22 IC 3 - 7


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required

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required

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suggested

Checklist A Y N R

Refer to Table A

A-1 Operator's andSafety manuals

A-2 Decals and placards

A-3 Damage, loose ormissing parts

A-4 Check engine oil level

A-5 Check engine coolant

A-6 Check for fuel leaks

A-7 Hydraulic oil level

A-8 Hydraulic leaks

A-9 Check the tire pressure

A-10 Platform andground controls

A-11 Auxiliary power

A-12 Tilt sensor

A-13 Limit switches

A-14 30 Day Service

Perform every 50 hours:

A-15 Clean the air filter


A-16 Drain the fuel filter/water separator -Diesel models

A-17 Check the engine belt


A-18 Engine oil and filter

Checklist B Y N R

Refer to Table B

B-1 Check the radiator

B-2 Check the enginechoke - gas/LPGB-3 Check the exhaust

B-4 Check the battery

B-5 Electrical wiring

B-6 Tires and wheels

B-7 Brake configuration

B-8 Torque hub oil level

B-9 Glow plugs - diesel

B-10 Check engine RPM

B-11 Key Switch

B-12 Emergency Stop

B-13 Ground controloverride

B-14 Platform leveling

B-15 Service horn

B-16 Foot switch

B-17 Engine idle select

B-18 Fuel select - gas/LPG

B-19 Drive enable system

B-20 Drive brakes

B-21 Drive speed-stowed

B-22 Drive speed-raised

B-23 Alarm package

B-24 Hydraulic oil analysis


B-25 Replace diesel fuel filter

Checklist C Y N R

Refer to Table C

C-1 Boom wear pads

C-2 Turntable bearing bolts

C-3 Free-wheel configuration

C-4 Grease rotation bearing

C-5 Torque hub oil

C-6 Hydraulic filters

C-7 Gasoline fuel filter

C-8 Distributor cap -gas/LPG

C-9 Spark plugs - gas/LPG

C-10 Air/LPG mixture -gas/LPG

C-11 Air filter

C-12 Ignition timing -gas/LPG

C-13 Valve clearance -gas/LPG

C-14 Platform rotator

Checklist D Y N R

Refer to Table D

D-1 Hydraulic oil

D-2 Engine coolant

D-3 Fuel lines

Instructions· Make copies of this page to use for

each inspection.

· Select the appropriate checklist(s)for the type of inspection to beperformed.

Daily Inspection: A

Quarterly Inspection: A+B

Annual Inspection: A+B+C

2 Year Inspection: A+B+C+D

· Place a check in the appropriate boxafter each inspection procedure iscompleted.

· Use the maintenance tables in thissection and the step-by-stepprocedures in section 4 to learn howto perform these inspections.

· If any inspection receives an “N”, tagand remove the machine fromservice, repair and re-inspect it. Afterrepair, place a check in the “R” box.

LegendY = yes, acceptableN = no, remove from service

R = repaired

Comments

Maintenance Inspection Report

Model

Serial number

Date

Hour meter

Machine owner

Inspected by (print)

Inspector signature

Inspector title

Inspector company

3 - 8 Genie Z-34/22 IC Part No. 43037


Tools arerequired

New partsrequired

Warmengine

required

Coldengine

required

Dealerservice

suggested

Part No. 43037 Genie Z-34/22 IC 4 - 1

Service Manual - First Edition Section 4 - Scheduled Maintenance Procedures

About This Section

This section contains detailed procedures for eachscheduled maintenance inspection.

Each procedure includes a description, safetywarnings and step-by-step instructions.

Symbols Legend





Indicates that a specific result is expected afterperforming a series of steps.

Scheduled Maintenance Procedures

Observe and Obey:

Maintenance inspections shall be completed bya person trained and qualified on themaintenance of this machine.

Scheduled maintenance inspections shall becompleted daily, quarterly, annually and every 2years as specified on the MaintenanceInspection Report.

Failure to properly complete eachinspection when required maycause death, serious injury orsubstantial machine damage.


Repair any machine damage or malfunctionbefore operating machine.

Keep records on all inspections for three years.

Unless otherwise specified, perform eachprocedure with the machine in the followingconfiguration:

· Machine parked on a firm, level surface

· Boom in the stowed position

· Turntable rotated with the boom between thenon-steer wheels

· Key switch in the OFF position with the keyremoved

· Wheels chocked

· All exernal AC power disconnected from themachine

4 - 2 Genie Z-34/22 IC Part No. 43037

Service Manual - First EditionSection 4 - Scheduled Maintenance Procedures

A-1Inspect the Operator’s andSafety ManualsMaintaining the operator’s and safety manuals ingood condition is essential to safe machineoperation. Manuals are included with eachmachine and should be stored in the containerprovided in the platform. An illegible or missingmanual will not provide safety and operationalinformation necessary for a safe operatingcondition.

1 Check to be sure the storage container ispresent and in good condition.

2 Check to make sure that the operator’s,responsibilities and safety manuals are presentand complete in the storage container in theplatform.

3 Examine the pages of each manual to be surethat they are legible and in good condition.

4 Always return the manuals to the storagecontainer after use.

Contact your authorized Geniedistributor or Genie Industries ifreplacement manuals are needed.

A-2Inspect theDecals and PlacardsMaintaining all of the safety and instructionaldecals and placards in good condition ismandatory for safe machine operation. Decalsalert operators and personnel to the many possiblehazards associated with using this machine. Theyalso provide users with operation and maintenanceinformation. An illegible decal will fail to alertpersonnel of a procedure or hazard and couldresult in unsafe operating conditions.

1 Refer to the Decals section in the appropriateGenie Z-34/22 IC Operator's Manual and usethe decal list and illustrations to determine thatall decals and placards are in place.

2 Inspect all decals for legibility and damage.Replace any damaged or illegible decalimmediately.

Contact your authorized Geniedistributor or Genie Industries ifreplacement decals are needed.

Table A Procedures

Part No. 43037 Genie Z-34/22 IC 4 - 3


A-3Inspect for Damage, Loose orMissing PartsDaily machine condition inspections are essentialto safe machine operation and good machineperformance. Failure to locate and repair damage,and discover loose or missing parts may result inan unsafe operating condition.

1 Inspect the entire machine for damage andimproperly installed or missing parts including:

· Electrical components, wiring and electricalcables

· Auxiliary power unit, hoses, fittings,cylinders and manifolds

· Fuel and hydraulic tanks

· Drive motors

· Turntable motors and torque hubs

· Boom components and wear pads

· Dents or damage to machine

· Tires and wheels

· Engine and related components

· Limit switches

· Alarms, service horn and beacon

· Nuts, bolts and other fasteners

· Platform entry mid-rail or gate

· Cracks in welds or structural components

· Compartment covers and latches

A-4Check the Engine Oil LevelMaintaining the proper engine oil level is essentialto good engine performance and service life.Operating the machine with an improper oil levelcan damage engine components.

Check the oil level with theengine off.

1 Check the oil level dipstick.

Result: The oil should be at the full mark on thedipstick. Add oil as needed.

Kubota Engine WG-750 3.9 quartsOil capacity (including filter) 3.25 liters


Extreme operating temperatures may require the use ofalternative engine oils. For oil requirements, refer to theEngine Operator's Manual on your machine.Units ship with 10W-40.

Kubota Engine D-905 5.4 quartsOil capacity (including filter) 5.1 liters


Extreme operating temperatures may require the use ofalternative engine oils. For oil requirements, refer to theEngine Operator's Manual on your machine.Units ship with 10W-40.

TABLE A PROCEDURES

4 - 4 Genie Z-34/22 IC Part No. 43037


A-5Check the Engine Coolant LevelMaintaining the engine coolant at the proper levelis essential to engine service life. Improper coolantlevel will affect the engine’s cooling capability anddamage engine components. Daily checks willallow the inspector to identify changes in coolantlevel that might indicate cooling system problems.

1 Check the fluid level in the coolant recoverytank. Add fluid as needed.

Result: The fluid level should be in theNORMAL range.

A-6Check for Fuel LeaksFailure to detect and repair fuel leaks will result inan unsafe condition. An explosion or fuel fire maycause death or serious injury.

Explosion and fire hazard. Enginefuels are combustible. Inspect themachine in an open, well-ventilated area away from heaters,sparks, flames and lightedtobacco. Always have anapproved fire extinguisher withineasy reach.

1 Open the shutoff valve on the liquid petroleumgas (LPG) tank by turning it counterclockwise.

2 Perform a visual inspection around the areaslisted below. An LPG detector may benecessary to locate LPG leaks.

Kubota Gas models:

· LPG tank, hoses and fittings, solenoid shutoffvalve, LPG regulator and carburetor

· gasoline tank, shutoff valve, solenoid shutoffvalve, hoses and fittings, fuel pump andcarburetor

Kubota Diesel models:

· fuel tank, shutoff valve, hoses and fittings,fuel pump, fuel filter/water separator, fuelinjection pump and fuel injectors

Explosion and fire hazard. If a fuelleak is discovered, keep anyadditional personnel from enteringthe area and do not operate themachine. Repair the leakimmediately.

TABLE A PROCEDURES

Part No. 43037 Genie Z-34/22 IC 4 - 5


A-7Check the Hydraulic Oil LevelMaintaining the hydraulic oil at the proper level isessential to machine operation. Improper hydraulicoil levels can damage hydraulic components. Dailychecks allow the inspector to identify changes in oillevel that might indicate the presence of hydraulicsystem problems.

1 Be sure that the boom is in the stowed position,then visually inspect the sight gauge located onthe side of the hydraulic tank.

Result: The hydraulic oil level should be withinthe top 2 inches (5 cm) of the sight gauge

Hydraulic Oil Specifications

Hydraulic oil type Dexron equivalent


Hydraulic system, 2WD Models 21 gallons(including tank) 79.5 liters


A-8Check for Hydraulic LeaksDetecting hydraulic fluid leaks is essential tooperational safety and good machine performance.Undiscovered leaks can develop into hazardoussituations, impair machine functions and damagemachine components.

1 Inspect for hydraulic oil puddles, dripping orresidue on or around the following areas:

· Hydraulic reservoir—filter, fittings, hoses andturntable surface

· Engine compartment—hydraulic power unit,pumps, suction filter, fittings, hoses, andturntable surface

· All hydraulic cylinders

· All hydraulic manifolds

· Primary, secondary and jib booms

· The underside of the turntable

· The underside of the drive chassis

· Ground area under the machine

TABLE A PROCEDURES

4 - 6 Genie Z-34/22 IC Part No. 43037


A-9Check the Tire Pressure

Bodily injury hazard. An over-inflated tire can explode and maycause death or serious injury.

This procedure does not needto be performed on machinesequipped with the foam-filledtire option.

To safeguard maximum stability, achieveoptimum machine handling and minimize tirewear, it is essential to maintain proper pressurein all air-filled tires.

1 Check each tire with an air pressure gauge andadd air as needed.

Tire Specifications 2WD Models 4WD Models

Industrial tire 9-14.5 LT100 psi / 6.89 bar

Rough terrain tire 10-16.5 NHS 10-16.5 NHS45 psi / 3.1 bar 45 psi / 3.1 bar

A-10Test the Platform andGround ControlsTesting the machine functions and the EmergencyStop buttons for malfunctions is essential for safemachine operation. An unsafe working conditionexists if any function fails to operate properly oreither Emergency Stop button fails to stop all themachine functions. Each function should operatesmoothly and be free of hesitation, jerking andunusual noise.

1 Start the engine from the ground controls.

2 Do not hold the function enable switch to eitherside. Attempt to activate each boom andplatform function toggle switch.

Result: All boom and platform functions shouldnot operate.

3 Hold the function enable switch to either sideand activate each boom and platform functiontoggle switch.

Result: All boom and platform functions shouldoperate through a full cycle. Descent alarm (ifequipped) should sound while boom islowering.

Machines equipped with PlatformLevel Control Disable Function:The platform level toggle switchwill not operate when the boom israised past the drive speed limitswitch.

TABLE A PROCEDURES

Part No. 43037 Genie Z-34/22 IC 4 - 7


TABLE A PROCEDURES

4 Push in the Emergency Stop button to the OFF

position.

Result: No function should operate, themachine should stop.

5 Turn the key switch to platform control and pullout the Emergency Stop button to the ON

position at both the ground and platformcontrols.

6 Start the engine from the platform controls.

7 Operate each machine function through a fullcycle.

Result: All machine functions should operatesmoothly.


position.


Kubota Diesel models:All functions should stopimmediately. The engine will shutoff after 2 to 3 seconds.

As a safety feature, selectingand operating the groundcontrols will override theplatform controls, includingthe Emergency Stop button.

A-11Test the Auxiliary PowerOperation

Detection of auxiliary power system malfunctions isessential for safe machine operation. An unsafeworking condition exists if the auxiliary poweredfunctions do not operate in the event of a mainpower loss. Auxiliary power is designed for shortterm emergency use only. Excessive use will resultin battery drain and component damage.

1 Turn the key switch to ground control and pullout the Emergency Stop button to the ON

position.

2 Simultaneously hold theauxiliary power switch ON

while activating each functionthrough a partial cycle.

Result: Each function shouldoperate smoothly.

3 Turn the key switch to platform control.

4 At the platform controls, pull out the EmergencyStop button to the ON position, then press downthe foot switch.

5 Simultaneously holdthe auxiliary powerswitch on whileactivating eachfunction through apartial cycle.

Result: Each function should operate smoothly.

4 - 8 Genie Z-34/22 IC Part No. 43037


TABLE A PROCEDURES

A-12Test the Tilt SensorThe tilt sensor sounds an alarm in the platformwhen the incline of the drive chassis exceeds4.5 degrees.

Select a level test area. The tiltalarm should not be sounding priorto the test.

1 Turn the key switch to platform control. Thenpull out the Emergency Stop button to the ON


2 Open the engine side cover and press downon one side of the tilt sensor.

Result: After a 1.5 second delay, the alarm inthe platform should sound.

A-13Test the Limit SwitchesDetecting limit switch malfunctions is essential tosafe machine operation. The drive limit switchesare used to restrict drive speed when the boom israised. The drive enable limit switch activates asignal light to inform the operator that the platformis over the steering wheels, and stops drivemovement unless the drive enable override switchis used. Improperly functioning limit switches willallow the boom to raise and/or drive into an unsafeposition.

Drive Limit Switch

1 With the engine off and the boom in the stowedposition, visually inspect the drive limit switchesfor the following:

· Broken or missing rollers or arms

· Missing fasteners

· Loose wiring

2 Manually activate the primary boom drive limitswitch.

a primary boom drive limit switchb boom extend drive limit switchc secondary boom drive limit switch

Result: The drive limit switch arm should movefreely and spring return to center. A distinctclick should be felt and heard.

b

c

a

Part No. 43037 Genie Z-34/22 IC 4 - 9


3 Manually activate the boom extend limit switch.



5 Raise the secondary boom 5 feet (1.5 m).

6 Manually activate the secondary boom limitswitch.


7 Lower the boom to the stowed position.

8 Turn the key switch to the platform controls.

9 Slowly move the drive control handle off center.

Result: The machine should move at normaldrive speeds.

10 Raise the primary boom 5 feet (1.5 m).


Result: The machine should move at a reduceddrive speed.


13 Raise the secondary boom 5 feet (1.5 m).




16 Extend the primary boom 3 feet (0.9 m).



Drive speed, maximum, raised

40 feet/40 seconds 12.2 m/40 seconds

Drive Enable Limit Switch

1 With the engine off and the boom in the stowedposition, visually inspect the drive enable limitswitch for the following:

· Broken or missing rollers or arms

· Missing fasteners

· Loose wiring

2 Manually activate the drive enable limit switch.

a turntable rotation bearingb drive enable limit switchc drive chassis

Result: The drive enable limit switch rollershould move freely and spring return to center.A distinct click should be felt and heard.


4 Rotate the turntable to the left until the primaryboom is past the left non-steer wheel.

Result: The drive enable indicator light shouldbe ON. Drive function should not operate untilthe drive enable switch is activated.

5 Rotate the turntable to the right until the primaryboom is past the right non-steer wheel.

Result: The drive enable indicator light shouldbe ON. Drive function should not operate untilthe drive enable switch is activated.

TABLE A PROCEDURES

b

c

a

4 - 10 Genie Z-34/22 IC Part No. 43037


A-15Clean the Air Filter Element

Kubota engine specificationsrequire that this procedure beperformed every 50 hours.Perform this procedure more oftenif dusty conditions exist.

Maintaining the engine air filter in good condition isessential to good engine performance and servicelife. Failure to perform this procedure can lead topoor engine performance and component damage.

Perform this procedure with theengine off.

1 Diesel models: Remove the retaining fastenerfrom the air cleaner element end cap. Removethe end cap.

Gasoline/LPG models: Release the latchesfrom the air cleaner canister end cap. Removethe end cap.

2 Remove the filter element.

3 Clean the inside of the canister and the end capwith a damp cloth.

4 Inspect the air filter element. If needed, blowfrom the inside out using low pressure drycompressed air, or carefully tap out dust.Replace the filter if needed.

5 Install the filter element.

6 Diesel models: Install the air cleaner elementend cap retaining fastener.

Gasoline/LPG models: Install the air cleanerend cap and secure the latches.

A-14Perform 30 Day ServiceThe 30 day maintenance procedure is a onetimesequence of procedures to be performed after thefirst 30 days or 50 hours of usage. After thisinterval, refer to the maintenance tables forcontinued scheduled maintenance.

1 Perform the following maintenance procedures:· A-18 Replace the Engine Oil and Filter· B-6 Inspect Tires and Wheels· C-2 Check the Turnable Rotation Bearing

Bolts· C-6 Replace the Hydraulic Filters

TABLE A PROCEDURES

Part No. 43037 Genie Z-34/22 IC 4 - 11


A-16Drain the Fuel Filter/ WaterSeparator - Kubota Diesel Models

Engine specifications require thatthis procedure be performed every100 hours. Poor fuel quality orvery wet conditions maynecessitate performing thisprocedure more often.

Proper maintenance of the fuel filter/waterseparator is essential for good engineperformance. Failure to perform this procedure canlead to poor engine performance and componentdamage.

Explosion and fire hazard. Enginefuels are combustible. Perform thisprocedure in an open, well-ventilated area away from heaters,sparks, flames and lightedtobacco. Always have anapproved fire extinguisher withineasy reach.


1 Loosen the vent plug located on the fuel filter/water separator head.

Fuel filter/water separatora head boltb filter bowlc drain plugd vent pluge separator head

2 Loosen the drain plug located at the bottom ofthe bowl. Allow the water to drain into a suitablecontainer until fuel starts to come out.Immediately tighten the drain plug.

3 Tighten the vent plug and clean up any spills orwet surfaces.

If the fuel bowl is completelydrained, you must prime the fuelfilter/water separator beforestarting the engine. Refer to B-25in this section, Replace The DieselFuel Filter/Water Separator, forinstructions on how to prime thefuel filter/water separator.

4 Start the engine from the ground controls andcheck the fuel filter/water separator for leaks.

TABLE A PROCEDURES

a

e

d

b

c

4 - 12 Genie Z-34/22 IC Part No. 43037


TABLE A PROCEDURES

A-17Check the Engine Belt

Kubota engine specificationsrequire that this procedure beperformed every 100 hours.

Maintaining the engine belt is essential to goodengine performance and service life. The machinewill not operate properly with a loose or defectivebelt and continued use may cause componentdamage.

Bodily injury hazard. Do notinspect while the engine isrunning. Remove the key tosecure from operation.

Bodily injury hazard. Beware ofhot engine components. Contactwith hot engine components maycause severe burns.

1 Inspect the engine belt for:

· Cracking

· Glazing

· Separation

· Breaks

2 Check the engine belt for proper tension.

Belt deflection 1/4 to 3/8 inch7 to 9 mm

A-18Replace the Engine Oil andFilter

Kubota engine specificationsrequire that this procedure beperformed every 200 hours.Perform this procedure more oftenif dusty conditions exist or themachine is subjected to extendedlow idle operation.

Periodic replacement of the engine oil and filteris essential to good engine performance. Operatingthe machine with an improper oil level orneglecting periodic oil and filter changes candamage engine components. A daily check ofelapsed machine hours against the hours notedon the oil filter will allow the inspector to anticipateand perform oil and filter changes at the 200 hourinterval.

Bodily injury hazard. Beware ofhot engine parts and oil. Contactwith hot engine oil and/or engineparts may cause severe burns.

Perform this procedure afterwarming the engine to normaloperating temperature.

1 Remove the oil filler cap located on thevalve cover.

2 Pull the end of the oil drain hose out fromunder the engine.

3 Open the drain valve on the oil pan and allow allof the oil from the engine to drain into a suitablecontainer. Dispose of the oil properly.

4 Close the drain valve.

Part No. 43037 Genie Z-34/22 IC 4 - 13


TABLE A PROCEDURES

5 Pull up on the pull pin on the engine pivot platelocated under the pump. Swing the engine pivotplate away from the machine to access the oilfilter.

6 Clean the area around the oil filter, then use anoil filter wrench and remove the filter.

7 Apply a thin layer of oil to the new oil filtergasket. Then install the filter and tighten itsecurely by hand.

8 Use a permanent ink marker to write the dateand number of hours from the hour meter onthe oil filter.

9 Fill the engine with new oil per specificationsand install the filler cap.

10 Start the engine from the ground controls.Allow the engine to run for 30 seconds, thenturn the engine off.

11 Check the oil filter and the oil drain valvefor leaks.

12 Swing the engine pivot plate back to its originalposition and make sure the pull pin locks intothe hole.

13 Check the engine oil level dipstick. Add oilif needed.

Kubota Engine WG-750 3.9 quartsOil capacity (including filter) 3.25 liters


Use oils meeting API classification SF (labeled SF/CCor SF/CD) for improved wear protection.Units ship with 10W-40 SG/CC

Oil filter - Genie Part Number 22106

Kubota Engine D-905 5.4 quartsOil capacity (including filter) 5.1 liters


Engine oil should have properties of API classificationCC/SE, CD/SE, CC/SF or CD/SF grades. Units ship with10W-40 SG/CC

Oil filter - Genie Part Number 31744

4 - 14 Genie Z-34/22 IC Part No. 43037


a b

d c b

B-1Check the RadiatorMaintaining the radiator in good condition isessential for good engine performance. Operatinga machine with a damaged or leaking radiator mayresult in engine damage. Also, restricting air flowthrough the radiator (i.e., dirt or debris) will affectthe performance of the cooling system. A frequentcheck allows the inspector to identify changes inthe condition of the radiator that might indicatecooling system problems.



1 Inspect the radiator for leaks and physicaldamage.

2 Clean the radiator fins of debris and foreignmaterials.

B-2Check the Engine Choke -Kubota Gasoline/LPG ModelsA properly functioning choke is essential to goodengine performance. An improperly functioningchoke will result in difficulty with engine starting.

The manual choke is solenoidoperated and is only operational inthe gasoline mode. This choke willnot operate in propane mode.

1 Check the choke linkage connections.

a carburetorb linkagec linkage lock nutsd choke solenoid

2 Turn the key switch to ground control and thenpull out the ground control Emergency Stopbutton to the ON position.

3 While operating the choke switch, inspect thechoke solenoid.

Result: The choke solenoid should be fullyretracted when the choke switch is activated.


5 Pull out the platform control Emergency Stopbutton to the ON position and then operate thechoke switch and listen for choke solenoidoperation.

Table B Procedures

Part No. 43037 Genie Z-34/22 IC 4 - 15


TABLE B PROCEDURES

B-3Check the Exhaust SystemMaintaining the exhaust system is essential togood engine performance and service life. Runningthe engine with a damaged or leaking exhaustsystem can cause component damage and unsafeoperating conditions.



1 Pull up on the pull pin on the engine pivot platelocated under the pump. Swing the engine pivotplate away from the machine to access theexhaust system.

2 Be sure that all nuts and bolts are tight.

3 Inspect all welds for cracks.

4 Inspect for exhaust leaks; i.e., carbon builduparound seams and joints.

B-4Check the BatteryProper battery condition is essential to goodmachine performance and operational safety.Improper fluid levels or damaged cables andconnections can result in engine componentdamage and hazardous conditions.

Bodily injury hazard. Batteriescontain acid. Avoid spilling orcontacting battery acid. Neutralizebattery acid spills with baking sodaand water.

1 Put on protective clothing and eye wear.

2 Be sure that the battery cable connections arefree of corrosion.

3 Be sure that the battery hold downs and cableconnections are tight.

4 Remove the battery vent caps and check thespecific gravity of each battery cell with ahydrometer.

5 Check the battery acid level of the battery. Ifneeded, replenish with distilled water to thebottom of the battery fill tube. Do not overfill.

6 Install the battery vent caps.

4 - 16 Genie Z-34/22 IC Part No. 43037


B-5Inspect the Electrical WiringMaintaining electrical wiring in good condition isessential to safe operation and good machineperformance. Failure to find and replace burnt,chafed, corroded or pinched wires could result inunsafe operating conditions and may causecomponent damage.

Electrocution hazard. Contactwith hot or live circuits maycause death or serious injury.Remove all rings, watches andother jewelry.

1 Inspect the following areas for burnt, chafed,corroded and loose wires:

· Engine compartment electrical panel

· Engine wiring harness

· Inside of the ground control box

· Turntable manifold wiring


3 Raise the secondary boom until the lowermid-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 turnthe engine off.

6 Inspect the following areas for burnt, chafed,corroded, pinched and loose wires:

· Cable track on the primary, jib andsecondary booms

· Jib boom to platform cable harness

· Inside of the platform control box

B-6Inspect the Tires and Wheels(including lug nut torque)Maintaining the tires and wheels in goodcondition is essential to safe operation and goodperformance. Tire and/or wheel failure could resultin a machine tip-over. Component damage mayalso result if problems are not discovered andrepaired in a timely fashion.

1 Check the tire surface and sidewalls for cuts,cracks, punctures and unusual wear.

2 Check each wheel for damage, bends andcracked welds.

3 Check each lug nut for proper torque.

Tire Specifications 2WD Models 4WD Models

Industrial tire 9-14.5 LT100 psi / 6.89 bar

Rough terrain tire 10-16.5 NHS 10-16.5 NHS45psi / 3.1 bar 45 psi / 3.1 bar

Lug nut torque Lubricated Dry94 ft-lbs 125 ft-lbs127 Nm 169 Nm

TABLE B PROCEDURES

Part No. 43037 Genie Z-34/22 IC 4 - 17


TABLE B PROCEDURES

B-8Check the Oil Levelin the Torque HubsFailure to maintain proper torque hub oil levelsmay cause the machine to perform poorly andcontinued use may cause component damage.

1 Drive the machine to rotate the hub until theplugs are located one on top and the other at90 degrees.

2 Remove the plug located at 90 degrees andcheck the oil level.

Result: The oil level should be even with thebottom of the plug hole.

3 If necessary, remove the top plug and add oiluntil the oil level is even with the bottom of theside plug hole.

4 Apply pipe thread sealant to the plugs, theninstall the plugs into the hub.

5 Repeat this procedure for each torque hub.

Drive Torque Hub Oil

Capacity 17 fl oz0.5 L

Type: SAE 90 multipurpose hypoid gear oil -API service classification GL5

B-7Confirm the ProperBrake ConfigurationProper brake configuration is essential to safeoperation and good machine performance.Hydraulically-released, spring-applied individualwheel brakes can appear to operate normally whenthey are actually not fully operational.

1 Check each torque hub disconnect cap to besure it is in the engaged position.

brake disengage position

brake engage position

4 - 18 Genie Z-34/22 IC Part No. 43037


a b c d e

B-9Check the Glow Plugs -Kubota Diesel ModelsMaintaining the glow plugs in good condition isessential to good engine performance and servicelife. Improperly functioning glow plugs will causethe engine to perform poorly and may result incomponent damage.

Perform this procedure with theengine turned off.

1 Connect the leads from an ohmmeter betweenthe far left glow plug and machine ground.

Result: The resistance should be approximately1.0Ω.

2 If the ohm reading is different than 1.0Ω,remove the wire and connector plate from thethree individual glow plugs. Then, one glowplug at a time, check the resistance betweenthe glow plug and machine ground.

Result: The resistance should be approximately1.8Ω for each individual glow plug.


position.

4 Connect the red (+) lead from a volt meterto the number three glow plug. Connect theblack (-) lead to ground.

5 Hold the glow plug switch in the ON position.

Result: The volt meter should read 12 volts.

TABLE B PROCEDURES

B-10Check and Adjust the EngineRPMMaintaining the engine rpm at the proper setting forboth low and high idle is essential to good engineperformance and service life. The machine will notoperate properly if the rpm is incorrect andcontinued use may cause component damage.

Kubota Gasoline/LPG Models

Perform this procedure in gasolinemode with the engine at normaloperating temperature.

1 Connect an rpm gauge to the engine, then startthe engine from the ground controls.

Result: Low idle should be 1600 rpm.

Skip to step 3 if the low idle rpm is correct.

2 Turn the low idle adjustment screw on thecarburetor clockwise to increase rpm orcounterclockwise to decrease rpm.

Kubota Gasoline/LPG idle adjustmentsa solenoid bootb high idle adjustment nutc spring lock nutd low idle adjustmente carburetor

Part No. 43037 Genie Z-34/22 IC 4 - 19


TABLE B PROCEDURES

3 Move the engine idle control switch to high idle(rabbit symbol) from the ground controls.

Result: High idle should be 3000 rpm.

If high idle rpm is correct, disregardadjustment steps 4 through 6.

4 Loosen the spring lock nut.

5 Turn the high idle adjustment nut and springlock nut clockwise to increase the rpm orcounterclockwise to decrease the rpm.

6 Tighten the spring lock nut. Then recheck therpm.

Kubota Gas/LPG Models

Low idle 1600 rpm

High idle 3000 rpm

Kubota Diesel models

1 Connect an rpm gauge to the engine, and thenstart the engine from the ground controls.

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 idleadjustment screw clockwise to increase the rpmor counterclockwise to decrease the rpm.Tighten the lock nut and recheck the rpm.

Kubota Diesel idle adjustmentsa lock nutb high idle adjustment nutc low idle adjustment screwd rpm solenoid

3 Move the engine idle control switch to high idle(rabbit symbol) from the ground controls.

Result: High idle should be 3000 rpm.

If high idle rpm is correct, disregardadjustment step 4.

4 Loosen the lock nut on the solenoid, then turnthe solenoid boot counterclockwise to increasethe rpm or clockwise to decrease the rpm.Tighten the lock nut and recheck the rpm.

Kubota Diesel models

Low idle 1300 rpm

High idle 3000 rpm

d b

c

a

4 - 20 Genie Z-34/22 IC Part No. 43037


TABLE B PROCEDURES

B-11Test the Key SwitchProper key switch action and response is essentialto safe machine operation. The machine can beoperated from the ground or platform controls andthe activation of one or the other is accomplishedwith the key switch. Failure of the key switch toactivate the appropriate control panel could causea hazardous operating situation.

1 Pull out the Emergency Stop button to the ON



3 Check the machine functions from the groundcontrols.

Result: The machine functions should notoperate.

4 Turn the key switch to ground control.

5 Check the machine functions from the platformcontrols.


6 Turn the key switch to the OFF position.


B-12Test the Emergency Stop ButtonsProperly functioning Emergency Stop buttonsare essential for safe machine operation. Animproperly operating Emergency Stop buttonmay fail to shut off power and stop all machinefunctions resulting in a hazardous situation.

As a safety feature, selectingand operating the ground controlswill override the platform controls,including the Emergency Stopbutton.


position.


position.

Result: No functions should operate, themachine should stop.

3 Turn the key switch to platform control and pullout the Emergency Stop button to the ON


4 Push down the Emergency Stop button to theOFF position.

Result: No machine functions should operate.

The ground Emergency Stopbutton will stop all machineoperation, even if the key switchis switched to platform control.

Part No. 43037 Genie Z-34/22 IC 4 - 21


B-14Test the Platform Self-levelingAutomatic platform self-leveling throughoutthe full cycle of boom raising and lowering isessential for safe machine operation. Theplatform is maintained at level by the platformleveling slave cylinder which is controlled by themaster cylinder located at the base of the primaryboom. A platform self-leveling failure creates anunsafe working condition.


position.


3 Adjust the platform to a level position using theplatform leveling switch.

4 Raise and lower the primary boom througha full cycle.

Result: The platform should remain level atall times to within ±5 degrees.

B-13Test the Ground Control OverrideA properly functioning ground control override isessential to safe machine operation. The groundcontrol override function is intended to allowground personnel to operate the machine from theground controls whether or not the EmergencyStop button on the platform controls is in the ON orOFF position. This function is particularly useful ifthe operator at the platform controls cannot returnthe boom to the stowed position.

1 Push in the platform Emergency Stop buttonto the OFF position.


position.

3 Operate each boom function through apartial cycle at the ground controls.

Result: All boom functions should operate.

TABLE B PROCEDURES

4 - 22 Genie Z-34/22 IC Part No. 43037


B-15Test the Service HornA functioning service horn is essential to safemachine operation. The service horn is activated atthe platform controls and sounds at the ground asa warning to ground personnel. An improperlyfunctioning horn will prevent the operator fromalerting ground personnel of hazards or unsafeconditions.

1 Turn the key switch to platform control andpull out the Emergency Stop button to theON position at both the ground andplatform controls.

2 Push down the service horn button at theplatform controls.

Result: The service horn should sound.

B-16Test the Foot SwitchA properly functioning foot switch is essential tosafe machine operation. Machine functions shouldactivate and operate smoothly as long as the footswitch is pressed down, and promptly stop whenthe foot switch is released. An improperlyfunctioning foot switch can cause an unsafeworking condition.

The engine should not start withthe footswitch pressed down.


2 Without pressing down the foot switch, checkthe machine functions.


3 Press down the foot switch and operate themachine functions.

Result: The machine functions should operate.

TABLE B PROCEDURES

Part No. 43037 Genie Z-34/22 IC 4 - 23


6 Move the engine idle control switch to low idle(turtle symbol).

Result: The engine should change to low idle.

7 Move the engine idle control switch to footswitch activated high idle (rabbit and foot switchsymbol).

Result: The engine should not change tohigh idle.

8 Press down the foot switch.

Result: The engine should change to high idle.

TABLE B PROCEDURES

B-17Test the Engine Idle SelectA properly operating engine idle select switchis essential to good engine performance and safemachine operation. There are three settings.

Low idle (turtle symbol) allows the operator tocontrol individual boom functions and to drive themachine at a reduced speed.

High idle (rabbit symbol) allows the operatorto control multiple boom and/or drive functionssimultaneously. This setting maintains aconsistent high idle.

Foot switch activated high idle (rabbit and footswitch symbols) should be used for normalmachine operation. This selection activates highidle only when the foot switch is pressed down.

1 Pull out the Emergency Stop button to theON position at both the ground and platformcontrols.

2 Start the engine from the ground controls. Thenmove the engine idle control switch to high idle(rabbit symbol) and hold in the ON position.


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 idlecontrol switch to high idle (rabbit symbol).


4 - 24 Genie Z-34/22 IC Part No. 43037


B-18Test the Fuel Select Operation -Kubota Gasoline/LPG ModelsThe ability to select and switch betweengasoline and LPG fuels as needed is essential tosafe machine operation. A fuel selection can bemade when the engine is running or not.Switching malfunctions and/or the failure of theengine to start and run properly in both fuelmodes and through all idle speeds can indicatefuel system problems that could develop into ahazardous situation.

Perform this test after checkingthe gasoline and LPG fuel levels,and warming the engine to normaloperating temperature.

1 Move the fuel select switch to gasoline and thenmove the engine idle control switch to footswitch activated high idle (rabbit and foot switchsymbol).

2 Start the engine from the platform controls andallow it to run at low idle.

3 Press down the foot switch to allow the engineto run at high idle.

Result: The engine should start promptly andoperate smoothly in low and high idle.

4 Release the foot switch and stop the engine.

5 Move the fuel select switch to LPG.

6 Restart the engine and allow it to run atlow idle.

7 Press down the foot switch to allow the engineto run at high idle.

Result: The engine should start promptly andoperate smoothly in low and high idle.

The engine may hesitatemomentarily and then continueto run on the selected fuel if thefuel source is switched whilethe engine is running.

B-19Test the Drive Enable SystemProper drive enable system operation isessential to safe machine operation. When theprimary boom is past the non-steering wheels,drive movement is stopped and the indicator lightturns on. The drive enable switch must be usedto reactivate drive function and should informthe operator that the machine will move in theopposite direction that the drive and steer controlsare moved. An improperly functioning drive enablesystem may allow the machine to be moved intoan unsafe position.


2 Rotate the turntable to the right until the primaryboom is past the right non-steer wheel.

Result: The drive enable indicator light shouldturn on.


Result: The drive function should not operate.

4 Hold the drive enable toggle switch to eitherside and slowly move the drive control handleoff center.

Result: The drive function should operate.

Collision hazard. Always use thecolor-coded direction arrows onthe platform control panel and thedrive chassis to identify whichdirection the machine will travel.

TABLE B PROCEDURES

Part No. 43037 Genie Z-34/22 IC 4 - 25


5 Rotate the turntable to the left until the primaryboom is past the left non-steer wheel.

Result: The drive enable indicator light shouldcome on.

6 Repeat steps 3 and 4.

B-20Test the Drive BrakesProper brake action is essential to safe machineoperation. The drive brake function should operatesmoothly, free of hesitation, jerking and unusualnoise. Hydrostatic brakes and hydraulically-released individual wheel brakes can appear tooperate normally when not fully operational.

Bodily injury hazard. Be sure thatthe machine is not in free-wheel orpartial free-wheel configuration.Refer to B-7 in this section,Confirm the Proper BrakeConfiguration.

Select a test area that is firm, leveland free of obstructions.

1 Mark a test line on the ground for reference.


3 Select high range drive (machine on levelsurface symbol).

4 Move the engine idle control switch to footswitch activated high idle (rabbit and footswitch).

5 Lower the boom into the stowed position.

6 Choose a point on the machine; i.e., contactpatch of a tire, as a visual reference for usewhen crossing the test line.

7 Bring the machine to top drive speed beforereaching the test line. Release the drive joystickwhen your reference point on the machinecrosses the test line.

8 Measure the distance between the test line andyour machine reference point.

Braking: high range, paved surface

Stopping distance 3 to 4 ft0.91 to 1.22 m

The brakes must be able to holdthe machine on any slope it is ableto climb.

TABLE B PROCEDURES

4 - 26 Genie Z-34/22 IC Part No. 43037


TABLE B PROCEDURES

B-21Test the Drive Speed -Stowed PositionProper drive function movement is essential to safemachine operation. The drive function shouldrespond quickly and smoothly to operator control.Drive performance should also be free ofhesitation, jerking and unusual noise over theentire proportionally controlled speed range.


1 Create start and finish lines by marking twolines on the ground 40 feet (12.2 m) apart.


3 Select high range drive (machine on levelsurface symbol).

4 Move the engine idle control switch to footswitch activated high idle (rabbit and footswitch).

5 Lower the boom into the stowed position.

6 Choose a point on the machine; i.e., contactpatch of a tire, as a visual reference for usewhen crossing the start and finish lines.

7 Bring the machine to top drive speed beforereaching the start line. Begin timing when yourreference point on the machine crosses thestart line.

8 Continue at full speed and note the time whenthe machine reference point passes over thefinish line.

Drive speed: stowed position, maximum

High range (2WD) 40 ft/6.1 sec12.2m/6.1 sec

High range (4WD) 40 ft/6.8 sec12.2m/6.8 sec

B-22Test the Drive Speed -Raised or Extended PositionProper drive function movement is essential tosafe machine operation. The drive function shouldrespond quickly and smoothly to operator control.Drive performance should also be free ofhesitation, jerking and unusual noise over theentire proportionally controlled speed range.


1 Create start and finish lines by marking twolines on the ground 40 feet (12.2 m) apart.


3 Move the engine idle select switch to foot switchactivated high idle (rabbit and foot switchsymbol).

4 Press down the foot switch and raise theprimary boom above horizontal.



7 Continue at full speed and note the time whenthe machine reference point crosses the finishline.

8 Lower the boom to the stowed position andextend the boom 1 foot / 30 cm.

Part No. 43037 Genie Z-34/22 IC 4 - 27




11 Continue at top speed and note the time whenthe machine reference point crosses the finishline.

Drive speed: raised or extended position, maximum

Raised or extended position 0.6 mph0.98 km/h

40 ft / 40 sec12.2 m / 40 sec

B-23Test the Alarm Package -Optional EquipmentThe alarm package includes:

· Travel alarm

· Descent alarm

· Flashing beacon

Alarms and a beacon are installed to alertoperators and ground personnel of machineproximity and motion. The alarm package isinstalled on the ground controls side turntablecover.

The alarms and beacon willoperate with the enginerunning or not running.

1 At the ground controls pull out the EmergencyStop button to the ON position and turn the keyswitch to ground control.

Result: The flashing beacon should be on andflashing.

2 Move the primary boom switch to the DOWN

position, hold for a moment and then releaseit. Move the secondary boom switch to the DOWN

position, hold for a moment and thenrelease it.

Result: The descent alarm should sound wheneach switch is held down.


TABLE B PROCEDURES

4 - 28 Genie Z-34/22 IC Part No. 43037


TABLE B PROCEDURES

4 At the platform controls pull out the EmergencyStop button to the ON position.

Result: The flashing beacon should be onand flashing.

5 Press down the foot switch. Move the primaryboom switch to the DOWN position, hold for amoment and then release it. Move thesecondary boom switch to the DOWN position,hold for a moment and then release it.

Result: The descent alarm should sound wheneach control switch is held down.

6 Press down the foot switch. Move the drivecontrol handle off center, hold for a momentand then release it. Move the drive controlhandle off center in the opposite direction, holdfor a moment and then release it.

Result: The travel alarm should sound when thedrive control handle is moved off center ineither direction.

B-24Perform Hydraulic Oil AnalysisSee D-1, Test or Replace the Hydraulic Oil.

Part No. 43037 Genie Z-34/22 IC 4 - 29


a

e

d

b

c

B-25Replace the Diesel Fuel Filter/Water Separator Element -Kubota Diesel Models

Kubota engine specificationsrequire that this procedure beperformed every 400 hours.

Replacing the diesel fuel filter is essential to goodengine performance and service life. A dirty orclogged filter may cause the engine to performpoorly and continued use may cause componentdamage. Extremely dirty conditions may requirethat the filter be replaced more often.

Explosion and fire hazard. Enginefuels are combustible. Replace thefuel filter in an open, well-ventilated area away from heater,sparks, flames and lightedtobacco. Always have anapproved fire extinguisher withineasy reach.


1 Loosen the vent plug located on the fuel filter/water separator head.

Fuel filter/water separatora head boltb filter bowlc drain plugd vent pluge separator head

TABLE B PROCEDURES

2 Place a container under the filter bowl. Thenloosen the drain plug located at the bottom ofthe bowl. Completely drain the fuel.

3 Loosen the head bolt then rotate the filter bowlcounterclockwise and remove it.

4 Remove the filter element from the bowl.

5 Apply a thin layer of oil onto the bowl gasketand then install the new filter element (Geniepart no. 22942).

6 Tighten the drain plug and fill the bowl withclean diesel fuel.

7 Install the bowl onto the filter head, and thentighten the head bolt to 65 inch-pounds (7 Nm).

8 Tighten the vent plug.

9 Clean up any diesel fuel that may have spilledduring the installation procedure.

Bleed the fuel system:

Before bleeding the system, fill thefuel tank.

10 Loosen the vent plug located on the filter head.

11 Tighten the vent plug when air stops comingthrough the vent.

12 Loosen the air vent screw, located on top of thefuel injection pump.

13 Tighten the air vent screw when air stopscoming through the air vent.

14 Clean up any fuel that may have spilled.

15 Start the engine from the ground controls andinspect the fuel filter/water separator for leaks.


4 - 30 Genie Z-34/22 IC Part No. 43037


C-1Check the Primary BoomWear PadsMaintaining the primary boom wear pads in goodcondition is essential to safe machine operation.Wear pads are placed on boom tube surfaces toprovide a low friction, replaceable wear padbetween moving parts. Improperly shimmed wearpads or continued use of worn out wear pads mayresult in component damage and unsafe operatingconditions.


position.

2 Extend the primary boom 10 inches (25 cm).

3 Measure each wear pad. Replace the wear padif it is less than 0.41 inches (1 cm) thick. If thewear pad is more than 0.41 inches (1 cm) thick,shim as necessary to obtain zero clearance andzero drag.

4 Extend and retract the primary boom throughthe entire range of motion to check for tightspots that could cause binding or scraping.

Always maintain squarenessbetween the primary boom outerand inner tubes.

C-2Check the Turntable RotationBearing BoltsMaintaining proper torque on the turntable bearingbolts is essential to safe machine operation.Improper bolt torque could result in an unsafeoperating condition and component damage.

1 Raise the secondary boom and place a safetychock on the secondary boom lift cylinder.Carefully lower the boom onto the lift cylindersafety chock.

Crushing hazard. Keep handsaway from the cylinder and allmoving parts when lowering thesecondary boom.

The lift cylinder safety chock isavailable through Genie (partnumber 36555).

2 Check to ensure that each turntable bearingbolt is torqued in specified order to190 foot-pounds (258 Newton meters).

Bolt torque sequence

3 Remove the safety chock. Lower the boom tothe stowed position.

Table C Procedures

Part No. 43037 Genie Z-34/22 IC 4 - 31


TABLE C PROCEDURES

4 Access the turntable bearing bolts through theaccess hole on the side of the chassis.

5 Check to ensure that each bearing mountingbolt under the drive chassis is torqued inspecified order to 190 foot-pounds(258 Newton meters).

Bolt torque sequence

C-3Check the Free-wheelConfigurationProper use of the free-wheel configuration isessential to safe machine operation. Thefree-wheel configuration is used primarily fortowing. A machine configured to free-wheel withoutoperator knowledge may cause death or seriousinjury and property damage.

Collision hazard. Select a worksite that is firm and level.

1 Chock the steer wheels to prevent the machinefrom rolling.

2 Center a lifting jack of ample capacity(15000 lbs/6804 kg) under the drive chassisbetween the non-steering wheels.

3 Lift the wheels off the ground and then placejack stands under the drive chassis for support.

4 Disengage the torque hubs by turning over thetorque hub disconnect caps on eachnon-steering wheel hub.

5 Manually rotate each non-steering wheel.

Result: Each non-steering wheel should rotatewith minimum effort.

6 Re-engage the torque hubs by turning overthe hub disconnect caps. Carefully removethe jack stands, lower the machine andremove the jack.

Collision hazard. Failure tore-engage the torque hubs maycause death or serious injury andproperty damage.

brake disengage position

brake engage position

4 - 32 Genie Z-34/22 IC Part No. 43037


TABLE C PROCEDURES

C-4Grease the Turntable RotationBearing and Worm Drive GearYearly application of lubrication to the turntablebearing and worm drive gear is essential to goodmachine performance and service life. Continueduse of an improperly greased gear will result incomponent damage.

1 Raise the secondary boom and place a safetychock on the secondary boom lift cylinder.Carefully lower the boom onto the lift cylindersafety chock.

Crushing hazard. Keep handsaway from the cylinder and allmoving parts when lowering thesecondary boom.

The lift cylinder safety chock isavailable through Genie (partnumber 36555).

2 Locate the grease fitting on the inside of thebearing in the middle of the turntable.

3 Pump grease into the turntable rotation bearing.Rotate the turntable in increments of 4 to 5inches (10 to 13 cm) at a time and repeat thisstep until the entire bearing has been greased.

4 Remove the safety chock. Lower the boom tothe stowed position.

5 Locate the grease fitting on the worm drivehousing.

a grease fitting

6 Pump grease into the gear until you see itcoming out of the side of the gear housing.

7 Grease each tooth on the outside of theturntable rotation bearing.

Lubricant Type Multipurpose grease

a

Part No. 43037 Genie Z-34/22 IC 4 - 33


C-5Replace the Torque Hub OilReplacing the torque hub oil is essential for goodmachine performance and service life. Failure toreplace the torque hub oil at yearly intervals maycause the machine to perform poorly andcontinued use may cause component damage.

1 Select the drive torque hub to be serviced. Thendrive the machine until one of the two plugs isat the lowest point.

2 Remove both plugs and drain the oil.

3 Drive the machine until one plug is at the topand the other is at 90 degrees.

4 Fill the hub with oil from the top hole until the oillevel is even with the bottom of the side hole.

5 Apply pipe thread sealant to the plugs, theninstall the plugs.

6 Repeat this procedure for each torque hub.

Oil capacity per hub 17 fluid ounces0.5 liters

Type: SAE 90 multipurpose hypoid gear oil - APIservice classification GL5

C-6Replace the Hydraulic FiltersReplacement of the hydraulic filters areessential for good machine performance andservice life. A dirty or clogged filter may cause themachine to perform poorly and continued use maycause component damage. Extremely dirtyconditions may require that the filter be replacedmore often.

Hydraulic Return Filter:

Burn hazard. Beware of hot oil.Contact with hot oil may causesevere burns.

The return hydraulic filter ismounted on the hydraulic tank.

1 Clean the area around the oil filter, then removethe filter with an oil filter wrench.

2 Apply a thin layer of oil to the new oil filtergasket.

3 Install the new filter and tighten it securely byhand. Clean up any oil that may have spilledduring the replacement procedure.

Return oil filter - Genie part number 44207

TABLE C PROCEDURES

4 - 34 Genie Z-34/22 IC Part No. 43037


a b c

Hydraulic Suction Filter:

Burn hazard. Beware of hot oil.Contact with hot oil may causesevere burns.

The suction hydraulic filter ismounted in the enginecompartment.

1 Close the shut off valve behind the filter.

2 Clean the area around the oil filter, then removethe filter with an oil filter wrench.

3 Apply a thin layer of oil to the new oil filtergasket.

4 Install the new filter and tighten it securely byhand. Clean up any oil that may have spilledduring the replacement procedure.

Suction oil filter - Genie part number 43686

C-7Replace the Gasoline FuelFilter - Kubota Gasoline/LPGModelsReplacing the gasoline fuel filter is essential togood engine performance and service life. A dirtyor clogged filter may cause the engine to performpoorly and continued use may cause componentdamage. Extremely dirty conditions may requirethat the filter be replaced more often.

Explosion and fire hazard. Enginefuels are combustible. Replace thefuel filter in an open, well-ventilated area away from heaters,sparks, flames and lightedtobacco. Always have anapproved fire extinguisher withineasy reach.


1 Disconnect the fuel hoses from the filter, thenremove the filter.

Kubota Gasoline/LPG modelsa hose from the fuel filter to

the carburetorb fuel filterc hose from the fuel filter to

the fuel pump

TABLE C PROCEDURES

Part No. 43037 Genie Z-34/22 IC 4 - 35


2 Install the new fuel filter (Genie part no. 23168)with the flow direction arrow on the filter,pointing toward the carburetor. Then connectthe fuel hoses to the filter.

3 Clean up any fuel that may have spilled duringthe replacement procedure.

4 Start the machine from the ground controls,then inspect the fuel filter and hoses for leaks.

Explosion and fire hazard. If a fuelleak is discovered, keep anyadditional personnel from enteringthe area and do not operate themachine. Repairthe leak immediately.

C-8Clean or Replace theDistributor Cap and Rotor -Kubota Gasoline/LPG ModelsA distributor cap and rotor that are clean and freeof damage, wear and corrosion are essential togood engine performance and service life. A dirtyor worn cap and rotor may cause the engine toperform poorly and continued use may causecomponent damage. Extremely dirty conditionsmay require that the cap and rotor be cleaned orreplaced more often.


1 Remove the distributor access cover from theside of the engine to access the distributor.

a distributor access cover

2 Label and disconnect the coil and spark plugwires from the distributor cap.

3 Remove the cap and rotor from the distributor.

TABLE C PROCEDURES

a

4 - 36 Genie Z-34/22 IC Part No. 43037


4 Clean the cap and rotor using electrical contactcleaner or a damp cloth.

5 Completely dry the cap and rotor.

Moisture in the distributor cap willcause the engine to run poorly.

6 Inspect the cap and rotor for corrosion, cracksand abrasion. Replace the cap and rotor if theyare damaged.

7 Install the rotor and cap, then connect the coiland spark plug wires.

8 Start the engine and check for smoothoperation.

C-9Replace the Spark Plugs -Kubota Gasoline/LPG ModelsPeriodic replacement of the spark plugs isessential to good engine performance andservice life. Worn, loose or corroded spark plugswill cause the engine to perform poorly and mayresult in component damage.


1 Label, then disconnect the plug wires from thespark plugs by grasping the molded boot. Donot pull on the plug wire.

2 Blow out any debris around spark plugs.

3 Remove all the spark plugs from the engine.

4 Adjust the gap on each new spark plug.

5 Install the new spark plugs, then connect thewires. Be sure that each spark plug wire isattached to the correct spark plug.

Spark plug specifications

Spark plug type NGK BCP4ES-11

Spark plug gap 0.039 to 0.043 inch1.0 to 1.1 mm

Spark plug torque 14 to 18 ft-lbs20 to 24 Nm

TABLE C PROCEDURES

Part No. 43037 Genie Z-34/22 IC 4 - 37


C-10Check and Adjust the Air/LPGMixture - Kubota Gasoline/LPGModelsMaintaining the proper air-to-fuel mixture duringliquid propane gas (LPG) operation is essential togood engine performance.

Explosion and fire hazard. Enginefuels are combustible. Perform thisprocedure in an open, well-ventilated area away from heaters,sparks, flames and lightedtobacco. Always have anapproved fire extinguisher withineasy reach.

The engine rpm needs to bepreset for gasoline fuel operationbefore adjusting the LPG idlemixture. Refer to B-10, Check andAdjust the Engine RPM.

The engine should be warmed tonormal operating temperaturebefore performing this procedure.

1 Move the fuel select switch to LPG fuel andstart the engine from the ground controls.

TABLE C PROCEDURES

2 Loosen the high idle mixture adjustmentlock nut.

a high idle mixtureadjustment screw

3 Load the system by pressing the primary boomretract switch with the primary boom fullyretracted, then move the engine idle controlswitch to high idle (rabbit symbol).

4 Adjust the high idle adjustment screw to obtainan air-to-fuel mixture ratio of 13.0:1 to 13.2:1,using an exhaust gas analyzer.

If an exhaust gas analyzer is notavailable, adjust to obtain peak oroptimum rpm.

5 Hold the adjustment screw and tighten thelock nut.

a

4 - 38 Genie Z-34/22 IC Part No. 43037


6 Move the engine idle control switch to low idle(turtle symbol) and adjust the low idle mixtureadjustment screw to obtain an air-to-fuelmixture ratio of 13.0:1 to 13.2:1.

a low idle mixture adjustment screw

TABLE C PROCEDURES

a

C-11Replace the Engine Air Filter

Kubota specifications require thatthis procedure be performed every1000 hours. Perform thisprocedure more often if dustyconditions exist.

Maintaining the engine air filter in good condition isessential to good engine performance and servicelife. Failure to perform this procedure can lead topoor engine performance and component damage.


1 Diesel models: Remove the retaining fastenerfrom the air cleaner element end cap. Removethe end cap.

Gasoline/LPG models: Release the latchesfrom the air cleaner canister end cap. Removethe end cap.

2 Remove the filter element.

3 Clean the inside of the canister and the end capwith a damp cloth.

4 Install the new filter element.

5 Diesel models: Install the air cleaner elementend cap retaining fastener.

Gasoline/LPG models: Install the air cleanerend cap and secure the latches.

Air filters - Genie part numbersKubota D-905 Engine 31745Kubota WG-750 Engine 22107

Part No. 43037 Genie Z-34/22 IC 4 - 39


TABLE C PROCEDURES

C-12Check and Adjust the IgnitionTiming - Kubota Gasoline/LPGModelsComplete information to perform this procedure isavailable in the Kubota WG-750 Workshop Manual(Kubota number: 97897-00643). Genie partnumber 52492.

C-13Check the Engine ValveClearance - Kubota Gasoline/LPGModelsComplete information to perform this procedure isavailable in the Kubota WG-750 Workshop Manual(Kubota number: 97897-00643). Genie partnumber 52492.

C-14Bleed the Platform RotatorSee Repair procedure 2-3, How to Bleed thePlatform Rotator.

4 - 40 Genie Z-34/22 IC Part No. 43037


D-1Test or Replace the Hydraulic OilReplacement or testing of the hydraulic oil isessential for good machine performance andservice life. Dirty oil and suction strainers maycause the machine to perform poorly andcontinued use may cause component damage.Extremely dirty conditions may require oil changesto be performed more often.

The machine uses Dexronequivalent hydraulic oil. Beforereplacing the hydraulic oil, the oilmay be tested by an oil distributorfor specific levels of contaminationto verify that changing the oil isnecessary. If the hydraulic oilis not replaced at the two yearinspection, test the oil quarterly.Replace the oil when it fails thetest.

Perform this procedure with theboom in the stowed position.

1 Remove the plug from the drain hose on thehydraulic tank.

2 Completely drain the tank into a suitablecontainer. See capacity specifications listedbelow.

3 Remove the fasteners from the hydraulic tankhold down straps. Remove the straps.

4 Attach a strap from an overhead crane to thehydraulic tank and remove it from the machine.

5 Remove the suction strainers and clean themusing a mild solvent.

6 Rinse out the inside of the tank with a mildsolvent.

7 Install the suction strainers using a threadsealant on the threads.

8 Re-install the tank on the machine. Install thehydraulic tank hold down straps.

9 Install the plug on the drain hose.

Table D Procedures

10 Fill the tank with hydraulic oil until the fluid untilthe fluid is within the top 2 inches (5.1 cm) ofthe sight gauge. Do not overfill.

11 Clean up any oil that may have spilled. Properlydiscard of oil.

Hydraulic Oil Specifications

Hydraulic oil type Dexron equivalent




Part No. 43037 Genie Z-34/22 IC 4 - 41


D-2Change or Recondition theEngine CoolantReplacing or reconditioning the engine coolant isessential to good engine performance and servicelife. Old or dirty coolant may cause the engine toperform poorly and continued use may causeengine damage. Extremely dirty conditions mayrequire coolant to be changed more frequently.

Bodily injury hazard. Beware ofhot engine parts and coolant.Contact with hot engine parts and/or coolant will cause severe burns.

Perform this procedure with theengine off and cooled.

1 Put on protective clothing and eye wear.

2 Disconnect the coolant return hose at theradiator and drain the coolant return tank.

3 Remove the radiator cap from the radiator.

4 Open the petcock on the radiator and allowall the coolant to drain into a suitable container.

5 After all the coolant has drained, close thepetcock. Connect the coolant return hose tothe radiator.

6 Open the petcock on the engine block and allowthe coolant to drain into a suitable container.After the fluid is drained, close the petcock.

7 Replace all coolant hoses and clamps.

8 Pour the proper coolant mixture (anti-freeze andwater) for your climate into the radiator until it isfull.

9 Clean up any coolant spilled during thisprocedure.

10 Start the engine from the ground controls,run it for 30 seconds, and then turn it off.

11 Inspect for leaks and then check the fluidlevel in the coolant recovery tank. Addwater if needed.

Coolant capacity

Kubota WG-750 3.1 quarts2.9 liters

Kubota D-905 3.3 quarts3.1 liters

12 Start the engine from the ground controlsand run it until reaching normal operatingtemperature.

13 Allow engine to cool and check the fluid level inthe coolant recovery tank. Add water if needed.

TABLE D PROCEDURES

4 - 42 Genie Z-34/22 IC Part No. 43037


D-3Change the Fuel Lines

Maintaining the fuel lines in good condition isessential to safe operation and good engineperformance. Failure to detect a worn, cracked orleaking fuel line may cause an unsafe operatingcondition.

Explosion and fire hazard. Enginefuels are combustible. Replace thefuel lines in an open, well-ventilated area away from heaters,sparks, flames and lightedtobacco. Always have anapproved fire extinguisher withineasy reach.


1 Close the manual fuel shutoff valve, locatednext to the fuel tank.

2 Remove and replace the fuel line hoses andclamps according to the following illustrations:

Explosion and fire hazard. Fuelmay be expelled under pressure.Wrap a cloth around fuel hoses toabsorb leaking fuel beforedisconnecting them.

TABLE D PROCEDURES

Kubota Diesel modelsa hose from the injection pump

to the injectorsb hose from the fuel pump to

the injection pumpc hose from the fuel filter to the

fuel pumpd hose from the fuel tank to

the fuel filtere hose from the injector to

the fuel tank

a

d ce

b

Part No. 43037 Genie Z-34/22 IC 4 - 43


TABLE D PROCEDURES

c

d

ba

Kubota Gasoline/LPG Modelsa hose from the fuel filter to

the carburetorb fuel filterc hose from the fuel filter

to the fuel pumpd hose from the fuel pump

to the fuel shutoff valve (not shown)

3 Clean up any fuel that may have spilled duringthis procedure.

4 Start the engine from the ground controls, theninspect the fuel filter and hoses for leaks.


Once air has been introduced intothe diesel fuel injection system,the injectors must be bled beforethe engine is restarted. SeeMaintenance procedure B-25,Replace the Diesel Fuel Filter/Water Separator Element - KubotaDiesel Models for information onhow to bleed the fuel system.

4 - 44 Genie Z-34/22 IC Part No. 43037


Part No. 43037 Genie Z-34/22 IC 5 - 1

Service Manual - First Edition Section 5 - Troubleshooting Flow Charts

Before Troubleshooting:

Read, understand and obey the safety rules andoperating instructions printed in theGenie Z-34/22 IC Operator’s Manual.

Be sure that all necessary tools and testequipment are available and ready for use.

Read each appropiate flow chart thoroughly.Attempting shortcuts may produce hazardousconditions.

Be aware of the following hazards and followgenerally accepted safe workshop practices.

Crushing hazard. When testingor replacing any hydrauliccomponent, always supportthe structure and secure itfrom movement.

Electrocution hazard. Contactwith electrically charged circuitsmay result in death or seriousinjury. Remove all rings, watchesand other jewelry.

Bodily injury hazard. Sprayinghydraulic oil can penetrate andburn skin. Loosen hydraulicconnections very slowly to allowthe oil pressure to dissipategradually. Do not allow oil tosquirt or spray.

Perform all troubleshooting on afirm level surface.

Two persons will be required tosafely perform sometroubleshooting procedures.

Troubleshooting Flow Charts

Observe and Obey:

Troubleshooting and repair procedures shall becompleted by a person trained and qualified onthe repair of this machine.


Repair any machine damage or malfunctionbefore operating the machine.

Unless otherwise specified, perform eachrepair procedure with the machine in thefollowing configuration:



· Turntable rotated with the boom between thenon-steer wheels


· Wheels chocked


5 - 2 Genie Z-34/22 IC Part No. 43037

Service Manual - First EditionSection 5 - Troubleshooting Flow Charts

General Repair Process

TROUBLESHOOTING FLOW CHARTS

About This SectionWhen a malfunction is discovered, the flow chartsin this section will help a service professionalpinpoint the cause of the problem. To use thissection, basic hand tools and certain pieces of testequipment are required—voltmeter, ohmmeter,pressure gauges.

The location of terminals mentioned in this sectioncan be found on the appropriate electrical orhydraulic schematics provided in Section 6,Schematics.

Since various degrees of a particular functionloss may occur, selecting the appropriate flowchart may be troublesome. When a function will notoperate with the same speed or power as amachine in good working condition, refer to theflow chart which most closely describes theproblem.

Malfunctiondiscovered

Identifysymptoms

Troubleshoot

Performrepair

Return toservice problem

solved

problemstill exists

Inspectand test

Part No. 43037 Genie Z-34/22 IC 5 - 3


Engine Will NotCrank Over -Kubota Gas/LPG ModelsBe sure key switch is inthe appropriate position.

Be sure the EmergencyStop buttons are pulledup to the ON position.

Be sure the circuitbreaker and fuses arenot tripped or blown.

Chart 1

Check battery voltage. Check battery conditionOR check alternatorOR check battery cablesOR replace the battery.

less than12V

12V or more

Check voltage at centerterminal on start switch.

0V Trace circuit backthrough the key switch,emergency stop buttonand CB1, repair open.12V

Hold start switch andcheck voltage at eitherside terminal on startswitch.

0V Replace start toggleswitch.

12V

Hold start switch andcheck voltage atterminal TB33.

0V Repair blk wire circuitfrom start switch toTB33 OR replace diodeat start switch becauseof open.12V

Hold start switch andcheck voltage atterminal #3 on ign./startmodule.

0V Repair blk wire circuitfrom TB33 to ign./startmodule terminal #3.

Continued on the nextpage.

12V

Check voltage atterminal #6 on ign./startmodule.

0VRepair open in CB2 ORin power supply wire toterminal #6 on ign./startmodule.

12V


0V Repair open in groundwire to terminal #5 onign./start module.

12V

5 - 4 Genie Z-34/22 IC Part No. 43037


CHART 1

Hold start switch andcheck voltage at terminal#86 on CR1.

Continued from theprevious page.

12V

0V Repair open in blk wirefrom terminal #1 on ign./start module to CR1.

Check voltage at terminal#30 on CR1.

0V

12V

Repair open in red wirefrom CB2 to CR1terminal #30.


0V Check ground to terminal#85 on CR1.

Check voltage at initiateterminal starter solenoid.

good

bad

Replace CR1 relay.

Repair open in ground toCR1.

12V

12V

0V Repair open in blk wirecircuit from CR1 tostarter solenoid.

Check, repair or replacestarter or starter solenoid.

Part No. 43037 Genie Z-34/22 IC 5 - 5


Chart 2

Engine CranksOver But WillNot Start -Kubota Gas/LPG ModelsBe sure to check fuellevels (gasoline/LPG).

Be sure the fuel shut-offvalves are turned on(gasoline/LPG).

Be sure to check theengine oil level and theengine coolant level. Fillas needed.

Be sure the choke is notsticking closed.

Perform the followingtests in the gasolinemode only.

Hold start switch andcheck battery voltagewhile engine is cranking.

lessthan11V

Check battery conditionOR check alternator ORcheck for short circuitsOR check battery cablesOR replace the battery.

more than 11V

Check if engine coolantover-temperature sendingsignal post has continuityto ground.

continuity Check if radiator and/orengine block feelsexcessively hot.

hot Check engine coolantlevel OR check radiatorfins for clogging ORcheck engine fan beltsOR see Kubota servicemanual fortroubleshooting anoverheating engine.

not hot

Remove wht wire fromtemperature sendingunit,. Check continuity toground on temperaturesending unit.

continuity Replace temperatureswitch sender.

no continuity

Remove wht wire fromTB24 and checkcontinuity to ground.

continuityRepair short in wht/redwire circuit from TB24 totemperature sender.

no continuity

Repair short in wht wirecircuit from terminal #10start lock out module toTB24 OR consult GenieIndustries ServiceDepartment.

no continuity

Remove #1 spark plugand ground spark plugbody. Crank engine andobserve spark.

goodspark

Go to Chart 2A.

weak or no spark

Disable starter byremoving blk wire at thestarter solenoid, holdstart switch and checkvoltage at positiveterminal of ignition coil.

12VSee Kubota servicemanual fortroubleshooting ignitionsystem.

0V


5 - 6 Genie Z-34/22 IC Part No. 43037


CHART 2


Hold start switch andcheck voltage at wht#21 on terminal #87 ofCR2.

12VRepair open in wht #21wire to ignition coil.

0V

Check voltage at redwire on terminal #30 ofCR2.

0VRepair open in red wirecircuit from battery toCB2 to CR1 to CR2.

12V

Hold start switch andcheck voltage atterminal #86 of CR2.

0VRepair open in blk wirefrom terminal #86 onCR2 to terminal #9 onign./start module.

12V

Check ground toterminal #85 on CR2.

no good Repair open in groundwire to CR2.

good


12V

0V


12V

0V Repair open in powersupply wires to terminal#7 on ign./start module.

If weak spark still exists,contact Genie IndustriesService Department ORconsult Kubota engineservice manual fortroubleshooting enginewith weak spark.

Replace ign./startmodule OR consultGenie Industries ServiceDepartment.

Part No. 43037 Genie Z-34/22 IC 5 - 7


Chart 2A

Engine CranksOver But WillNot Start OREngine RunsWhile CrankingThen Dies -Kubota Gas/LPG ModelsContinuation of "goodspark" fault path.

Perform the followingtests in the gasolinemode only.

With keyswitch turned toground position andEmergency Stop switchpulled out, check voltageat red/wht #23 wire onvacuum switch.

0VRepair open in red/wht#23 wire circuit fromTB23 to vacuum switch.

12V

Remove the blk wire withdiode from terminal #86on CR3, crank the engineover for 15 seconds andcheckvoltage at red/blk wire onvacuum switch(reconnect blk wire aftertest).

0VTurn machine off. SeeRepair section forvacuum switch check.

badReplace vacuum switch.

ok

Check vacuum line forrestrictions.

badReplace vacuum line.

ok

See Kubota servicemanual to troubleshootlow manifold vacuum.

12V

With keyswitch on andboth Emergency Stopbuttons pulled out,disconnect wires fromvacuum switch andconnect the wirestogether. Check thevoltage at terminal #86 onCR6.

0V Repair open in red/blkwire circuit from vacuumswitch to CR6.

12V


Check choke for properadjustment or internaldamage.

badAdjust choke OR consultGenie Industries ServiceDepartment.

good

5 - 8 Genie Z-34/22 IC Part No. 43037



With keyswitch onground position andEmergency Stop switchpulled out, crank engineand check voltage atterminal #87 on CR6.

0V Check ground wire onterminal #85 of CR6.

good

no good Repair open in groundwire.

Replace CR6.

With keyswitch onground position andEmergency Stop switchpulled out, checkvoltage at centerterminal on fuel selectswitch in ground controlbox.

0V Repair open in redpower wire circuit withdiode.

12V

With keyswitch onground position andEmergency Stop switchpulled out, checkvoltage on gasoline side(blu/wht wire) of fuelselect switch.

0VReplace toggle switch.

12V

With keyswitch onground position andEmergency Stop switchpulled out, checkvoltage at terminalTB38.

0VRepair open in blu/whtwire circuit from toggleswitch to TB38.

12V

With keyswitch onground position andEmergency Stop switchpulled out, checkvoltage at blu/wht wireat terminal #30 on CR6.

Repair open in blu/whtwire circuit from TB38 toterminal #30 on CR6.

12V

0V


12V

CHART 2A

Part No. 43037 Genie Z-34/22 IC 5 - 9


CHART 2A

Hold start switch andcheck voltage at blu/whtwire on anti-diesel valve(on engine carburetor).

0V Repair open in blu/wht R6wire circuit CR6 to anti-diesel valve.

12V

Hold start switch andcheck voltage at blu/whtR6 wire on gasoline fuelpump.

0V

Repair open in blu/wht R6wire circuit from anti-diesel valve to fuel pump.

Reconnect the two wiresto vacuum switch andcheck for fuel lineblockage OR replaceanti-diesel valve OR seeKubota service manualfor troubleshooting fuelpump and/or carburetorOR Consult GenieIndustries ServiceDepartment.


12V

Hold start switch, doesengine fire?

no

yes

Go to chart 2B.

5 - 10 Genie Z-34/22 IC Part No. 43037


Chart 2B

Crank engine and checkvoltage at terminal #2 onign./start module.

0V Crank engine and checkvoltage at org/blk #41wire on alternator.

0V Check alternator wiringOR repair or replacealternator OR contactGenie Industries ServiceDepartment.

6 to 7V

Repair open in org/blk#41 wire circuit fromalternator to TB41 toterminal #2 on ign./startmodule.

6 to 7V

While cranking enginefor 15 seconds, checkcontinuity to ground onterminal #10 ign./startmodule. Is continuitymaintained?

yes

Disconnect wht #24 wirefrom oil pressure senderand check continuity toground on signal post ofsender, while crankingthe engine. Is continuitymaintained?

yes

Check oil level ORreplace oil pressuresending unit OR refer toKubota service manualfor troubleshooting lowoil pressure.

no

Repair short to groundin wht #24 wire fromsender to TB24 to ign./start module terminal#10.

no


12V Repair short to power inred wire circuit fromTB27.

Replace start lockoutmodule OR consultGenie Industries ServiceDepartment.

0V

Engine RunsWhile CrankingThen Dies -Kubota Gas/LPG Models

Part No. 43037 Genie Z-34/22 IC 5 - 11


Engine CranksOver But WillNot Start -Kubota DieselModelsBe sure to check thefuel level.

Be sure to check engineoil level and enginecoolant level, fill asneeded.

Be sure the diesel shut-off valve is in the onposition.

Be sure the engine glowplugs operate normally.See the MaintenanceSection.

Chart 3

Hold start switch andcheck battery voltagewhile engine is cranking.

lessthan11V

Check battery conditionOR check alternator ORcheck for short circuitsOR check battery cablesOR replace the battery.

more than 11V

Check if engine coolantover-temperaturesending signal post hascontinuity to ground.

continuity Check if radiatorand/or engine blockfeels excessively hot.

hot Check engine oil levelOR check radiator finsfor clogging OR checkengine fan belts OR seeKubota service manualfor troubleshooting anoverheating engine.not hot

Remove wht wire fromtemperature sendingunit. Check continuity toground on temperaturesending unit.

continuity Replace temperatureswitch sender.

no continuity

Remove wht wire fromTB24.

continuity Repair short in wht wirecircuit from TB24 totemperature sender.

no continuity

Repair short in wht wirecircuit from ign./startmodule to TB24 ORconsult Genie IndustriesService Department.

no continuity

Hold start switch andcheck voltage at the blkwire where it connects tothe red wire of the fuelsolenoid (pull side).

12V

0V


Replace the fuelsolenoid.

5 - 12 Genie Z-34/22 IC Part No. 43037


CHART 3


Hold start switch andcheck voltage at wht #21wire on terminal #87 ofCR2.

12VRepair open in wht #21wire from CR2 to whereit connects to the whtwire of the fuel solenoid(hold side) OR replacefuel solenoid.

0V

Check voltage at red wireon terminal #30 of CR2.

0V Repair open in red wirecircuit from battery toCB2 to CR1 to CR2.

12V

Hold start switch andcheck voltage at terminal#86 of CR2.

0VRepair open in blk wirefrom terminal #86 on CR2to terminal #9 on ign./start module.

12V

Check ground to terminal#85 on CR2.

no good Repair open in groundwire to CR2.

good

Hold start switch andcheck voltage at terminal#9 on ign./start module.

12V

Replace the ign./startmodule OR consultGenie Industries ServiceDepartment.

0V

Check voltage at terminal#7 on start lockoutmodule.

12V

0V Repair open in powersupply wire to terminal #7on ign./start module.


Part No. 43037 Genie Z-34/22 IC 5 - 13


CHART 3

Crank engine and checkvoltage at terminal #2 onign./start module.

0V Crank engine and checkvoltage at org/blk #41wire on alternator.

0V Repair or replacealternator OR contactGenie Industries ServiceDepartment.

6 to 7V

Repair open in org/blk#41 wire circuit fromalternator to TB41 toterminal #2 on ign./startmodule.

6 to 7V

While cranking engine for15 seconds, checkcontinuity to ground onterminal #10 on ign./startmodule. Is continuitymaintained?

yes Disconnect wht #24 wirefrom oil pressure senderand check continuity toground on signal post ofsender, while crankingthe engine. Is continuitymaintained?

yes

Check oil level ORreplace oil pressuresending unit OR refer toKubota service manualfor troubleshooting low oilpressure.

no

Repair short to groundwht #24 wire from senderto TB24 to terminal #10on ign./start module.

no

Check voltage at terminal#4 on ign./start module.

12V Disconnect red wire fromterminal #4 on ign./startmodule and checkvoltage at terminal #4.

12V

Replace ign./start moduleOR consult GenieIndustries ServiceDepartment.

0V

Repair short in red wirecircuit from TB27.

0V

Replace ign./start moduleOR consult GenieIndustries ServiceDepartment.


5 - 14 Genie Z-34/22 IC Part No. 43037


Chart 4

Engine Will NotStart On LPG,But Will StartOn Gasoline -KubotaGasoline/LPGModelsBe sure the fuel selectswitch is switched toLPG.

Be sure to check theLPG fuel level.

Perform these tests withthe keyswitch in theground position.

If engine starts ongasoline from theground controls but notfrom the platformcontrols, troubleshootthe platform fuel selectswitch or the controlcables.

Disconnect LPG supplyline from LPG tank andbleed pressure fromline.

With keyswitch onground position andEmergency Stop switchpulled out, checkvoltage at LPG side (blu/red wire) of fuel selectswitch.

0V Replace fuel selectswitch.

12V

With keyswitch onground position andEmergency Stop switchpulled out, checkvoltage at TB39.

0V Repair open in blu/redwire circuit from fuelselect switch to TB39.

12V

With keyswitch onground position andEmergency Stop switchpulled out, checkvoltage at terminal #30on CR7.

0V Repair open in blu/redwire circuit from TB39 toterminal #30 on CR7.

12V

Crank engine for 15seconds and checkvoltage at terminal #86on CR7.


12V

Check ground wire toterminal #85 on CR7.

bad Repair open in groundto terminal #85 on CR7.

good


Part No. 43037 Genie Z-34/22 IC 5 - 15


CHART 4



0V Replace CR7 relay.

Hold start switch andcheck voltage at blu/redwire on LPG solenoid.

0VRepair open in blu/redwire circuit from CR7terminal #87 to LPGsolenoid.

12V

Check resistance ofLPG solenoid.

0 orinfiniteohms Replace LPG solenoid.

9 to 10 ohms

Reconnect LPG tankand starter then seeMaintenance section forLPG adjustments ORconsult Genie IndustriesService Department.

12V

5 - 16 Genie Z-34/22 IC Part No. 43037


Chart 5

Engine ChokeInoperative -KubotaGasoline/LPGModelsBe sure the fuel selectswitch is in the gasolineposition.

Be sure the chokesolenoid to carburetorlinkage is in place andproperly attached.

Be sure choke solenoidplunger can be manuallypushed into the solenoidand the linkage in turnrotates the choke platelinkage.

Hold choke switch andstart switch and checkvoltage at blk/wht #R8wire on choke solenoid.

12VCheck solenoid ground.

0V

Hold choke switch andstart switch and checkvoltage at terminal 87 onCR8 with blk/wht wireattached.

12V

Replace solenoid. Note:Resistance acrosssolenoid terminalsshould be approximately0.3 ohms.

Repair open in groundwire circuit.

good

Repair open in blk/wht#R8 wire from CR8terminal 87 to chokesolenoid.

12V

Repair open in wht wirecircuit from terminal #87on CR2 to terminal #30on CR4 to terminal #30on CR8.

0V

Check voltage atterminal #30 on CR8.

0V

Replace CR8.

bad

Check ground onterminal #85 on CR8.

12V

Turn keyswitch toground control positionand check voltage oncenter terminal of chokeswitch.

good

Repair open in groundwire on terminal 85 onCR8.

0V

Hold ground controlchoke switch and checkvoltage at blk/wht wirewhere it connects to thediode.

0V Replace toggle switchOR replace diode.

12V


bad

Hold choke switch andstart switch and checkvoltage at terminal #86on CR8.

0V

Repair open in circuitsupplying 12V to chokeswitch.

12V

Part No. 43037 Genie Z-34/22 IC 5 - 17


CHART 5


Hold ground controlchoke switch and checkvoltage at red wire oncenter terminal of fuelselect switch.

0V

Repair open in red wirecircuit from from chokeswitch to fuel selectswitch.

12V

Hold ground controlchoke switch and checkvoltage at blk/wht wireon fuel select switch.


12V

Hold ground controlchoke switch and checkvoltage at TB34.

0V

12V

Replace CR8 and holdground control chokeswitch.

choke does not work Consult Genie IndustriesService Department.

good

Repair open in blk/whtwire circuit from fuelselect switch to TB34.

Repair open in blk/whtwire circuit from TB34 toterminal #86 on CR8.

12V

0V

Check ground wirecircuit on terminal #85on CR8.

Hold ground controlchoke switch and checkvoltage at terminal #86on CR8.

bad Repair open in groundwire circuit.

choke works


5 - 18 Genie Z-34/22 IC Part No. 43037


CHART 5


Turn keyswitch toplatform controls and holdthe platform choke switchand check choke. Note:Do not press down thefootswitch.

chokeworks

Adjust choke if needed.See Repair Section.

choke does not work

Check voltage on centerterminal on platformchoke switch.

Repair open in powersupply wire circuit.

0V

12V

Hold platform chokeswitch and check voltageon output at the diode.

0VReplace toggle switchOR replace diode.

12V

Consult Genie IndustriesService Department.

Part No. 43037 Genie Z-34/22 IC 5 - 19


Engine GlowPlugsInoperative -Kubota DieselModelsBe sure the battery isfully charged.

Chart 6

Hold glow plug switchand check voltage at blk/wht #R8 wire on glowplugs.

12V Refer to Kubota ServiceManual on troubleshooting glow plugs.

0V

Hold glow plug switchand check voltage atterminal 87 on CR8 withblk/wht wire attached.

12VRepair open in blk/whtwire from CR8 terminal87 to glow plugs.

12V

Repair open in red wirecircuit from CB2.

0V


0V

Replace CR8.

bad

Check ground onterminal #85 on CR8.

12V

Turn keyswitch toground control positionand check voltage oncenter terminal of glowplug switch.

good

Repair open in groundwire on terminal 85 onCR8.

0V

Hold ground controlglow plug switch andcheck voltage at blk/wht#41 wire on toggleswitch.


12V


Hold glow plug switchand check voltage atterminal #86 on CR8.

0V

Repair open in circuitsupplying 12V to glowplug switch.

12V

Hold ground controlglow plug switch andcheck voltage at TB34.

0VRepair open in blk/whtwire circuit from glowplug switch to TB34.

12V

5 - 20 Genie Z-34/22 IC Part No. 43037


CHART 6


Hold ground controlglow plug switch andcheck voltage atterminal #86 on CR8.

0VRepair open in blk/whtwire circuit from fromTB34 to terminal #86 onCR8.

12V

Check ground wirecircuit on terminal #85on CR8.

bad Repair open in groundwire circuit.

good

Replace CR8 and holdground control glow plugswitch.

glow plug does not work

glow plug works

Hold platorm glow plugswitch and checkvoltage on output diodewith blk/wht wireattached.

12V


Start engine. If enginewon't start, refer toEngine Cranks Over, butWill Not Start - KubotaDiesel Models, Chart 3.

glow plugdoes notwork

glowplugworks

Check voltage on centerterminal on platformglow plug switch.

Turn keyswitch toplatform and hold theplatform control glowplug switch and checkglow plug. Note: Do notdepress the footswitch.

0V Repair open in powersupply wire circuit.

12V


Hold platform glow plugswitch and checkvoltage at TB34.

0V Repair open in blk/whtfrom cable #1 wirecircuit from platformglow plug switch toTB34.12V


Part No. 43037 Genie Z-34/22 IC 5 - 21


Chart 7

Engine Will NotStart OnGasoline, ButWill Start OnLPG - KubotaGasoline/LPGModelsBe sure the fuel selectswitch is switched togasoline.

Be sure to checkgasoline fuel level.

Be sure that enginechoke is operatingproperly.

Perform these tests withthe keyswitch in theground position.

If the engine starts onLPG from the groundcontrols but not from theplatform controls,troubleshoot theplatform fuel selectswitch or the controlcables.

With keyswitch onground position andEmergency Stop switchpulled out, check voltageat gasoline side (blu/whtwire) of fuel selectswitch.


12V

With keyswitch onground position andEmergency Stop switchpulled out, check voltageat TB38.

0VRepair open in blu/whtwire circuit from fuelselect switch toTP38 to TB38.

12V

Hold start switch andcheck voltage at blu/whtwire on anti-diesel valve(on carburetor).

0VRepair open in blu/whtwire circuit from CR6terminal #87to anti-diesel valve ORreplace CR6.

12V

With keyswitch onground position andEmergency Stop switchpulled out, check voltageat terminal #30 on CR6.

0V Repair open in blu/whtwire circuit from TB38 toterminal #30 on CR6.

12V

Crank engine for 15seconds and checkvoltage at terminal #86on CR6 while cranking.


12V


bad Repair open in groundwire to terminal #85 onCR6.

good


5 - 22 Genie Z-34/22 IC Part No. 43037


CHART 7

Check resistance ofanti-diesel valve.

0 orinfiniteohms Replace anti-diesel

valve.

24 to 25 ohms

Reconnect starter,check anti-diesel andfuel valve for defectsOR see Kubota servicemanual for carburetortroubleshooting.


Hold start switch andcheck voltage at blu/whton fuel pump (next tofuel tank).

0V Repair open in blu/whtwire between fuelsolenoid and fuel pump.

12V

Check ground wire tofuel pump.

badRepair ground wire.

good

Install a pressure gaugeto the fuel pump.

less than7 psi

Replace fuel pump.

more than 7 psi

Part No. 43037 Genie Z-34/22 IC 5 - 23


Chart 8

Engine HighIdle Inoperative-KubotaGasoline/LPGModelsBe sure mechanicallinkage is not binding ordefective.

Be sure 2-speedsolenoid groundingwires are free ofcorrosion and have fullcontinuity to ground.

Check voltage at blk/redwire on rpm selectswitch.

0V Check voltage at centerterminal on rpm selectswitch.

0VRepair open in circuitsupplying 12V to centerterminal of switch.

12V

Replace rpm selecttoggle switch or replacediode.

12V

Check voltage at TB35.0V

Repair open in blk/redwire circuit from toggleswitch to TB35.

12V


0V Repair open in blk/redwire circuit fromTB35 to terminal #30 onCR3.

12V


Repair open in blk/redwire circuit from CR3 toCR4.



good

Check voltage toterminal #87 on CR3.

0V

12V

Check voltage at initiateterminal #86 on CR4.

0V

Replace CR3 relay.

12V

Start engine and switchrpm select to high idle(rabbit symbol) andcheck to see if the 2speed solenoid pulls in.

solenoid doesnot pull in

solenoidpulls in

Check high idleadjustment (seeMaintenance Section).

5 - 24 Genie Z-34/22 IC Part No. 43037


CHART 8


Check linkage or replacesolenoid.

Check voltage at the blk/red wire on the 2-speedsolenoid.

0V

12V

Check to see if 2-speedsolenoid moves in andout freely.

0V

moves freely

Replace 2-speedsolenoid. Note:resistance acrosssolenoid terminalsshould be approximately0.3 ohms.

solenoidbinds

bad

Repair open in wht wirecircuit from CR2 to CR3to CR4.


Repair ground wire toterminal #85 on CR4.

good


Replace CR4 relay ORrepair open in blk/redwire circuit from terminal#87 on CR4 to 2-speedsolenoid.

12V

Part No. 43037 Genie Z-34/22 IC 5 - 25


Engine Low IdleInoperative -KubotaGasoline/LPGModelsCheck mechanicallinkage from 2-speedsolenoid to carburetor isbinding or defective.

Chart 9

At the platform controls,start engine and switchrpm select switch tomaintained low idle(turtle symbol). Checkvoltage at blk/rd wirewhere it connects to thediode on the rpm selectswitch.

12V Replace defectiveswitch.

0V


solenoidbinds Check linkage or replace

solenoid.

moves freely

Check adjustment oflinkage at low idle. SeeMaintenance SectionOR consult GenieIndustries ServiceDepartment.


12VReplace CR4 relay.

0V

5 - 26 Genie Z-34/22 IC Part No. 43037


Chart 10

Engine HighIdle Inoperative-Kubota DieselModelsBe sure mechanicallinkage is not binding ordefective.

Be sure 2-speedsolenoid groundingwires are free ofcorrosion and have fullcontinuity to ground.

Start engine, switch rpmselect switch to high idle(rabbit symbol) andcheck if 2-speedsolenoid pulls in.

solenoidpulls in

Check high idleadjustment (seeMaintenance section) orsee Kubota workshopmanual to troubleshootfuel injection system.

solenoid doesnot pull in

Check voltage at blk/redwire on rpm selectswitch.

0V Check voltage on redwire at center terminal ofrpm select switch.

0V Repair open in circuitsupplying 12V to centerterminal of switch.

12V

Replace toggle switch.12V


Replace diode ORrepair open in blk/redwire circuit from toggleswitch to TB35.12V

Check voltage at initiateterminal #86 on CR4.

0V Repair open in blk/redwire circuit fromCR3 to CR4.


0V Repair open in blk/redwire circuit from TB35 toterminal #30 on CR3.

12V


12V

0V Repair open in wht wirecircuit from terminal #87on CR2 to terminal #86on CR3.



good



12V

12V


Part No. 43037 Genie Z-34/22 IC 5 - 27


CHART 10

Check voltage at theblk/red wire on the2-speed solenoid.

0V Replace CR4 relayOR repair open inblk/red wire circuit fromterminal #87 on CR4 to2-speed solenoid.

12V

Check if 2-speedsolenoid moves in andout freely.

solenoidbinds Check linkage or

replace solenoid.

moves freely

Replace 2-speedsolenoid. Note:resistance acrosssolenoid terminalsshould be approximately0.3 ohms.



bad Repair ground wire toterminal #85 on CR4.

good


0V Repair open in wht wirecircuit from CR2 to CR3to CR4.

12V

5 - 28 Genie Z-34/22 IC Part No. 43037


Engine Low IdleInoperative -Kubota DieselModelsCheck if mechanicallinkage from 2-speedsolenoid to fuel injectionsystem is binding ordefective.

Chart 11

At platform controls,start engine and switchrpm select switch tomaintained low idle(turtle symbol). Checkvolts at blk/red wire onrpm select switch.

12VIsolate the platform andground rpm switches,check individually andreplace defective switch.

0V

Check voltage at thered wire on the2-speed solenoid.


0V

Check if 2-speedsolenoid moves in andout freely.

solenoidbinds Check linkage or replace

solenoid.

moves freely

Check adjustment oflinkage and fuel injectionsystem low idle. SeeMaintenance section.

ok

See Kubota workshopmanual to troubleshootfuel injection system ORconsult Genie IndustriesService Department.

Part No. 43037 Genie Z-34/22 IC 5 - 29


Chart 12

All FunctionsInoperative,Engine Startsand Runs

Check hydraulicfluid level.

low Fill with Dexronequivalent hydraulicfluid.

ok

Check pump suction lineshutoff valves. Valvehandles should beparallel with hose.

closedOpen valves. If enginehas been run withvalves closed, it mayhave damaged oneor both pumps.

open

Disconnect center coilwire from distributor capand isolate fromgrounding (KubotaDiesel models,disconnect the blk #R1wire from the red wire ofthe fuel solenoid anddisconnect the wht #21wire from the wht wire ofthe fuel solenoid).Remove function pumpfrom main pump butleave all hosesconnected. Hold startswitch and crank engineover while observingfemale spline drive atrear of drive pump.

splineturns

Troubleshootinoperative boomfunctions andinoperative drivefunctions separately.

spline does not turn

Engine to pump flexplate coupling isdefective. SeeRepair section.

5 - 30 Genie Z-34/22 IC Part No. 43037


Chart 13

All Lift andSteer FunctionsInoperative,Drive FunctionsOperationalBe sure the hydraulicsuction line shut-offvalve for the lift steerpump is in the openposition.

Be sure all groundingwires for the functionmanifold valves are freeof corrosion and havefull continuity to ground.

Install a 0 to 5000 PSIpressure gauge onthe function manifold.Start engine, move andhold the rpm switch inthe high rpm position.Hold the boom retractfunction and check thehydraulic pressure.

3200psi ormore

Troubleshoot eachfunction individually orconsult Genie IndustriesService Department.

less than 3200 psi

Adjust the functionmanifold relief valve(item B) all the way in(clockwise) countingthe number of turns.Hold the boom retractswitch and recheckthe pressure.

3200psi ormore

Hold the boom retractswitch and readjustthe relief pressure to3200 psi.

less than 3200 psi

Check the functionpump. See Repairsection.

ok Replace the relief valveOR manifold hasinternal faults. ConsultGenie Industries ServiceDepartment.

bad

Replace the pump.

Check steer functions.steering operates

Repair or replacedifferential sensing valve(item C) OR repair orreplace flow regulatorvalve (item W) ORmanifold has internalfault. Consult GenieIndustries ServiceDepartment.

steering inoperative

Part No. 43037 Genie Z-34/22 IC 5 - 31


GroundControlsInoperative,PlatformControlsOperateNormallyBe sure all otherfunctions operatenormally, includingplatform controls.

Chart 14

Does the engine startfrom the groundcontrols?

yes Start the engine fromthe ground controls andcheck the voltage on thecenter pole (red wire) ofthe platform level switch.

0VRepair open in red wirecircuit from key switch tofunction switches.

12V

Troubleshoot thefunctions individually.

no

Check voltage at redwire on ground controlscontact of the key switch(the red wire checkedshould originate at theemergency stop button).

0VRepair open in red wirecircuit from emergencystop button to thekey switch.

12V

Check voltage at redwire at ground controlscontact on the keyswitch.

0V Check if key switchinternal cam is activatingground contact.

yes Replace key switchcontact for groundcontrols.

no

Replace key switch.12V

Repair open in red wirecircuit from key switch tofunction switches.

5 - 32 Genie Z-34/22 IC Part No. 43037


PlatformControlsInoperative,GroundControlsOperateNormallyBe sure all cables are ingood condition with nokinks or abrasions.

Chart 15

Does engine start fromthe platform controls?

yes Start engine from theplatform, then pressdown the foot switch andcheck voltage atterminal 1 of thehorsepower limiter.

0V

Test and replace footswitch OR repair open inwht wire circuit from footswitch to terminal 1 ofthe horsepower limiter.

12V

Repair open in wht wirecircuit from terminal 1 tofunction toggle switches.

no


Check for open in redwire circuit from keyswitch to TB22 ORreplace the key switchplatform contacts.12V

Check voltage at blk-2wire on platformemergency stop button.

0V Repair open in blk-2wire circuit from TB22to emergency stopbutton.

12V

Check voltage at blkwire on opposite end ofplatform emergency stopbutton.

0V Replace contact onemergency stop button.

12V

Check voltage at wht-2wire connected to diodeon platform emergencystop button.

0V Replace contact onemergency stop buttonOR replace diode.

12V

Repair open in blk wirecircuit from platformemergency stop switchto foot switch ORreplace foot switch ORrepair open in grn wirecircuit from foot switch tostart toggle switch ORconsult Genie IndustriesService Department.

Part No. 43037 Genie Z-34/22 IC 5 - 33


Primary BoomUp FunctionInoperativeBe sure all otherfunctions operatenormally.

If boom up functionoperates normally fromthe ground controls butnot from the platformcontrols, troubleshootthe platform controller ordiode. See RepairSection.

If boom up functionoperates normally fromthe platform controls butnot from the groundcontrols, troubleshootthe ground controltoggle switch OR diodeOR (R1) resistor. SeeRepair Section.

Chart 16

With key switch inground position and bothEmergency Stopswitches pulled out tothe on position, activatethe function enabletoggle switch (TS19, ifequipped) and theprimary boom toggleswitch (TS22) on groundpanel in up direction andcheck voltage on wht/red #6 wire on boomfunction proportionalvalve coil (item D).

0V

12V or more

With key switch inground position and bothEmergency Stopswitches pulled out tothe on position, activatethe function enabletoggle switch (TS19, ifequipped) and theprimary boom toggleswitch (TS22) on groundpanel in up direction andcheck voltage at TB6.

12V ormore

Repair open in wht/red#6 wire circuit from TB6to boom functionproportional valve coil(item D) OR repair openin ground wire circuit tovalve coil (item D).

0V

With key switch inplatform position, bothEmergency Stopswitches pulled out tothe on position andboom function speedcontroller turned to 9,activate footswitch andprimary boom functiontoggle switch (TS8) onplatform control panel inup direction and checkvoltage at TB6.

0V

12V or more

Troubleshoot primaryboom function toggleswitch (TS22) on groundcontrol panel OR repairopen in wht/red #6 wirecircuit from TS22 to TB6OR consult GenieIndustries ServiceDepartment.


Troubleshoot primaryboom function toggleswitches (TS22 andTS8) on ground andplatform control panelsOR repair open in wht/red #6 wire circuit fromTS22 to TB6 and fromTS8 to red wire on boomfunction speed controllerOR consult GenieIndustries ServiceDepartment.

If voltage to TB6 fromTS22 and TS8 has beenrestored and primaryboom up function is stillinoperative, pleasecontinue troubleshootingfrom beginning of chart.

5 - 34 Genie Z-34/22 IC Part No. 43037


CHART 16

With key switch inground position and bothEmergency Stopswitches pulled out tothe on position, activatethe function enabletoggle switch (TS19, ifequipped) and theprimary boom toggleswitch (TS22) on groundpanel in up direction andcheck voltage on red #1wire on boom functiondirectional valve coil(item S).

0V

12V or more

With keyswitch inground position and bothEmergency Stopswitches pulled out tothe on position, activatethe function enabletoggle switch (TS19, ifequipped) and theprimary boom toggleswitch (TS22) on groundpanel in up direction andcheck voltage at TB1.

12V ormore

Repair open in red #1wire circuit from TB1 toboom functiondirectional valve coil(item S) OR repair openin ground circuit tomanifold.

0V

With key switch inplatform position, bothEmergency Stopswitches pulled out intoon position and boomfunction speed controllerturned to 9, activatefootswitch and primaryboom toggle switch(TS8) on platformcontrol panel in updirection and checkvoltage TB1.

0V

12V or more

Troubleshoot primaryboom function toggleswitch (TS22) on groundcontrol panel ORreplace diode on TS22OR repair open in red#1 wire circuit fromTS22 to TB1 OR consultGenie Industries ServiceDepartment.


Troubleshoot primaryboom function toggleswitches (TS22 andTS8) on ground andplatform control panelsOR replace diodes onTS22 and TS8 ORrepair open in red #1wire circuit from TS22and TS8 to TB1 ORconsult Genie IndustriesService Department.

If voltage to TB1 fromTS22 and TS8 has beenrestored and primaryboom up function is stillinoperative, pleasecontinue troubleshootingfrom beginning of chart.


Part No. 43037 Genie Z-34/22 IC 5 - 35


CHART 16

Disconnect wire toprimary boom updirectional valve coil(item S). Remove coiland test resistance.


0 orinfiniteohms

4 to 8 ohms

Replace primary boomup directional valve coil(item S).

Install a 0 to 5000 PSIpressure gauge at thequick disconnectcoupling on the boomfunction manifold andactivate the primaryboom up function.

3200PSI

less than 3200 PSI

Repair cylinder orcylinder counterbalancevalve OR boom functionmanifold could have aninternal defect. ConsultGenie Industries ServiceDepartment.

Check for mechanicalrestrictions keepingprimary boom frommoving OR repaircylinder or cylindercounterbalance valveOR consult GenieIndustries ServiceDepartment.

Exchange primary boomup and down directionalvalves (item S + T) andactivate primary boomup function.

function inoperative

functionoperates Replace defective

directional valve.

5 - 36 Genie Z-34/22 IC Part No. 43037


Primary BoomDown FunctionInoperativeBe sure all otherfunctions operatenormally.

If boom down functionoperates normally fromthe ground controls butnot from the platformcontrols, troubleshootthe platform controller ordiode. See RepairSection.

If boom down functionoperates normally fromthe platform controls butnot from the groundcontrols, troubleshootthe ground controltoggle switch OR diodeOR (R1) resistor. SeeRepair Section.

Chart 17

With key switch inground position and bothEmergency Stopswitches pulled out tothe on position, activatethe function enabletoggle switch (TS19, ifequipped) and theprimary boom toggleswitch (TS22) on groundpanel in down directionand check voltage onwht/red #6 wire on boomfunction proportionalvalve coil (item D).

0V

12V or more

With key switch inground position and bothEmergency Stopswitches pulled out tothe on position, activatethe function enabletoggle switch (TS19, ifequipped) and theprimary boom toggleswitch (TS22) on groundpanel in down directionand check voltage atTB6.

12V ormore

Repair open in wht/red#6 wire circuit from TB6to boom functionproportional valve coil(item D) OR repair openin grn/yel ground wirecircuit to valve coil (itemD).

0V

With key switch inplatform position, bothEmergency Stopswitches pulled out tothe on position, andboom function speedcontroller turned to 9,activate footswitch andprimary boom toggleswitch (TS8) on platformcontrol panel in downdirection and checkvoltage at TB6.

0V

12V or more

Troubleshoot primaryboom function toggleswitch (TS22) on groundcontrol panel OR repairopen in wht/red #6 wirecircuit from TS22 to TB6OR consult GenieIndustries ServiceDepartment.


Troubleshoot primaryboom function toggleswitches (TS22 andTS8) on ground andplatform control panelsOR repair open in wht/red #6 wire circuit fromTS22 to TB6 and fromTS8 to red wire on boomfunction speed controllerOR consult GenieIndustries ServiceDepartment.

If voltage to TB6 fromTS22 and TS8 has beenrestored and primaryboom down function isstill inoperative, pleasecontinue troubleshootingfrom beginning of chart.

Part No. 43037 Genie Z-34/22 IC 5 - 37


CHART 17

With key switch inground position and bothEmergency Stopswitches pulled out tothe on position, activatethe function enabletoggle switch (TS19, ifequipped) and theprimary boom toggleswitch (TS22) on groundpanel in down directionand check voltage onred/blk #2 wire on boomfunction directional valvecoil (item T).

0V

12V or more

With key switch inground position and bothEmergency Stopswitches pulled out tothe on position, activatethe function enabletoggle switch (TS19, ifequipped) and theprimary boom toggleswitch (TS22) on groundpanel in down directionand check voltage atTB2.

12V ormore

Repair open in red/blk#2 wire circuit from TB2to boom functiondirectional valve coil(item T) OR repair openin ground circuit tomanifold.

0V

With key switch inplatform position, bothEmergency Stopswitches pulled out tothe on position andboom function speedcontroller turned to 9,activate footswitch andprimary boom functiontoggle switch (TS8) onplatform control panel indown direction andcheck voltage TB2.

0V

12V or more

Troubleshoot primaryboom function toggleswitch (TS22) on groundcontrol panel ORreplace diode on TS22OR repair open in red/blk #2 wire circuit fromTS22 to TB2 OR consultGenie Industries ServiceDepartment.


Troubleshoot primaryboom function toggleswitches (TS22 andTS8) on ground andplatform control panelsOR replace diodes onTS22 and TS8 ORrepair open in red/blk #2wire circuit from TS22and TS8 to TB2 ORconsult Genie IndustriesService Department.

If voltage to TB2 fromTS22 and TS8 has beenrestored and primaryboom down function isstill inoperative, pleasecontinue troubleshootingfrom beginning of chart.


5 - 38 Genie Z-34/22 IC Part No. 43037


CHART 17

Disconnect wire toprimary boom downdirectional valve coil(item T). Remove coiland test resistance.


0 orinfiniteohms

4 to 8ohms

Replace primary boomdown directional valvecoil (item T).

Install a 0 to 3000 PSIpressure gauge at thequick disconnectcoupling on the boomfunction manifold andactivate the primaryboom down function.

1400PSI

less than 1400 PSI

Reset primary downrelief (item K) pressureOR replace primarydown relief valve (itemK) OR repair cylinder orcylinder counterbalancevalve OR boom functionmanifold could have aninternal defect. ConsultGenie Industries ServiceDepartment.

Check for mechanicalrestrictions keepingprimary boom frommoving OR repaircylinder or cylindercounterbalance valveOR consult GenieIndustries ServiceDepartment.

Exchange primary boomdown and up directionalvalves (item T + S) andactivate primary boomdown function.



directional valve.

Part No. 43037 Genie Z-34/22 IC 5 - 39


SecondaryBoom UpFunctionInoperativeBe sure all otherfunctions operatenormally.

If secondary boom upfunction operatesnormally from theground controls but notfrom the platformcontrols, troubleshootthe platform controller ordiode. See RepairSection.

If secondary boom upfunction operatesnormally from theplatform controls but notfrom the groundcontrols, troubleshootthe ground controltoggle switch OR diodeOR (R1) resistor. SeeRepair Section.

Chart 18

With key switch inground position and bothEmergency Stopswitches pulled out tothe on position, activatethe function enabletoggle switch (TS19, ifequipped) and thesecondary boom toggleswitch (TS21) on groundpanel in up direction andcheck voltage on wht/red #6 wire on boomfunction proportionalvalve coil (item D).

0V

12V or more

With key switch inground position and bothEmergency Stopswitches pulled out tothe on position, activatethe function enabletoggle switch (TS19, ifequipped) and thesecondary boom toggleswitch (TS21) on groundpanel in up direction andcheck voltage at TB6.

12V ormore


0V

With key switch inplatform position, bothEmergency Stopswitches pulled out tothe on position andboom function speedcontroller turned to 9,activate footswitch andsecondary boomfunction toggle switch(TS7) on platformcontrol panel in updirection and checkvoltage at TB6.

0V

12V or more

Troubleshoot secondaryboom function toggleswitch (TS21) on groundcontrol panel OR repairopen in wht/red #6 wirecircuit from TS21 to TB6OR consult GenieIndustries ServiceDepartment.


Troubleshoot secondaryboom function toggleswitches (TS21 andTS7) on ground andplatform control panelsOR repair open in wht/red #6 wire circuit fromTS21 to TB6 and fromTS7 to red wire on boomfunction speed controllerOR consult GenieIndustries ServiceDepartment.

If voltage to TB6 fromTS21 and TS7 has beenrestored and secondaryboom up function is stillinoperative, pleasecontinue troubleshootingfrom beginning of chart.

5 - 40 Genie Z-34/22 IC Part No. 43037


CHART 18

With key switch inground position and bothEmergency Stopswitches pulled out tothe on position, activatethe function enabletoggle switch (TS19, ifequipped) and thesecondary boom toggleswitch (TS21) on groundpanel in up direction andcheck voltage on blu#10 wire on boomfunction directional valvecoil (item Q).

0V

12V or more

With key switch inground position and bothEmergency Stopswitches pulled out tothe on position, activatethe function enabletoggle switch (TS19, ifequipped) and thesecondary boom toggleswitch (TS21) on groundpanel in up direction andcheck voltage at TB10.

12V ormore

Repair open in blu #10wire circuit from TB10 toboom functiondirectional valve coil(item Q) OR repair openin ground wire circuit tomanifold (item Q).

0V

With key switch inplatform position, bothEmergency Stopswitches pulled out tothe on position andboom function speedcontroller turned to 9,activate footswitch andsecondary boom toggleswitch (TS7) on platformcontrol panel in updirection and checkvoltage at TB10.

0V

12V or more

Troubleshoot secondaryboom function toggleswitch (TS21) on groundcontrol panel ORreplace diode on TS21OR repair open in blu#10 wire circuit fromTS21 to TB10 ORconsult Genie IndustriesService Department.


Troubleshoot secondaryboom function toggleswitches (TS21 andTS7) on ground andplatform control panelsOR replace diodes onTS21 and TS2 ORrepair open in blu #10wire circuit from TS21and TS7 to TB10 ORconsult Genie IndustriesService Department.

If voltage to TB10 fromTS21 and TS7 has beenrestored and secondaryboom up function is stillinoperative, pleasecontinue troubleshootingfrom beginning of chart.


Part No. 43037 Genie Z-34/22 IC 5 - 41


CHART 18

Disconnect wire tosecondary boom updirectional valve coil(item Q). Remove coiland test resistance.


0 orinfiniteohms

4 to 8 ohms

Replace secondaryboom up directionalvalve coil (item Q).

Install a 0 to 5000 PSIpressure gauge at thequick disconnectcoupling on the boomfunction manifold andactivate the secondaryboom up function.

3200PSI

less than 3200 PSI

Repair cylinder orcylinder counterbalancevalve OR boom functionmanifold could have aninternal fault. ConsultGenie Industries ServiceDepartment.

Check for mechanicalrestrictions keepingsecondary boom frommoving OR repaircylinder or cylindercounterbalance valveOR consult GenieIndustries ServiceDepartment.

Exchange secondaryboom up and downdirectional valves (itemQ + P) and activatesecondary boom upfunction.



directional valve.

5 - 42 Genie Z-34/22 IC Part No. 43037


SecondaryBoom DownFunctionInoperativeBe sure all otherfunctions operatenormally.

If secondary boomdown function operatesnormally from theground controls but notfrom the platformcontrols, troubleshootthe platform controller ordiode. See RepairSection.

If secondary boomdown function operatesnormally from theplatform controls but notfrom the groundcontrols, troubleshootthe ground controltoggle switch OR diodeOR (R1) resistor. SeeRepair Section.

Chart 19

With key switch inground position and bothEmergency Stopswitches pulled out tothe on position, activatethe function enabletoggle switch (TS19, ifequipped) and thesecondary boom toggleswitch (TS21) on groundpanel in down directionand check voltage onwht/red #6 wire on boomfunction proportionalvalve coil (item D).

0V

12V or more

With key switch inground position and bothEmergency Stopswitches pulled out tothe on position, activatethe function enabletoggle switch (TS19, ifequipped) and thesecondary boom toggleswitch (TS21) on groundpanel in down directionand check voltage atTB6.

12V ormore


0V

With key switch inplatform position, bothEmergency Stopswitches pulled out tothe on position andboom function speedcontroller turned to 9,activate footswitch andsecondary boom toggleswitch (TS7) on platformcontrol panel in downdirection and checkvoltage at TB6.

0V

12V or more

Troubleshoot secondaryboom function toggleswitch (TS21) on groundcontrol panel OR repairopen in wht/red #6 wirecircuit from TS21 to TB6OR consult GenieIndustries ServiceDepartment.


Troubleshoot secondaryboom function toggleswitches (TS21 andTS7) on ground andplatform control panelsOR repair open in wht/red #6 wire circuit fromTS21 to TB6 and fromTS7 to red wire on boomfunction speed controllerOR consult GenieIndustries ServiceDepartment.

If voltage to TB6 fromTS21 and TS7 has beenrestored and secondaryboom down function isstill inoperative, pleasecontinue troubleshootingfrom beginning of chart.

Part No. 43037 Genie Z-34/22 IC 5 - 43


CHART 19

With key switch inground position and bothEmergency Stopswitches pulled out tothe on position, activatethe function enabletoggle switch (TS19, ifequipped) and thesecondary boom toggleswitch (TS21) on groundpanel in down directionand check voltage onblu/blk #11 wire onboom functiondirectional valve coil(item R).

0V

12V or more

With key switch inground position and bothEmergency Stopswitches pulled out tothe on position, activatethe function enabletoggle switch (TS19, ifequipped) and thesecondary boom toggleswitch (TS21) on groundpanel in down directionand check voltage atTB11.

12V ormore

Repair open in blu/blk#11 wire circuit fromTB11 to boom functiondirectional valve coil(item R) OR repair openin ground wire circuit tomanifold (item R).

0V

With key switch inplatform position, bothEmergency Stopswitches pulled out tothe on position andboom function speedcontroller turned to 9,activate footswitch andsecondary boomfunction toggle switch(TS7) on platformcontrol panel in downdirection and checkvoltage TB11.

0V

12V or more

Troubleshoot secondaryboom function toggleswitch (TS21) on groundcontrol panel ORreplace diode on TS21OR repair open in blu/blk #11 wire circuit fromTS21 to TB11 ORconsult Genie IndustriesService Department.


Troubleshoot secondaryboom function toggleswitches (TS21 andTS7) on ground andplatform control panelsOR replace diodes onTS21 and TS7 ORrepair open in blu/blk#11 wire circuit fromTS21 and TS7 to TB11OR consult GenieIndustries ServiceDepartment.

If voltage to TB11 fromTS21 and TS7 has beenrestored and secondaryboom down function isstill inoperative pleasecontinue troubleshootingfrom beginning of chart.


5 - 44 Genie Z-34/22 IC Part No. 43037


CHART 19

Disconnect wire tosecondary boom downdirectional valve coil(item R). Remove coiland test resistance.


0 orinfiniteohms

4 to 8 ohms

Replace secondaryboom down directionalvalve coil (item R).

Install a 0 to 3000 PSIpressure gauge at thequick disconnectcoupling on the boomfunction manifold andactivate the secondaryboom down function.

1600PSI

less than 1600 PSI

Reset secondary downrelief (item J) pressureOR replace secondarydown relief valve (itemJ) OR repair cylinder orcylinder counterbalancevalve OR boom functionmanifold could have aninternal fault. ConsultGenie Industries ServiceDepartment.

Check for mechanicalrestrictions keepingsecondary boom frommoving OR repaircylinder or cylindercounterbalance valveOR consult GenieIndustries ServiceDepartment.

Exchange secondaryboom down and updirectional valves (itemR + Q) and activatesecondary boom downfunction.



directional valve.

Part No. 43037 Genie Z-34/22 IC 5 - 45


Primary BoomExtendFunctionInoperativeBe sure all otherfunctions operatenormally.

If primary boom extendfunction operatesnormally from theground controls but notfrom the platformcontrols, troubleshootthe platform controller ordiode. See RepairSection.

If primary boom extendfunction operatesnormally from theplatform controls but notfrom the groundcontrols, troubleshootthe ground controltoggle switch OR diodeOR (R1) resistor. SeeRepair Section.

Chart 20

With key switch inground position and bothEmergency Stopswitches pulled out tothe on position, activatethe function enabletoggle switch (TS19, ifequipped) and the ext./ret. boom toggle switch(TS23) on ground panelin extend direction andcheck voltage on wht/red #6 wire on boomfunction proportionalvalve coil (item D).

0V

12V or more

With key switch inground position and bothEmergency Stopswitches pulled out tothe on position, activatethe function enabletoggle switch (TS19, ifequipped) and the ext./ret. boom toggle switch(TS23) on ground panelin extend direction andcheck voltage at TB6.

12V ormore

Repair open in wht/red#6 wire circuit from TB6to boom functionproportional valve coil(item D) OR open inground wire circuit tovalve coil (item D).

0V

With key switch inplatform position, bothEmergency Stopswitches pulled out tothe on position andboom function speedcontroller turned to 9,activate footswitch andext./ret. boom toggleswitch (TS9) on platformcontrol panel in extenddirection and checkvoltage at TB6.

0V

12V or more

Troubleshoot ext./ret.boom function toggleswitch (TS23) on groundcontrol panel OR repairopen in wht/red #6 wirecircuit from TS23 to TB6OR consult GenieIndustries ServiceDepartment.


Troubleshoot ext./ret.boom function toggleswitches (TS23 andTS9) on ground andplatform control panelsOR repair open in wht/red #6 wire circuit fromTS23 to TB6 and fromTS9 to red wire on boomfunction speed controllerOR consult GenieIndustries ServiceDepartment.

If voltage to TB6 fromTS23 and TS9 has beenrestored and boomextend function is stillinoperative, pleasecontinue troubleshootingfrom beginning of chart.

5 - 46 Genie Z-34/22 IC Part No. 43037


CHART 20

With key switch inground position and bothEmergency Stopswitches pulled out tothe on position, activatethe function enabletoggle switch (TS19, ifequipped) and the ext./ret. boom toggle switch(TS23) on ground panelin extend direction andcheck voltage on blk #7wire on boom functiondirectional valve coil(item U).

0V

12V or more

With key switch inground position and bothEmergency Stopswitches pulled out tothe on position, activatethe function enabletoggle switch (TS19, ifequipped) and the ext./ret. boom toggle switch(TS23) on ground panelin extend direction andcheck voltage at TB7.

12V ormore

Repair open in blk #7wire circuit from TB7 toboom functiondirectional valve coil(item U) OR repair openin ground wire circuit tomanifold (item U).

0V

With key switch inplatform position, bothEmergency Stopswitches pulled out tothe on position andboom function speedcontroller turned to 9,activate footswitch andext./ret. boom functiontoggle switch (TS9) onplatform control panel inextend direction andcheck voltage TB7.

0V

12V or more

Troubleshoot ext./ret.boom function toggleswitch (TS23) on groundcontrol panel ORreplace diode on TS23OR repair open in blk #7wire circuit from TS23 toTB7 OR consult GenieIndustries ServiceDepartment.


Troubleshoot ext./ret.boom function toggleswitches (TS23 andTS9) on ground andplatform control panelsOR replace diodes onTS23 and TS9 ORrepair open in blk #7wire circuit from TS23and TS9 to TB7 ORconsult Genie IndustriesService Department.

If voltage to TB7 fromTS23 and TS9 has beenrestored and boomextend function is stillinoperative, pleasecontinue troubleshootingfrom beginning of chart.


Part No. 43037 Genie Z-34/22 IC 5 - 47


CHART 20

Disconnect wire to boomextend directional valvecoil (item U). Removecoil and test resistance.


0 orinfiniteohms

4 to 8 ohms

Replace primary boomextend directional valvecoil (item U).

Install a 0 to 3000 PSIpressure gauge at thequick disconnectcoupling on the boomfunction manifold andactivate the extendboom function.

1800PSI

less than 1800 PSI

Reset extend relief (itemL) pressure OR replacesecondary down reliefvalve (item L) OR repaircylinder or cylindercounterbalance valveOR boom functionmanifold could have aninternal fault. ConsultGenie Industries ServiceDepartment.

Check for mechanicalrestrictions keepingextension boom frommoving OR repaircylinder or cylindercounterbalance valveOR consult GenieIndustries ServiceDepartment.

Exchange primary boomextend and retractdirectional valves (itemU + V) and activateprimary boom extendfunction.



directional valve.

5 - 48 Genie Z-34/22 IC Part No. 43037


Primary BoomRetractFunctionInoperativeBe sure all otherfunctions operatenormally.

If primary boom retractfunction operatesnormally from theground controls but notfrom the platformcontrols, troubleshootthe platform controller ordiode. See RepairSection.

If primary boom retractfunction operatesnormally from theplatform controls but notfrom the groundcontrols, troubleshootthe ground controltoggle switch OR diodeOR (R1) resistor. SeeRepair Section.

Chart 21

With key switch inground position and bothEmergency Stopswitches pulled out tothe on position, activatethe function enabletoggle switch (TS19, ifequipped) and the ext./ret. boom toggle switch(TS23) on ground panelin retract direction andcheck voltage on wht/red #6 wire on boomfunction proportionalvalve coil (item D).

0V

12V or more

With key switch inground position and bothEmergency Stopswitches pulled out tothe on position, activatethe function enabletoggle switch (TS19, ifequipped) and the ext./ret. boom toggle switch(TS23) on ground panelin retract direction andcheck voltage at TB6.

12V ormore


0V

With key switch inplatform position, bothEmergency Stopswitches pulled out tothe on position andboom function speedcontroller turned to 9activate footswitch andext./ret. boom functiontoggle switch (TS9) onplatform control panel inretract direction andcheck voltage at TB6.

0V

12V or more

Troubleshoot ext./ret.boom function toggleswitch (TS23) on groundcontrol panel OR repairopen in wht/red #6 wirecircuit from TS23 to TB6OR consult GenieIndustries ServiceDepartment.


Troubleshoot ext./ret.boom function toggleswitches (TS23 andTS9) on ground andplatform control panelsOR repair open in wht/red #6 wire circuit fromTS23 to TB6 and fromTS9 to red wire on boomfunction speed controllerOR consult GenieIndustries ServiceDepartment.

If voltage to TB6 fromTS23 and TS9 has beenrestored and retractfunction is stillinoperative, pleasecontinue troubleshootingfrom beginning of chart.

Part No. 43037 Genie Z-34/22 IC 5 - 49


CHART 21

With key switch inground position and bothEmergency Stopswitches pulled out tothe on position, activatethe function enabletoggle switch (TS19, ifequipped) and the ext./ret. boom toggle switch(TS23) on ground panelin retract direction andcheck voltage on blk/wht#8 wire on boomfunction directional valvecoil (item V).

0V

12V or more

With key switch inground position and bothEmergency Stopswitches pulled out tothe on position, activatethe function enabletoggle switch (TS19, ifequipped) and the ext./ret. boom toggle switch(TS23) on ground panelin retract direction andcheck voltage at TB8.

12V ormore

Repair open in blk/wht#8 wire circuit from TB8to boom functiondirectional valve coil(item V) OR repair openin ground wire circuit tomanifold (item V).

0V

With key switch inplatform position, bothEmergency Stopswitches pulled out tothe on position andboom function speedcontroller turned to 9,activate footswitch andext./ret. boom toggleswitch (TS9) on platformcontrol panel in retractdirection and checkvoltage to TB8.

0V

12V or more

Troubleshoot ext./ret.boom function toggleswitch (TS23) on groundcontrol panel ORreplace diode on TS23OR repair open in blk/wht #8 wire circuit fromTS23 to TB8 OR consultGenie Industries ServiceDepartment.


Troubleshoot ext./ret.boom function toggleswitches (TS23 andTS9) on ground andplatform control panelsOR replace diodes onTS23 and TS9 ORrepair open in blk/wht #8wire circuit from TS23and TS9 to TB8 ORconsult Genie IndustriesService Department.

If voltage to TB8 fromTS23 and TS9 has beenrestored and boomretract function is stillinoperative, pleasecontinue troubleshootingfrom beginning of chart.


5 - 50 Genie Z-34/22 IC Part No. 43037


CHART 21

Disconnect wire to boomretract directional valvecoil (item V). Removecoil and test resistance.


0 orinfiniteohms

4 to 8 ohms

Replace retract boom updirectional valve coil(item V).

Install a 0 to 5000 PSIpressure gauge at thequick disconnectcoupling on the boomfunction manifold andactivate the retractboom function.

3200PSI

less than 3200 PSI

Repair cylinder orcylinder counterbalancevalve OR boom functionmanifold could have aninternal fault. ConsultGenie Industries ServiceDepartment.

Check for mechanicalrestrictions keepingextension boom frommoving OR repaircylinder or cylindercounterbalance valveOR consult GenieIndustries ServiceDepartment.

Exchange primary boomextend and retractdirectional valves (itemU + V) and activateprimary boom retractfunction.



directional valve.

Part No. 43037 Genie Z-34/22 IC 5 - 51


TurntableRotate LeftFunctionInoperativeBe sure all otherfunctions operatenormally.

If turntable rotate leftfunction operatesnormally from theground controls but notfrom the platformcontrols, troubleshootthe platform controller ordiode. See RepairSection.

If turntable rotate leftfunction operatesnormally from theplatform controls but notfrom the groundcontrols, troubleshootthe ground controltoggle switch OR diodeOR (R1) resistor. SeeRepair Section.

Chart 22

With key switch inground position and bothEmergency Stopswitches pulled out tothe on position, activatethe function enabletoggle switch (TS19, ifequipped) and theturntable rotate toggleswitch (TS20) on groundpanel in left directionand check voltage onwht/red #6 wire on boomfunction proportionalvalve coil (item D).

0V

12V or more

With key switch inground position and bothEmergency Stopswitches pulled out tothe on position, activatethe function enabletoggle switch (TS19, ifequipped) and theturntable rotate toggleswitch (TS20) on groundpanel in left directionand check voltage atTB6.

12V ormore


0V

With key switch inplatform position, bothEmergency Stopswitches pulled out tothe on position andboom function speedcontroller turned to 9,activate footswitch andturntable rotate toggleswitch (TS6) on platformcontrol panel in leftdirection and checkvoltage at TB6.

0V

12V or more

Troubleshoot turntablerotate function toggleswitch (TS20) on groundcontrol panel OR repairopen in wht/red #6 wirecircuit from TS20 to TB6OR consult GenieIndustries ServiceDepartment.


Troubleshoot turntablerotate function toggleswitches (TS20 andTS6) on ground andplatform control panelsOR repair open in wht/red #6 wire circuit fromTS20 to TB6 and fromTS6 to red wire on boomfunction speed controllerOR consult GenieIndustries ServiceDepartment.

If voltage to TB6 fromTS20 and TS6 has beenrestored and turntablerotate left function is stillinoperative, pleasecontinue troubleshootingfrom beginning of chart.

5 - 52 Genie Z-34/22 IC Part No. 43037


CHART 22

With key switch inground position and bothEmergency Stopswitches pulled out tothe on position, activatethe function enabletoggle switch (TS19, ifequipped) andtheturntable rotatetoggle switch (TS20) onground panel in leftdirection and checkvoltage on wht #4 wireon boom functiondirectional valve coil(item P).

0V

12V or more

With key switch inground position and bothEmergency Stopswitches pulled out tothe on position, activatethe function enabletoggle switch (TS19, ifequipped) and theturntable rotate toggleswitch (TS20) on groundpanel in left directionand check voltage atTB4.

12V ormore

Repair open in wht #4wire circuit from TB10 toboom functiondirectional valve coil(item P) OR repair openin ground wire circuit tomanifold (item P).

0V

With key switch inplatform position, bothEmergency Stopswitches pulled out tothe on position andboom function speedcontroller turned to 9,activate footswitch andturntable rotate functiontoggle switch (TS6) onplatform control panel inleft direction and checkvoltage at TB4.

0V

12V or more

Troubleshoot turntablerotate function toggleswitch (TS20) on groundcontrol panel ORreplace diode on TS20OR repair open in wht#4 wire circuit fromTS20 to TB4 OR consultGenie Industries ServiceDepartment.


Troubleshoot turntablerotate function toggleswitches (TS20 andTS6) on ground andplatform control panelsOR replace diodes onTS20 and TS6 ORrepair open in wht #4wire circuit from TS20and TS6 to TB4 ORconsult Genie IndustriesService Department.

If voltage to TB4 fromTS20 and TS6 has beenrestored and turntablerotate left function is stillinoperative, pleasecontinue troubleshootingfrom beginning of chart.


Part No. 43037 Genie Z-34/22 IC 5 - 53


CHART 22

Disconnect wire toturntable rotate leftdirectional valve coil(item P). Remove coiland test resistance.


0 orinfiniteohms

4 to 8 ohms

Replace turntable rotateleft directional valve coil(item P).

Install a 0 to 3000 PSIpressure gauge at thequick disconnectcoupling on the boomfunction manifold andactivate the turntablerotate left function.

1750PSI

less than 1750 PSI

Reset turntable rotateleft relief (item H)pressure OR replaceturntable rotate left reliefvalve (item H) OR repairhydraulic motor or wormgear OR boom functionmanifold could have aninternal fault. ConsultGenie Industries ServiceDepartment.

Check for mechanicalrestrictions keepingturntable rotate leftfunction from movingOR the 0.050 orifice(item X) could beplugged OR repairhydraulic motor or wormgear OR consult GenieIndustries ServiceDepartment.

Exchange turntablerotate left and rightdirectional valve's (itemP + O) and activateturntable rotate leftfunction.



directional valve.

5 - 54 Genie Z-34/22 IC Part No. 43037


TurntableRotate RightFunctionInoperativeBe sure all otherfunctions operatenormally.

If turntable rotate rightfunction operatesnormally from theground controls but notfrom the platformcontrols, troubleshootthe platform controller ordiode. See RepairSection.

If turntable rotate rightfunction operatesnormally from theplatform controls but notfrom the groundcontrols, troubleshootthe ground controltoggle switch OR diodeOR (R1) resistor. SeeRepair Section.

Chart 23

With key switch inground position and bothEmergency Stopswitches pulled out tothe on position, activatethe function enabletoggle switch (TS19, ifequipped) and theturntable rotate toggleswitch (TS20) on groundpanel in right directionand check voltage onwht/red #6 wire on boomfunction proportionalvalve coil (item D).

0V

12V or more

With key switch inground position and bothEmergency Stopswitches pulled out tothe on position, activatethe function enabletoggle switch (TS19, ifequipped) and theturntable rotate toggleswitch (TS20) on groundpanel in right directionand check voltage atTB6.

12V ormore


0V

With key switch inplatform position, bothEmergency Stopswitches pulled out tothe on position andboom function speedcontroller turned to 9,activate footswitch andturntable rotate toggleswitch (TS6) on platformcontrol panel in rightdirection and checkvoltage at TB6.

0V

12V or more

Troubleshoot turntablerotate function toggleswitch, (TS20), onground control panel ORrepair open in wht/red#6 wire circuit fromTS20 to TB6 OR consultGenie Industries ServiceDepartment.


Troubleshoot turntablerotate function toggleswitches (TS20 andTS6) on ground andplatform control panelsOR repair open in wht/red #6 wire circuit fromTS20 to TB6 and fromTS6 to red wire on boomfunction speed controllerOR consult GenieIndustries ServiceDepartment.

If voltage to TB6 fromTS20 and TS6 has beenrestored and turntablerotate right function isstill inoperative, pleasecontinue troubleshootingfrom beginning of chart.

Part No. 43037 Genie Z-34/22 IC 5 - 55


CHART 23

With key switch inground position and bothEmergency Stopswitches pulled out tothe on position, activatethe function enabletoggle switch (TS19, ifequipped) and theturntable rotate toggleswitch (TS20) on groundpanel in right directionand check voltage onwht/blk #5 wire on boomfunction directional valvecoil (item O).

0V

12V or more

With key switch inground position and bothEmergency Stopswitches pulled out tothe on position, activatethe function enabletoggle switch (TS19, ifequipped) and theturntable rotate toggleswitch (TS20) on groundpanel in right directionand check voltage atTB5.

12V ormore

Repair open in wht/blk#5 wire circuit from TB5to boom functiondirectional valve coil(item O) OR repair openin ground wire circuit tomanifold (item O).

0V

With key switch inplatform position, bothEmergency Stopswitches pulled out tothe on position andboom function speedcontroller turned to 9,activate footswitch andturntable rotate functiontoggle switch (TS6) onplatform control panel inright direction and checkvoltage at TB5.

0V

12V or more

Troubleshoot turntablerotate function toggleswitch (TS20) on groundcontrol panel ORreplace diode on TS20OR repair open in wht/blk #5 wire circuit fromTS20 to TB5 OR consultGenie Industries ServiceDepartment.


Troubleshoot turntablerotate function toggleswitches (TS20 andTS6) on ground andplatform control panelsOR replace diodes onTS20 and TS6 ORrepair open in wht/blk #5wire circuit from TS20and TS6 to TB5 ORconsult Genie IndustriesService Department.

If voltage to TB5 fromTS20 and TS6 has beenrestored and turntablerotate right function isstill inoperative, pleasecontinue troubleshootingfrom beginning of chart.


5 - 56 Genie Z-34/22 IC Part No. 43037


CHART 23

Disconnect wire toturntable rotate rightdirectional valve coil(item O). Remove coiland test resistance.


0 orinfiniteohms

4 to 8 ohms

Replace turntable rotateright directional valvecoil (item O).

Install a 0 to 3000 PSIpressure gauge at thequick disconnectcoupling on the boomfunction manifold andactivate the turntablerotate right function.

1750PSI

less than 1750 PSI

Reset turntable rotateright relief (item I)pressure OR replaceturntable rotate rightrelief valve (item I) ORrepair hydraulic motor orworm gear OR boomfunction manifold couldhave an internal fault.Consult Genie IndustriesService Department.

Check for mechanicalrestrictions keepingturntable rotate rightfunction from movingOR the 0.050 orifice(item X) could beplugged OR repairhydraulic motor or wormgear OR consult GenieIndustries ServiceDepartment.

Exchange turntablerotate left and rightdirectional valves (itemP + O) and activateturntable rotate rightfunction.



directional valve.

Part No. 43037 Genie Z-34/22 IC 5 - 57


Chart 24

All PlatformLevelingFunctionsInoperativeBe sure all otherfunctions operatenormally.

Be sure both automaticand manual platformleveling do not operate.

If automatic levelingoperates but manualleveling does not,troubleshoot platformleveling up functioninoperative.

Remove both hydraulichoses from the manifold(ports C1 & C2) andinstall adjustable orificevalves. Then reconnectthe hydraulic hoses withvalves to manifold.Bleed the system, seeRepair Procedures.Close the adjustableorifice valves. Operateprimary boom upfunction and check ifplatform levels.

no

Plumb a pressure gaugeinto the barrel-endhydraulic hose (hoseconnected to port C1)using a tee fitting.Operate primary boomup function and read thepressure.

less than 2000 PSI

Deadhead the pressuregauge into the barrel-end hydraulic hose fromthe master cylinder andraise the primary boomone inch at a time.Continually monitor thepressure gauge duringboom up. Do not allowthe pressure to exceed2500 PSI.

2000 PSI or more

Repair or replace theslave cylinder.

Replace thecounterbalance valveson function manifold(items F & G).

yes

2000PSI

Check for mechanicalrestrictions OR replacethe slave cylindercounterbalance valves.

less than 2000 PSI Repair or replace themaster cylinder.

5 - 58 Genie Z-34/22 IC Part No. 43037


Chart 25

Platform LevelUp FunctionInoperativeBe sure all otherfunctions operatenormally.

If platform level upfunction operatesnormally from theground controls but notfrom the platformcontrols, troubleshootthe platform controller ordiode. See RepairSection.

If platform level upfunction operatesnormally from theplatform controls but notfrom the groundcontrols, troubleshootthe ground controltoggle switch OR diodeOR (R1) resistor. SeeRepair Section.

With key switch inground position and bothEmergency Stopswitches pulled out tothe on position, activatethe function enabletoggle switch (TS19, ifequipped) and theplatform level toggleswitch (TS24) on groundpanel in up direction andcheck voltage on wht/red #6 wire on boomfunction proportionalvalve coil (item D).

0V

12V or more

With key switch inground position and bothEmergency Stopswitches pulled out tothe on position, activatethe function enabletoggle switch (TS19, ifequipped) and theplatform level toggleswitch (TS24) on groundpanel in up direction andcheck voltage at TB6.

12V ormore


0V

With key switch inplatform position, bothEmergency Stopswitches pulled out tothe on position andboom function speedcontroller turned to 9,activate footswitch andplatform level toggleswitch (TS10) onplatform control panel inup direction and checkvoltage at TB6.

0V

12V or more

Troubleshoot platformlevel function toggleswitch (TS24) on groundcontrol panel OR repairopen in wht/red #6 wirecircuit from TS24 to TB6OR consult GenieIndustries ServiceDepartment.


Troubleshoot platformlevel function toggleswitches (TS24 andTS10) on ground andplatform control panelsOR repair open in wht/red #6 wire circuit fromTS24 to TB6 and fromTS10 to red wire onboom function speedcontroller OR consultGenie Industries ServiceDepartment.

If voltage to TB6 fromTS24 and TS10 hasbeen restored andplatform level upfunction is stillinoperative, pleasecontinue troubleshootingfrom beginning of chart.

Part No. 43037 Genie Z-34/22 IC 5 - 59


CHART 25

With key switch inground position and bothEmergency Stopswitches pulled out tothe on position, activatethe function enabletoggle switch (TS19, ifequipped) and theplatform level toggleswitch (TS24) on groundpanel in up direction andcheck voltage on org#14 wire on boomfunction directional valvecoil (item M).

0V

12V or more

With key switch inground position and bothEmergency Stopswitches pulled out tothe on position, activatethe function enabletoggle switch (TS19, ifequipped) andtheplatform level toggleswitch (TS24) on groundpanel in up direction andcheck voltage at TB14.

20V ormore

Repair open in org #14wire circuit from TB14 toboom functiondirectional valve coil(item M) OR repair openin ground wire circuit tomanifold (item M).

0V

With key switch inplatform position, bothEmergency Stopswitches pulled out tothe on position andboom function speedcontroller turned to 9,activate footswitch andplatform level functiontoggle switch (TS10) onplatform control panel inup direction and checkvoltage at TB14.

0V

12V or more

Troubleshoot platformlevel function toggleswitch (TS24) on groundcontrol panel ORreplace diode on TS24OR repair open in org#14 wire circuit fromTS24 to TB14 ORconsult Genie IndustriesService Department.


Troubleshoot platformlevel function toggleswitches (TS24 andTS10) on ground andplatform control panelsOR replace diodes onTS24 and TS10 ORrepair open in org #14wire circuit from TS24and TS10 to TB14 ORconsult Genie IndustriesService Department.

If voltage to TB14 fromTS24 and TS10 hasbeen restored andplatform level upfunction is stillinoperative, pleasecontinue troubleshootingfrom beginning of chart.


5 - 60 Genie Z-34/22 IC Part No. 43037


CHART 25

Disconnect wire toplatform level updirectional valve coil(item M). Remove coiland test resistance.


0 orinfiniteohms

4 to 8 ohms

Replace platform levelup directional valve coil(item M).

Install a 0 to 5000 PSIpressure gauge at thequick disconnectcoupling on the boomfunction manifold andactivate the platformlevel up function.

3200PSI

less than 3200 PSI

Test master cylinder(refer to Chart #22) ORrepair or replace slavecylinder or slave cylindercounterbalance valvesOR boom functionmanifold could have aninternal fault. ConsultGenie Industries ServiceDepartment.

Check for mechanicalrestrictions keepingplatform level upfunction from movingOR replace slavecylinder OR replaceslave cylindercounterbalance valvesOR consult GenieIndustries ServiceDepartment.

Exchange platform levelup and down directionalvalves (item M + N) andactivate platform levelup function.



directional valve.

Exchange platform levelup and downcounterbalance valves(item F + G) andactivate platform levelup function.



counterbalance valve.

Part No. 43037 Genie Z-34/22 IC 5 - 61


Platform LevelDown FunctionInoperativeBe sure all otherfunctions operatenormally.

If platform level downfunction operatesnormally from theground controls but notfrom the platformcontrols, troubleshootthe platform controller ordiode. See RepairSection.

If platform level downfunction operatesnormally from theplatform controls but notfrom the groundcontrols, troubleshootthe ground controltoggle switch OR diodeOR (R1) resistor. SeeRepair Section.

Chart 26

With key switch inground position and bothEmergency Stopswitches pulled out tothe on position, activatethe function enabletoggle switch (TS19, ifequipped) andtheplatform level toggleswitch (TS24) on groundpanel in down directionand check voltage onwht/red #6 wire on boomfunction proportionalvalve coil (item D).

0V

12V or more

With key switch inground position and bothEmergency Stopswitches pulled out tothe on position, activatethe function enabletoggle switch (TS19, ifequipped) andtheplatform level toggleswitch (TS24) on groundpanel in down directionand check voltage atTB6.

12V ormore


0V

With key switch inplatform position, bothEmergency Stopswitches pulled out tothe on position andboom function speedcontroller turned to 9,activate footswitch andplatform level toggleswitch (TS10) onplatform control panel indown direction andcheck voltage at TB6.

0V

12V or more

Troubleshoot platformlevel function toggleswitch (TS24) on groundcontrol panel OR repairopen in wht/red #6 wirecircuit from TS24 to TB6OR consult GenieIndustries ServiceDepartment.


Troubleshoot platformlevel function toggleswitches (TS24 andTS10) on ground andplatform control panelsOR repair open in wht/red #6 wire circuit fromTS24 to TB6 and fromTS10 to red wire onboom function speedcontroller OR consultGenie Industries ServiceDepartment.

If voltage to TB6 fromTS24 and TS10 hasbeen restored andplatform level downfunction is stillinoperative, pleasecontinue troubleshootingfrom beginning of chart.

5 - 62 Genie Z-34/22 IC Part No. 43037


CHART 26

With key switch inground position and bothEmergency Stopswitches pulled out tothe on position, activatethe function enabletoggle switch (TS19, ifequipped) andtheplatform level toggleswitch (TS24) on groundpanel in down directionand check voltage onorg/blk #15 wire onboom functiondirectional valve coil(item N).

0V

12V or more

With key switch inground position and bothEmergency Stopswitches pulled out tothe on position, activatethe function enabletoggle switch (TS19, ifequipped) andtheplatform level toggleswitch (TS24) on groundpanel in down directionand check voltage atTB15.

12V ormore

Repair open in org/blk#15 wire circuit fromTB15 to boom functiondirectional valve coil(item N) OR repair openin ground wire circuit tomanifold (item N).

0V

With key switch inplatform position, bothEmergency Stopswitches pulled out tothe on position andboom function speedcontroller turned to 9,activate footswitch andplatform level functiontoggle switch (TS10) onplatform control panel indown direction andcheck voltage at TB15.

0V

12V or more

Troubleshoot platformlevel function toggleswitch (TS24) on groundcontrol panel ORreplace diode on TS24OR repair open in org/blk #15 wire circuit fromTS24 to TB15 ORconsult Genie IndustriesService Department.


Troubleshoot platformlevel function toggleswitches (TS24 andTS10) on ground andplatform control panelsOR replace diodes onTS24 and TS10 ORrepair open in org/blk#15 wire circuit fromTS24 and TS10 to TB15OR consult GenieIndustries ServiceDepartment.

If voltage to TB15 fromTS24 and TS10 hasbeen restored andplatform level downfunction is stillinoperative, pleasecontinue troubleshootingfrom beginning of chart.


Part No. 43037 Genie Z-34/22 IC 5 - 63


CHART 26

Disconnect wire toplatform level downdirectional valve coil(item N). Remove coiland test resistance.


0 orinfiniteohms

4 to 8 ohms

Replace platform leveldown directional valvecoil (item N).

Install a 0 to 5000 PSIpressure gauge at thequick disconnectcoupling on the boomfunction manifold andactivate the platformlevel down function.

3200PSI

less than 3200 PSI

Test master cylinder(refer to Chart #22) ORrepair or replace slavecylinder or slave cylindercounterbalance valvesOR boom functionmanifold could have aninternal fault. ConsultGenie Industries ServiceDepartment.

Check for mechanicalrestrictions keepingplatform level downfunction from movingOR repair or replaceslave cylinder ORreplace slave cylindercounterbalance valvesOR consult GenieIndustries ServiceDepartment.

Exchange platform levelup and down directionalvalves (item M + N) andactivate platform leveldown function.



directional valve.

Exchange platform levelup and downcounterbalance valves(item F + G) andactivate platform leveldown function.



counterbalance valve.

5 - 64 Genie Z-34/22 IC Part No. 43037


Platform RotateLeft FunctionInoperativeBe sure all otherfunctions operatenormally.

If platform rotate leftfunction operatesnormally from theground controls but notfrom the platformcontrols, troubleshootthe platform controller ordiode. See RepairSection.

If platform rotate leftfunction operatesnormally from theplatform controls but notfrom the groundcontrols, troubleshootthe ground controltoggle switch OR diodeOR (R1) resistor. SeeRepair Section.

Chart 27

With key switch inground position and bothEmergency Stopswitches pulled out tothe on position, activatethe function enabletoggle switch (TS19, ifequipped) andtheplatform rotate toggleswitch (TS25) on groundpanel in left directionand check voltage onwht/red #6 wire on boomfunction proportionalvalve coil (item D).

0V

12V or more

With key switch inground position and bothEmergency Stopswitches pulled out tothe on position, activatethe function enabletoggle switch (TS19, ifequipped) andtheplatform rotate toggleswitch (TS25) on groundpanel in left directionand check voltage atTB6.

12V ormore


0V

With key switch inplatform position, bothEmergency Stopswitches pulled out tothe on position andboom function speedcontroller turned to 9,activate footswitch andplatform rotate toggleswitch (TS11) onplatform control panel inleft direction and checkvoltage at TB6.

0V

12V or more

Troubleshoot platformrotate function toggleswitch (TS25) on groundcontrol panel OR repairopen in wht/red #6 wirecircuit from TS25 to TB6OR consult GenieIndustries ServiceDepartment.


Troubleshoot platformrotate function toggleswitches (TS25 andTS11) on ground andplatform control panelsOR repair open in wht/red #6 wire circuit fromTS25 to TB6 and fromTS11 to red wire onboom function speedcontroller OR consultGenie Industries ServiceDepartment.

If voltage to TB6 fromTS25 and TS11 hasbeen restored andplatform rotate leftfunction is stillinoperative, pleasecontinue troubleshootingfrom beginning of chart.

Part No. 43037 Genie Z-34/22 IC 5 - 65


CHART 27

With key switch inground position and bothEmergency Stopswitches pulled out tothe on position, activatethe function enabletoggle switch (TS19, ifequipped) andtheplatform rotate toggleswitch (TS25) on groundpanel in left directionand check voltage onorg wire on boomfunction directional valvecoil (item C).

0V

12V or more

With key switch inground position and bothEmergency Stopswitches pulled out tothe on position, activatethe function enabletoggle switch (TS19, ifequipped) andtheplatform rotate toggleswitch (TS25) on groundpanel in left directionand check voltage atTB17.

12V ormore

Repair open in grn #17wire circuit from TB17 toboom functiondirectional valve coil(item C) OR repair openin ground circuit tomanifold (item C).

0V

With key switch inplatform position, bothEmergency Stopswitches pulled out tothe on position andboom function speedcontroller turned to 9,activate footswitch andplatform rotate functiontoggle switch (TS11) onplatform control panel inleft direction and checkvoltage on org wire onboom functiondirectional valve coil(item C).

0V

12V or more

Troubleshoot platformrotate function toggleswitch (TS25) on groundcontrol panel ORreplace diode on TS25OR repair open in grn#17 wire circuit fromTS25 to boom functiondirectional valve (itemC) OR consult GenieIndustries ServiceDepartment.


Troubleshoot platformrotate function toggleswitches (TS25 andTS11) on ground andplatform control panelsOR replace diodes onTS25 and TS11 ORrepair open in org wirecircuit from TS25 andTS11 to boom functiondirectional valve (itemC) OR consult GenieIndustries ServiceDepartment.

If voltage to boomfunction directional valvecoil (item C) from TS25and TS11 has beenrestored and platformrotate left function is stillinoperative, pleasecontinue troubleshootingfrom beginning of chart.


5 - 66 Genie Z-34/22 IC Part No. 43037


CHART 27

Disconnect wire toplatform rotate leftdirectional valve coil(item C). Remove coiland test resistance.


0 orinfiniteohms

4 to 8 ohms

Replace platform rotateleft directional valve coil(item C).

Install a 0 to 5000 PSIpressure gauge at thequick disconnectcoupling on the boomfunction manifold andactivate the platformrotate left function.

3200PSI

less than 3200 PSI

Repair hydraulic rotationmotor OR platformrotate/jib functionmanifold could have aninternal fault. ConsultGenie Industries ServiceDepartment.

Check for mechanicalrestrictions keepingplatform rotate leftfunction from movingOR the .030 orifice (itemE) could be plugged ORrepair hydraulic rotationmotor OR consult GenieIndustries ServiceDepartment.

Exchange platformrotate left and rightdirectional valves (itemC + D) and activateplatform rotate leftfunction.



directional valve.

Part No. 43037 Genie Z-34/22 IC 5 - 67


Platform RotateRightInoperativeBe sure all otherfunctions operatenormally.

If platform rotate rightfunction operatesnormally from theground controls but notfrom the platformcontrols, troubleshootthe platform controller ordiode. See RepairSection.

If platform rotate rightfunction operatesnormally from theplatform controls but notfrom the groundcontrols, troubleshootthe ground controltoggle switch OR diodeOR (R1) resistor. SeeRepair Section.

Chart 28

With key switch inground position and bothEmergency Stopswitches pulled out tothe on position, activatethe function enabletoggle switch (TS19, ifequipped) andtheplatform rotate toggleswitch (TS25) on groundpanel in right directionand check voltage onwht/red #6 wire on boomfunction proportionalvalve coil (item D).

0V

12V or more

With key switch inground position and bothEmergency Stopswitches pulled out tothe on position, activatethe function enabletoggle switch (TS19, ifequipped) andtheplatform rotate toggleswitch (TS25) on groundpanel in right directionand check voltage atTB6.

12V ormore


0V

With key switch inplatform position, bothEmergency Stopswitches pulled out tothe on position andboom function speedcontroller turned to 9,activate footswitch andplatform rotate toggleswitch (TS11) onplatform control panel inright direction and checkvoltage at TB6.

0V

12V or more

Troubleshoot platformrotate function toggleswitch (TS25) on groundcontrol panel OR repairopen in wht/red #6 wirecircuit from TS25 to TB6OR consult GenieIndustries ServiceDepartment.


Troubleshoot platformrotate function toggleswitches (TS25 andTS11) on ground andplatform control panelsOR repair open in wht/red #6 wire circuit fromTS25 to TB6 and fromTS11 to red wire onboom rotary speedcontroller OR consultGenie Industries ServiceDepartment.

If voltage to TB6 fromTS25 and TS11 hasbeen restored andplatform rotate rightfunction is stillinoperative, pleasecontinue troubleshootingfrom beginning of chart.

5 - 68 Genie Z-34/22 IC Part No. 43037


CHART 28

With key switch inground position and bothEmergency Stopswitches pulled out tothe on position, activatethe function enabletoggle switch (TS19, ifequipped) andtheplatform rotate toggleswitch (TS25) on groundpanel in right directionand check voltage onyellow wire on boomfunction directional valvecoil (item D).

0V

12V or more

With key switch inground position and bothEmergency Stopswitches pulled out tothe on position, activatethe function enabletoggle switch (TS19, ifequipped) andtheplatform rotate toggleswitch (TS25) on groundpanel in right directionand check voltage atTB18.

12V ormore

Repair open in grn/blk#18 wire circuit fromTB18 to boom functiondirectional valve coil(item D) OR repair openin ground wire circuit tomanifold (item D).

0V

With key switch inplatform position, bothEmergency Stopswitches pulled out tothe on position andboom function speedcontroller turned to 9,activate footswitch andplatform rotate functiontoggle switch (TS11) onplatform control panel inright direction and checkvoltage on yellow wireon boom functiondirectional valve coil(item D).

0V

12V or more

Troubleshoot platformrotate function toggleswitch (TS25) on groundcontrol panel ORreplace diode on TS25OR repair open in grn/blk #18 wire circuit fromTS25 to boom functiondirectional valve(item D) OR consultGenie Industries ServiceDepartment.


Troubleshoot platformrotate function toggleswitches (TS25 andTS11) on ground andplatform control panelsOR replace diodes onTS25 and TS11 ORrepair open in yellowwire circuit from TS25and TS11 to boomfunction directional valve(item D) OR consultGenie Industries ServiceDepartment.

If voltage to boomfunction directional valvecoil (item D) from TS25and TS11 has beenrestored and platformrotate right function isstill inoperative, pleasecontinue troubleshootingfrom beginning of chart.


Part No. 43037 Genie Z-34/22 IC 5 - 69


CHART 28

Disconnect wire toplatform rotate rightdirectional valve coil(item D). Remove coiland test resistance.


0 orinfiniteohms

4 to 8 ohms

Replace platform rotateright directional valvecoil (item D).

Install a 0 to 5000 PSIpressure gauge at thequick disconnectcoupling on the boomfunction manifold andactivate the platformrotate right function.

3200PSI

less than 3200 PSI

Repair hydraulic rotationmotor OR platformrotate/jib functionmanifold could have aninternal fault. ConsultGenie Industries ServiceDepartment.

Check for mechanicalrestrictions keepingplatform rotate rightfunction from movingOR the 0.030 orifice(item E) could beplugged OR repairhydraulic rotation motorOR consult GenieIndustries ServiceDepartment.

Exchange platformrotate left and rightdirectional valves (itemC + D) and activateplatform rotate rightfunction.



directional valve.

5 - 70 Genie Z-34/22 IC Part No. 43037


Jib Boom UpFunctionInoperativeBe sure all otherfunctions operatenormally.

If jib boom up functionoperates normally fromthe ground controls butnot from the platformcontrols, troubleshootthe platform controller ordiode. See RepairSection.

If jib boom up functionoperates normally fromthe platform controls butnot from the groundcontrols, troubleshootthe ground controltoggle switch OR diodeOR (R1) resistor. SeeRepair Section.

Chart 29

With key switch inground position and bothEmergency Stopswitches pulled out tothe on position, activatethe function enabletoggle switch (TS19, ifequipped) and thejibtoggle switch (TS26) onground panel in updirection and checkvoltage on wht/red #6wire on boom functionproportional valve coil(item D).

0V

12V or more

With key switch inground position and bothEmergency Stopswitches pulled out tothe on position, activatethe function enabletoggle switch (TS19, ifequipped) and thejibtoggle switch (TS26) onground panel in updirection and checkvoltage at TB6.

12V ormore


0V

With key switch inplatform position, bothEmergency Stopswitches pulled out tothe on position andboom function speedcontroller turned to 9,activate footswitch andjib toggle switch (TS12)on platform controlpanel in up direction andcheck voltage at TB6.

0V

12V or more

Troubleshoot jib functiontoggle switch (TS26) onground control panel ORrepair open in wht/red#6 wire circuit fromTS26 to TB6 OR consultGenie Industries ServiceDepartment.


Troubleshoot jib functiontoggle switches (TS26and TS12) on groundand platform controlpanels OR repair openin wht/red #6 wire circuitfrom TS26 to TB6 andfrom TS12 to red wireon boom function speedcontroller OR consultGenie Industries ServiceDepartment.

If voltage to TB6 fromTS26 and TS12 hasbeen restored and jib upfunction is stillinoperative, pleasecontinue troubleshootingfrom beginning of chart.

Part No. 43037 Genie Z-34/22 IC 5 - 71


CHART 29

With key switch inground position and bothEmergency Stopswitches pulled out tothe on position, activatethe function enabletoggle switch (TS19, ifequipped) and thejibtoggle switch (TS26) onground panel in updirection and checkvoltage on blk wire onboom functiondirectional valve coil(item A).

0V

12V or more

With key switch inground position and bothEmergency Stopswitches pulled out tothe on position, activatethe function enabletoggle switch (TS19, ifequipped) and thejibtoggle switch (TS26) onground panel in updirection and checkvoltage at TB43.

12V ormore

Repair open in grn #43wire circuit from TB43 toboom functiondirectional valve coil(item A) OR repair openin ground wire circuit tomanifold (item A).

0V

With key switch inplatform position, bothEmergency Stopswitches pulled out tothe on position andboom function speedcontroller turned to 9,activate footswitch andjib function toggle switch(TS12) on platformcontrol panel in updirection and checkvoltage on blk wire onboom functiondirectional valve coil(item A).

0V

12V or more

Troubleshoot jib functiontoggle switch (TS26) onground control panel ORreplace diode on TS26OR repair open in grn#43 wire circuit fromTS26 to boom functiondirectional valve coil(item A) OR consultGenie Industries ServiceDepartment.


Troubleshoot jib functiontoggle switches (TS26and TS12) on groundand platform controlpanels OR replacediodes on TS26 andTS12 OR repair open ingrn #43 wire circuit fromTS26 and TS12 to boomfunction directional valvecoil (item A) OR consultGenie Industries ServiceDepartment.

If voltage to boomfunction directional valvecoil (item A) from TS26and TS12 has beenrestored and jib upfunction is stillinoperative, pleasecontinue troubleshootingfrom beginning of chart.


5 - 72 Genie Z-34/22 IC Part No. 43037


CHART 29

Disconnect wire to jib updirectional valve coil(item A). Remove coiland test resistance.


0 orinfiniteohms

4 to 8 ohms

Replace jib updirectional valve coil(item A).

Install a 0 to 5000 PSIpressure gauge at thequick disconnectcoupling on the boomfunction manifold andactivate the jib upfunction.

3200PSI

less than 3200 PSI

Repair or replace jibcylinder OR replace jibcylinder counterbalancevalves OR platformrotate/jib functionmanifold could have aninternal fault. ConsultGenie Industries ServiceDepartment.

Check for mechanicalrestrictions keeping jibup function from movingOR repair or replace jibcylinder OR replace jibcylinder counterbalancevalves OR consult GenieIndustries ServiceDepartment.

Exchange jib up anddown directional valves(item A + B) and activatejib up function.



directional valve.

Part No. 43037 Genie Z-34/22 IC 5 - 73


Chart 30

Jib Boom DownFunctionInoperativeBe sure all otherfunctions operatenormally.

If jib boom downfunction operatesnormally from theground controls but notfrom the platformcontrols, troubleshootthe platform controller ordiode. See RepairSection.

If jib boom downfunction operatesnormally from theplatform controls but notfrom the groundcontrols, troubleshootthe ground controltoggle switch OR diodeOR (R1) resistor. SeeRepair Section.

With key switch inground position and bothEmergency Stopswitches pulled out tothe on position, activatethe function enabletoggle switch (TS19, ifequipped) and thejibtoggle switch (TS26) onground panel in downdirection and checkvoltage on wht/red #6wire on boom functionproportional valve coil(item D).

0V

12V or more

With key switch inground position and bothEmergency Stopswitches pulled out tothe on position, activatethe function enabletoggle switch (TS19, ifequipped) and thejibtoggle switch (TS26) onground panel in downdirection and checkvoltage at TB6.

12V ormore


0V

With key switch inplatform position, bothEmergency Stopswitches pulled out tothe on position andboom function speedcontroller turned to 9,activate footswitch andjib toggle switch (TS12)on platform controlpanel in down directionand check voltage atTB6.

0V

12V or more

Troubleshoot jib functiontoggle switch (TS26) onground control panel ORrepair open in wht/red#6 wire circuit fromTS26 to TB6 OR consultGenie Industries ServiceDepartment.


Troubleshoot jib functiontoggle switches (TS26and TS12) on groundand platform controlpanels OR repair openin wht/red #6 wire circuitfrom TS26 to TB6 andfrom TS12 to red wireon boom function speedcontroller OR consultGenie Industries ServiceDepartment.

If voltage to TB6 fromTS26 and TS12 hasbeen restored and jibdown function is stillinoperative, pleasecontinue troubleshootingfrom beginning of chart.

5 - 74 Genie Z-34/22 IC Part No. 43037


CHART 30

With key switch inground position and bothEmergency Stopswitches pulled out tothe on position, activatethe function enabletoggle switch (TS19, ifequipped) and thejibtoggle switch (TS26) onground panel in downdirection and checkvoltage on wht wire onboom functiondirectional valve coil(item B).

0V

12V or more

With key switch inground position and bothEmergency Stopswitches pulled out tothe on position, activatethe function enabletoggle switch (TS19, ifequipped) and thejibtoggle switch (TS26) onground panel in downdirection and checkvoltage at TB44.

12V ormore

Repair open in grn/blk#44 wire circuit fromTB44 to boom functiondirectional valve coil(item B) OR repair openin ground wire circuit tomanifold (item B).

0V

With key switch inplatform position, bothEmergency Stopswitches pulled out intoon position and boomfunction speed controllerturned to 9, activatefootswitch and jibfunction toggle switch(TS12) on platformcontrol panel in downdirection and checkvoltage on wht wire onboom functiondirectional valve coil(item B).

0V

12V or more

Troubleshoot jib functiontoggle switch (TS26) onground control panel ORreplace diode on TS26OR repair open in grn/blk #44 wire circuit fromTS26 to boom functiondirectional valve coil(item B) OR consultGenie Industries ServiceDepartment.


Troubleshoot jib functiontoggle switches (TS26and TS12) on groundand platform controlpanels OR replacediodes on TS26 andTS12 OR repair open ingrn/blk #44 wire circuitfrom TS26 and TS12 toboom functiondirectional valve coil(item B) OR consultGenie Industries ServiceDepartment.

If voltage to boomfunction directional valvecoil (item B) from TS26and TS12 has beenrestored and jib downfunction is stillinoperative, pleasecontinue troubleshootingfrom beginning of chart.


Part No. 43037 Genie Z-34/22 IC 5 - 75


CHART 30

Disconnect wires to jibdown directional valvecoil (item B). Removecoil and test resistance.


0 orinfiniteohms

4 to 8 ohms

Replace jib downdirectional valve coil(item B).

Install a 0 to 5000 PSIpressure gauge at thequick disconnectcoupling on the boomfunction manifold andactivate the jib downfunction.

3200PSI

less than 3200 PSI

Repair or replace jibcylinder OR replace jibcylinder counterbalancevalves OR platformrotate/jib functionmanifold could have aninternal fault. ConsultGenie Industries ServiceDepartment.

Check for mechanicalrestrictions keeping jibdown function frommoving OR repair orreplace jib cylinder ORreplace jib cylindercounterbalance valvesOR consult GenieIndustries ServiceDepartment.

Exchange jib up anddown directional valves(item A + B) and activatejib down function.



directional valve.

5 - 76 Genie Z-34/22 IC Part No. 43037


Steer LeftFunctionInoperativeBe sure all otherfunctions operatenormally.

Chart 31

Start the engine fromthe platform, press downfoot switch, hold thesteer switch left andcheck voltage atterminal 8 on the drivecontroller (blu wire).

0V Repair or replace thesteer microswitch incontroller handle.

12V

Hold the steer switchleft and check voltageat TB36.

0V Repair open in blu wirecircuit from steer switchto TB36.

12V

Hold the steer switch leftand check voltage at bluwire on steer valve.

0V Repair open in blu wirecircuit from TB36 tosteer valve.

12V

Remove both wires fromsteer left coil and checkresistance across coilterminals.

0 orinfiniteohms Replace steer left

valve coil.

4 to 8 ohms

Replace steer valve ORconsult Genie IndustriesService Department.

Part No. 43037 Genie Z-34/22 IC 5 - 77


Steer RightFunctionInoperativeBe sure all otherfunctions operatenormally.

Chart 32

Start the engine fromthe platform, press downfoot switch, hold thesteer switch right andcheck voltage atterminal 7 on the drivecontroller (blu/blk wire).

0V Repair or replace thesteer microswitch incontroller handle.

12V

Hold the steer switchright and check voltageat TB37.

0V Repair open in blu/blkwire circuit from steerswitch to TB37.

12V

Hold the steer switchright and check voltageat blu/blk wire onsteer valve.

0V Repair open in blu/blkwire circuit from TB37to steer valve.

12V

Remove both wires fromsteer right coil andcheck resistance acrosscoil terminals.

0 orinfiniteohms Replace steer right

valve coil.

4 to 8 ohms

Replace steer valve ORconsult Genie IndustriesService Department.

5 - 78 Genie Z-34/22 IC Part No. 43037


Chart 33

All DriveFunctionsInoperative, AllOtherFunctionsOperateNormallyBe sure the hydraulicsuction line valve is inthe open position.

Be sure the machine isnot in the free wheelconfiguration.

Start engine fromground controls andstanding clear of thetires, momentarily movepump control overridelever in each direction.

machine does not moveRepair or replace thedrive pump OR consultGenie Industries ServiceDepartment.

machine moves

Move to platform,press down foot switch,hold drive enableswitch to either sideand try to drive.

machinedrives

Place a jumper wirebetween TB30 andTB12 and test drivewithout holding driveenable switch.

no drive Repair open inwht wire circuit fromTS14 to TB30.

machine drives

Replace drive enablelimit switch OR repairopen in wire circuitsfrom terminal TB30 tolimit switch and fromlimit switch to TB12.

no drive

Disconnect drive pumpelectronic displacementcontroller (EDC) wires.Check resistance acrossboth wires on EDC sideof quick disconnect.

0 orinfiniteohms

Replace EDC.

20 to 24 ohms

Press down foot switchand check voltage athorsepower limiterboard terminal 1.

less than 12VCorrect insufficientvoltage supply(alternator or battery)OR repair open in whtwire circuit supplying12V to terminal 1.

12V or more


Part No. 43037 Genie Z-34/22 IC 5 - 79


CHART 33


Switch rpm select switchto rabbit with foot switch,press down foot switchand check voltage atterminal 3 onhorsepower limiter.

0V Check voltage at TB41.6 to 7V

Repair open in org/blkwire circuit from TB41 tohorsepower limiterterminal 3.

0V

Check voltage atorg/blk wire on enginealternator.

6 to 7V Repair open in org/blkwire circuit fromalternator to TB41.

0V

Repair or replacealternator.

6 to 7V

Press down foot switchand check voltage atterminal 10 onhorsepower limiter.

0V Replace horsepowerlimiter board.

9 to 12V

Press down foot switchand check voltage atterminal 6 on drivecontroller.

0VRepair open in red wirecircuit from horse powerlimiter board to drivecontrol terminal 6.

9 to 12V


5 - 80 Genie Z-34/22 IC Part No. 43037


CHART 33


Disconnect drive pumpEDC wires, press downfoot switch, hold drivecontroller in full forwardposition and checkvoltage acrossterminals 4 and 5on drive controller.

0V Repair or replace drivecontroller.

4 to 7V

0V

Repair open in eitherwht or wht/blk wirecircuit from drivecontroller to TB30 andTB31 respectively.

Press down foot switch,hold drive controller infull forward positionand check voltageacross terminalsTB30 and TB31.

4 to 7V

Press down foot switch,hold drive controller infull forward position andcheck voltage across thetwo wires at EDC quickdisconnect.

0V

Repair open in wht/blkwire circuit from TB31 toEDC quick disconnectOR repair open in whtwire circuit from TB30 toEDC quick disconnect.

4 to 7V

Replace drive pumpEDC OR consult GenieIndustries ServiceDepartment.

Part No. 43037 Genie Z-34/22 IC 5 - 81


Chart 34

DriveForward orReverseFunctionInoperativeBe sure all otherfunctions operatenormally includingdrive in oppositedirection ofmalfunction.

Be sure engine is inhigh rpm (rabbitsymbol).

Disconnect the EDCwire connector from thedrive pump, start engine,move the drive controllerto full forward positionand note the voltageacross terminals TB30and TB31. Reverse thevolt meter leads andmove the drive controllerto full reverse positionand note the voltage.

voltage readings different Repair or replace thedrive controller.

voltage readings the same

Adjust the drive pumpnull (neutral). SeeSundstrand Series 40Service Manual.

no improvementDefective Sundstranddrive pump, contactSundstrand authorizedrepair facility.

symptoms improve

Check all drive speedsand monitor for recurringsymptoms. Possiblecontamination inhydraulic system.

5 - 82 Genie Z-34/22 IC Part No. 43037


Chart 35

Any type of tractionproblem, consult GenieIndustries ServiceDepartment.

TractionFunctionInoperativeBe sure all otherfunctions operatenormally.

Part No. 43037 Genie Z-34/22 IC 5 - 83


Chart 36

Machine WillNot Drive AtFull SpeedBe sure all otherfunctions operatenormally.

Be sure the free wheelvalve is closed on thedrive pump.

Be sure the drive speedselect switch is on highrange (machine on levelsurface symbol).

With boom fully stowedand orange wire fromcable #1 disconnectedfrom TB40, check TB40for continuity to ground.

fullcontinuity

Repair or replace boomlift drive limit switch orboom extend limitswitch.

no continuity

With boom fully stowedand orange wire fromcable #1 disconnectedfrom TB40, checkhorsepower limiterboard terminal 6 forcontinuity to ground.

fullcontinuity

Orange wire shortedto ground, repairorange wire circuit fromTB40 to horsepowerlimiter board.

no continuity

Re-adjust or replacehorsepower limiterboard. See Repairsection OR consultGenie Industries ServiceDepartment.

5 - 84 Genie Z-34/22 IC Part No. 43037


Chart 37

MachineDrives AtFull SpeedWithPlatformRaised OrExtendedRemove machinefrom serviceimmediately.

Be sure boom lift/drive limit switch orboom extend drivelimit switch is notbeing held down orup.

Be sure wiring tolimit switches isintact and shows nosigns of tampering.

Be sure orangewire (cable #1) isproperly attached toterminal #6 of thehorsepower limiterboard.

Raise boom off drivelimit switch, turnmachine off and checkcontinuity betweenground and terminal 6on horsepower limiterboard.

fullcontinuity

Disconnect electronicdisplacement controller(EDC) wires on drivepump, move drivecontroller to full forwardposition and checkvoltage betweenterminals 4 and 5on drive controller.

0 to 3V

Defective Sundstranddrive pump. Replace orrepair at authorizedSundstrand repairfacility.

4 to 7V

Replace horsepowerlimiter board.

no continuity

Check continuitybetween groundand TB40.

fullcontinuity Repair open in org wire

circuit from TB40 tohorsepower limiterboard terminal 6.

no continuity

Repair limit switch wiringOR replace boom liftdrive limit switch ORreplace boom extenddrive limit switch.

Part No. 43037 Genie Z-34/22 IC 5 - 85


Chart 38

Drive EnableSystem IsMalfunctioning

Do not hold the driveenable switch andcheck if machine willdrive in the stowedposition with boom overnon-steer wheels.

no

Will holding the driveenable switch allowboom to drive instowed position overnon-steer wheels?

no

Troubleshoothorsepower limit board,drive controller ordrive pump. See chart31.

yes

Repair or replace driveenable limit switch.yes

Do not hold the driveenable switch and checkif machine will drive inthe stowed position withboom over the steerwheels.

yes Repair or replace driveenable limit switch.

no

Will holding the driveenable switch allowboom to drive instowed position oversteer wheels?

no

Repair or replace driveenable toggle switch.

5 - 86 Genie Z-34/22 IC Part No. 43037


Chart 39

AuxiliaryFunctionsInoperativeBe sure all otherfunctions operatenormally.

Be sure keyswitch is inthe appropriate positionand the EmergencyStop Buttons are pulledout to the on position.

Note: Operatingauxiliary power with theengine running shouldimmediately kill theengine.

With engine not running,lift switch cover, holdauxiliary switch andlisten for sound ofauxiliary pump running.

pumpruns

Install a 0 to 5000pressure gauge into thepressure port located onthe function manifoldand bump the auxiliarypower switch.

less than2000 psi

Replace pump.

2000 psi

Check battery condition.There is possibly notenough battery capacityto operate both auxiliarypump and functionvalves.

pump doesn't run

Hold the auxiliary powerswitch and check thevoltage at terminalTB27.

0V Replace defectiveauxiliary powertoggle switch.

12V

Hold the auxiliary powerswitch and check thevoltage at initiateterminal (red wire) onPR1 motor startsolenoid.

0V Repair open in red wirecircuit from TB27 toPR1.

12V

Hold the auxiliary powerswitch and check thevoltage at positive powercable on auxiliarypower unit.

0VReplace PR1 relay.

12V

Check auxiliary powerunit grounding cableOR repair or replaceelectric motor.

Schematics

Observe and Obey:

Troubleshooting and repair procedures shall becompleted by a person trained and qualified onthe repair of this machine.



Before Troubleshooting:

Read, understand and obey the safety rulesand operating instructions printed in theGenie Z-34/22 IC Operator's Manual.

Be sure that all necessary tools and testequipment are available and ready for use.

About This SectionThere are two groups of schematics in this section.An illustration legend precedes each group ofdrawings.

Electrical Schematics

Electrocution hazard. Contact withelectrically charged circuits mayresult in death or serious injury.Remove all rings, watches andother jewelry.

Hydraulic Schematics

Bodily injury hazard. Sprayinghydraulic oil can penetrate andburn skin. Loosen hydraulicconnections very slowly to allowthe oil pressure to dissipategradually. Do not allow oil to squirtor spray.



Identifysymptoms

Troubleshoot

Performrepair


solved

problemstill exists

Inspectand test

Part No. 43037 Genie Z-34/22 IC 6 - 1

Service Manual - First Edition Section 6 - Schematics

Service Manual - First EditionSection 6 - Schematics

6 - 2 Genie Z-34/22 IC Part No. 43037

Electrical Symbols Legend

+ +

- -

OR

G/B

LK-1

15AMP.

TB20

ALARMTILT

L1 DE

TP29

BLK

GR

N/B

LK

TB17

BLK #21 TB21

Battery

12V 6V

Wire colorwith cablenumber

Circuit breaker

Connectionno terminal

Terminal

P1

Emergency Stopbuttonnormally closed

KS1

GRND

PLAT

Key switch

Pressure switch

Brake releaseplug

PR4

Relay panelcontactor

Solenoid orrelay coil

Horn

Tilt sensor

NCLS2

Limit switchnormally closedheld open

NOLS1

Limit switchnormally openheld closed

HORN P4

Horn buttonnormally open

T-circuitsconnect

Light

Quick disconnectterminal

Diode

REDBLK

FS1

Foot switch

CR

4

Relay contactnormally open

TS3

STA

RT

EN

GIN

E

Toggle switch SPDTCircuits crossingno connection

TS6

RIG

HT

LEFT

Toggle switch DPDT

Groundsupressioncircuit

T-circuits connectat terminal

Auxiliary pump

Curtis motorcontroller

Dual polerelay controller

Drive motor

Rotary OEMflow control

Drive control

PUMPAUX.

Limit switch

NO

LS3

NC

B+

A2

M-3 1

B-

REV.

PR2

FWD.

A2

A1 S1

S2

WH

T

GRNRED

BP1

BLK

/RE

D

DP1

R+

X

A+-

L

PWMBRK.

R

-X

A

PWMDRV.

PSI

Spark plug

Water temperatureswitch, normally open

Oil pressure switch,normally closed

WT

S1

N.O

.O

PS

1N

.C.

VAC

Vacuum switchnormaly open

250

Resistor

Part No. 43037 Genie Z-34/22 IC 6 - 3

Service Manual - First Edition Section 6 - Schematics

Hydraulic Symbols Legend

E

Pressure gauge

Filter

Fixed displacementpump

Bi-directional motor

Bi-directional, variabledisplacement pump

2-speed,bi-directional motor

Pump prime moverengine or motor

Double actingcylinder

Orifice with size

0.035

Check valve

Relief valve

Priorityflow divider

Solenoid operateddump valve

Differentialsensing valve

Solenoid operatedproportional valve

Pressure switch

Brake

Variable orifice orshut off valve

Flow divider combiner

Solenoid operated 2 pos.,3 way, directional valve

Pilot operated flowcontrol valve

Solenoid operated 3 pos.,4 way, directional valve(D01)

Sequencing valve

Shuttle valve

Counterbalance valve

N.C.COM

N.O.

Service Manual - First EditionSection 6 - Schematics

6 - 4 Genie Z-34/22 IC Part No. 43037

6 - 5 Genie Z-34/22 IC Part No. 43037

Electrical Schematic, Diesel Models(before serial number 869)

Section 6 - Schematics Service Manual

1

2

3

4

5

6

7

8

A B C D E F G H I J K L M N

ES34D1D

WH

T#

21

-E.H

.

RE

D-E

.H.

OR

G/B

LK

#4

1-E

.H.

RE

D/B

LK

#2

8-E

.H.

RE

D/W

HT

#2

3-E

.H.

RE

D#

27

-E.H

.

BL

K/R

ED

EX

CT.

BA

TT

ER

Y

-

+

RE

GU

LA

TO

R

SE

RV

ICE

HO

RN

RE

LA

Y

ALT

ER

NA

TO

R

GL

OW

PL

UG

S

RP

MS

OL

EN

OID

SE

RV

ICE

HO

RN

-

BA

T.

AU

XIL

IAR

YP

OW

ER

RE

LA

Y

AU

XIL

IAR

YP

UM

P

LE

VE

LS

EN

SO

R

STA

RT

ER

MO

TO

R

BL

K/R

ED

#R

4-E

.H.

IND

.

BA

T.

STA

.+

BL

K#

R5

-E.H

.

CR4

NO

CR5 CR5

NO

PR1 PR1

OPS1 WTS1

NO

OIL

PR

ES

SU

RE

HO

UR

ME

TE

R

SE

ND

ER

NC

GL

OW

PL

UG

RE

LA

Y

WA

TE

RT

EM

P.

SE

ND

ER

WH

T/B

LK

#2

5E

.H.

WH

T

BL

K/W

HT

WN

T/R

ED

#2

6E

.H.

CR8

RP

MC

OIL

FL

AS

HIN

GB

EA

CO

NS

RP

MC

UT

OU

TC

OIL

RE

LA

Y

TU

RN

TA

BL

ER

OTA

TE

LE

FT

TU

RN

TA

BL

ER

OTA

TE

RIG

HT

CR4

CR3

FB

WH

T/B

LK

#5

-E.H

.

WH

T#

4-E

.H.

NO

CR1

TB22KS1

BL

K/R

ED

RE

D#

20

-E.H

.R

ED

TB20

CB1

10AMP.

10AMP.

TB27

OR

G/B

LK

-1

RED

TB41

TB9

TB28

TB23

P1

RED

GRND

REDPLAT

RE

D

TS15

WH

T-2

RE

D/B

LK

-1

BL

K/R

ED

-3

RE

D-1

CB2

BL

K-2 P3

HORN

RE

D

TS1

P2 FS1

BLK

RED

TB34TB33

TB24

1

10

5

6

7

8

9

4

3

2

BL

K#

R1

-E.H

.

CR1

TB21

NO

CR2 CR2

KEY BYPASS

IGN./FUEL ON

ENG. FAULT

GROUND

KEY PWR.

BATTERY

START INPUT

AUX. ONIGN./START

MODULE

START RELAY

TACHOMETER

TS16

BL

K

BL

K-1

TS17

BL

K/R

ED

RE

D/W

HT

#2

3-E

.H.

TB35

TB4

TB5

HIG

HR

PM

BL

K/R

ED

-1

WH

T/B

LK

-3

TS20

TS19

WH

T-3

TS2 TS3TS5

TS6

CR3

AU

XIL

IAR

YP

OW

ER

WHT

BL

U/W

HT

-1

BL

K/W

HT

#4

1-E

.H.

CR8

SELECT (OPTION)

LIFT/DRIVE

TS27

FU

EL

SO

LE

NO

ID

AU

XIL

IAR

YP

OW

ER

EN

GIN

ES

TA

RT

EN

GIN

ES

TA

RT

EN

GIN

EG

LO

WP

LU

G

EN

GIN

EG

LO

WP

LU

G

EN

GIN

ES

PE

ED

HIG

HR

PM

FU

NC

TIO

NE

NA

BL

E

SW

ING

LE

FT

RIG

HT

SW

ING

LE

FT

RIG

HT

HM

Part No. 43037 Genie Z-34/22 IC 6 - 6


Service Manual Section 6 - Schematics

1

2

3

4

5

6

7

8

N M L K J I H G F E D C B A

DE

CE

NT

AL

AR

M(O

PT

ION

AL

)

SE

CO

ND

AR

YB

OO

MU

P

SE

CO

ND

AR

YB

OO

MD

WN

PR

IMA

RY

BO

OM

DW

N

PR

IMA

RY

BO

OM

UP

BL

U#

10

-E.H

.

A3

BL

U/B

LK

#11

-E.H

.

RE

D/B

LK

#2

-E.H

.

RE

D#

1-E

.H.

PL

AT

FO

RM

LE

VE

LU

P

PL

AT

FO

RM

LE

VE

LD

WN

PR

IMA

RY

BO

OM

RE

TR

AC

T

PR

IMA

RY

BO

OM

EX

TE

ND

PL

AT

FO

RM

RO

TA

TE

BL

K/W

HT

#8

-E.H

.

BL

K#

7-E

.H.

OR

G/B

LK

#1

5-E

.H.

OR

G#

14

-E.H

.

DR

IVE

ED

C

BR

N-6

BR

N-7

BO

OM

UP

LIM

ITS

WIT

CH

BO

OM

EX

TE

ND

LIM

ITS

WIT

CH

BO

OM

FL

OW

CO

NT

RO

L

PL

AT

FO

RM

JIB

ST

EE

RR

IGH

T

ST

EE

RL

EF

T

MO

TO

RS

TR

OK

E

WH

T-6

WH

T-7

NC

LS1

NO

LS2

WH

T/R

ED

-E.H

.

TB40TB29

TB37

DR

IVE

EN

AB

LE

LIM

ITS

WIT

CH

GR

OU

ND

TB12

WHT#12-E.H.

NCNO

LS3

BL

K-3

TB10

TB11 TB2

TB1

BL

U/B

LK

-3

TS21

BL

U-3

BL

K/W

HT

-3

RE

D/B

LK

-3

TS22

RE

D-3

TB8

TB7

TB15

TB14

TB17

TB18

ORG-JIB

BLU-JIB

OR

G/B

LK

-3

TS23 TS24

OR

G-3

GR

N/B

LK

-3

TS25

BLK-JIB

GR

N-3

GR

N/B

LK

-1

GR

N-1

WHT-JIB

TS7 TS8 TS9 TS10

BR

N-J

IB

TS11 TS12

TB44

TB43

TB6

TB36 TB32 TB31

WH

T/R

ED

-3

TS26

OR

G-1

WH

T/B

LK

-1

WH

T/R

ED

-1

BL

U/B

LK

-1

RE

D/W

HT

-1

RED

BL

U-1

TB30 TB13

BL

U/R

ED

-3

BR

N-2

BL

U/W

HT

-3

WH

T-1

AOEM

CONTROL

FLOW

R

+

-

X

10

9

6

8

7

5

BP1

ROTARY

HORSE

POWER

LIMITER

BOARD

3

4

2

1

RE

D/W

HT

R2

25

0

HIG

H

RE

DL

OW

7

8

5

4

6

TS13

DP1

2

3

1

L1

TS14

5

R1

BL

K-5

BR

N-5

RE

D-5

WH

T-5

RE

D/W

HT

#2

5-E

.H.

BL

U/B

LK

#3

7-E

.H.

BL

U#

36

-E.H

.

WH

T/R

ED

#3

2-E

.H.

WH

T/B

LK

#3

1-E

.H.

LS4

NO

BR

N-8

WH

T-8

SE

CO

ND

AR

YU

PL

IMIT

SW

ITC

H

LS2

NC

CR9

CR10

CR9CR10

CUT-OUT (OPTION)

PLATFORM LEVEL

BL

K-6

RE

D-6

SE

CO

ND

AR

YB

OO

M

DO

WN

UP

PR

IMA

RY

BO

OM

DO

WN

UP

PR

IMA

RY

BO

OM

RE

TR

AC

T

EX

TE

ND

PL

AT

FO

RM

LE

VE

L

DO

WN

UP

PL

AT

FO

RM

RO

TA

TE

LE

FT

RIG

HT

JIB

BO

OM

DO

WN

UP

DR

IVE

EN

AB

LE

D.E.

JIB

BO

OM

DO

WN

UP

PL

AT

FO

RM

RO

TA

TE

LE

FT

RIG

HT

PL

AT

FO

RM

LE

VE

L

DO

WN

UP

PR

IMA

RY

BO

OM

RE

TR

AC

T

EX

TE

NDP

RIM

AR

YB

OO

M

DO

WN

UP

SE

CO

ND

AR

YB

OO

M

DO

WN

UP

ES34GP2D

BR

AK

ER

EL

EA

SE



6 - 7 Genie Z-34/22 IC Part No. 43037

Electrical Schematic, Diesel Models(from serial number 869 to 1186)


1

2

3

4

5

6

7

8


ES34D1E

WH

T#

21

-E.H

.

RE

D-E

.H.

OR

G/B

LK

#4

1-E

.H.

RE

D/B

LK

#2

8-E

.H.

RE

D/W

HT

#2

3-E

.H.

RE

D#

27

-E.H

.

BL

K/R

ED

EX

CT.

BA

TT

ER

Y

-

+

RE

GU

LA

TO

R

SE

RV

ICE

HO

RN

RE

LA

Y

ALT

ER

NA

TO

R

GL

OW

PL

UG

S

RP

MS

OL

EN

OID

SE

RV

ICE

HO

RN

-

BA

T.

AU

XIL

IAR

YP

OW

ER

RE

LA

Y

AU

XIL

IAR

YP

UM

P

LE

VE

LS

EN

SO

R

STA

RT

ER

MO

TO

R

BL

K/R

ED

#R

4-E

.H.

IND

.

BA

T.

STA

.+

BL

K#

R5

-E.H

.

CR4

NO

CR5 CR5

NO

PR1 PR1

OPS1 WTS1

NO

OIL

PR

ES

SU

RE

SE

ND

ER

HO

UR

ME

TE

R

NC

GL

OW

PL

UG

RE

LA

Y

WA

TE

RT

EM

P.

SE

ND

ER

WH

T/B

LK

#2

5E

.H.

WH

T

BL

K/W

HT

WN

T/R

ED

#2

6E

.H.

CR8

RP

MC

OIL

FL

AS

HIN

GB

EA

CO

NS

RP

MC

UT

OU

TC

OIL

RE

LA

Y

TU

RN

TA

BL

ER

OTA

TE

LE

FT

TU

RN

TA

BL

ER

OTA

TE

RIG

HT

CR4

CR3

FB

WH

T/B

LK

#5

-E.H

.

WH

T#

4-E

.H.

NO

CR1

TB22KS1

BL

K/R

ED

RE

D#

20

-E.H

.R

ED

TB20

CB1

10AMP.

10AMP.

TB27

OR

G/B

LK

-1

RED

TB41

TB9

TB28

TB23

P1

RED

GRND

REDPLAT

RE

D

TS15

WH

T-2

RE

D/B

LK

-1

BL

K/R

ED

-3

RE

D-1

CB2

BL

K-2

P3

HORN

RE

D

TS1

P2 FS1

BLK

RED

TB34TB33

TB24

1

10

5

6

7

8

9

4

3

2

BL

K#

R1

-E.H

.

CR1

TB21

NO

CR2 CR2

KEY BYPASS

IGN./FUEL ON

ENG. FAULT

MODULE

GROUND

KEY PWR.

BATTERY

START INPUT

AUX. ON

IGN./START

START RELAY

TACHOMETER

TS16

BL

K

BL

K-1

TS17

BL

K/R

ED

RE

D/W

HT

#2

3-E

.H.

TB35

TB4

TB5

HIG

HR

PM

BL

K/R

ED

-1

WH

T/B

LK

-3

TS20

TS19

WH

T-3

TS2 TS3TS5

TS6

CR3

AU

XIL

IAR

YP

OW

ER

WHT

BL

U/W

HT

-1

BL

K/W

HT

#4

1-E

.H.

CR8

SELECT (OPTION)

LIFT/DRIVE

TS27

FU

EL

SO

LE

NO

ID

LOAD SENSE OPTION(SEE DETAIL BELOW)

LOAD SENSE OPTION

RED/BLK

LOAD SENSE PCB

WHT

3A

421 3

BRN

5 76

421 3

RED/BLK

CR11

98 1110 12 WHT

RE

D/W

HT

CR11

FS1

BLK

REDP2

AU

XIL

IAR

YP

OW

ER

EN

GIN

ES

TA

RT

EN

GIN

ES

TA

RT

EN

GIN

EG

LO

WP

LU

G

EN

GIN

EG

LO

WP

LU

G

EN

GIN

ES

PE

ED

HIG

HR

PM

FU

NC

TIO

NE

NA

BL

E

SW

ING

LE

FT

RIG

HT

SW

ING

LE

FT

RIG

HT

HM

Part No. 43037 Genie Z-34/22 IC 6 - 8



1

2

3

4

5

6

7

8


DE

CE

NT

AL

AR

M(O

PT

ION

AL

)

SE

CO

ND

AR

YB

OO

MU

P

SE

CO

ND

AR

YB

OO

MD

WN

PR

IMA

RY

BO

OM

DW

N

PR

IMA

RY

BO

OM

UP

BL

U#

10

-E.H

.

A3

BL

U/B

LK

#11

-E.H

.

RE

D/B

LK

#2

-E.H

.

RE

D#

1-E

.H.

PL

AT

FO

RM

LE

VE

LU

P

PL

AT

FO

RM

LE

VE

LD

WN

PR

IMA

RY

BO

OM

RE

TR

AC

T

PR

IMA

RY

BO

OM

EX

TE

ND

PL

AT

FO

RM

RO

TA

TE

BL

K/W

HT

#8

-E.H

.

BL

K#

7-E

.H.

OR

G/B

LK

#1

5-E

.H.

OR

G#

14

-E.H

.

DR

IVE

ED

C

BR

N-6

BR

N-7

BO

OM

UP

LIM

ITS

WIT

CH

BO

OM

EX

TE

ND

LIM

ITS

WIT

CH

BO

OM

FL

OW

CO

NT

RO

L

PL

AT

FO

RM

JIB

ST

EE

RR

IGH

T

ST

EE

RL

EF

T

MO

TO

RS

TR

OK

E

WH

T-6

WH

T-7

NC

LS1

NO

LS2

WH

T/R

ED

-E.H

.

TB40TB29

TB37

DR

IVE

EN

AB

LE

LIM

ITS

WIT

CH

GR

OU

ND

TB12

WHT#12-E.H.

NCNO

LS3

BL

K-3

TB10

TB11 TB2

TB1

BL

U/B

LK

-3

TS21

BL

U-3

BL

K/W

HT

-3

RE

D/B

LK

-3

TS22

RE

D-3

TB8

TB7

TB15

TB14

TB17

TB18

ORG-JIB

BLU-JIB

OR

G/B

LK

-3

TS23 TS24

OR

G-3

GR

N/B

LK

-3

TS25

BLK-JIB

GR

N-3

GR

N/B

LK

-1

GR

N-1

WHT-JIB

TS7 TS8 TS9 TS10

BR

N-J

IB

TS11 TS12

TB44

TB43

TB6

TB36 TB32 TB31

WH

T/R

ED

-3

TS26

OR

G-1

WH

T/B

LK

-1

WH

T/R

ED

-1

BL

U/B

LK

-1

RE

D/W

HT

-1

RED

BL

U-1

TB30 TB13

BL

U/R

ED

-3

BR

N-2

BL

U/W

HT

-3

WH

T-1

AOEM

CONTROL

FLOW

R

+

-

X

10

9

6

8

7

5

BP1

ROTARY

HORSE

POWER

LIMITER

BOARD

3

4

2

1

RE

D/W

HT

R2

25

0

HIG

H

RE

DL

OW

7

8

5

4

6

TS13

DP1

2

3

1

L1

TS14

4

R1

BL

K-5

BR

N-5

RE

D-5

WH

T-5

RE

D/W

HT

#2

5-E

.H.

BL

U/B

LK

#3

7-E

.H.

BL

U#

36

-E.H

.

WH

T/R

ED

#3

2-E

.H.

WH

T/B

LK

#3

1-E

.H.

LS4

NO

BR

N-8

WH

T-8

SE

CO

ND

AR

YU

PL

IMIT

SW

ITC

H

LS2

NC

CR9

CR10

CR9CR10

CUT-OUT (OPTION)

PLATFORM LEVEL

BL

K-6

RE

D-6

SE

CO

ND

AR

YB

OO

M

DO

WN

UP

PR

IMA

RY

BO

OM

DO

WN

UP

PR

IMA

RY

BO

OM

RE

TR

AC

T

EX

TE

ND

PL

AT

FO

RM

LE

VE

L

DO

WN

UP

PL

AT

FO

RM

RO

TA

TE

LE

FT

RIG

HT

JIB

BO

OM

DO

WN

UP

DR

IVE

EN

AB

LE

D.E.

JIB

BO

OM

DO

WN

UP

PL

AT

FO

RM

RO

TA

TE

LE

FT

RIG

HT

PL

AT

FO

RM

LE

VE

L

DO

WN

UP

PR

IMA

RY

BO

OM

RE

TR

AC

T

EX

TE

NDP

RIM

AR

YB

OO

M

DO

WN

UP

SE

CO

ND

AR

YB

OO

M

DO

WN

UP

ES34GP2E

BR

AK

ER

EL

EA

SE



Electrical Schematic, Gasoline/LPG Models(before serial number 869)


6 - 9 Genie Z-34/22 IC Part No. 43037

1

2

3

4

5

6

7

8


RE

D/B

LK

#R

6-E

.H.

WH

T#

21

-E.H

.

RE

D-E

.H.

OR

G/B

LK

#4

1-E

.H.

RE

D/B

LK

#2

8-E

.H.

RE

D/W

HT

#2

3-E

.H.

RE

D#

27

-E.H

.

BL

K/R

ED

EX

CT.B

AT

TE

RY

-

+

RE

GU

LA

TO

R

SE

RV

ICE

HO

RN

RE

LA

Y

ALT

ER

NA

TO

R

CH

OK

ES

OL

EN

OID

RP

MS

OL

EN

OID

SE

RV

ICE

HO

RN

-

BA

T.

AU

XIL

IAR

YP

OW

ER

RE

LA

Y

AU

XIL

IAR

YP

UM

P

LE

VE

LS

EN

SO

R

STA

RT

ER

MO

TO

R

BL

K/R

ED

#R

4-E

.H.

BL

K/W

HT

#R

8-E

.H.

IND

.

BA

T.

STA

.

+

BL

K#

R5

-E.H

.

CR8 CR4

NOCR5 CR5

NOPR1 PR1

NO

CR6

BL

U/W

HT

#R

6-E

.H.

OPS1 WTS1

NO

IGN

ITIO

NS

YS

TE

M

OIL

PR

ES

SU

RE

SE

ND

ER

HO

UR

ME

TE

R

NC

CH

OK

ER

EL

AY

FU

EL

PU

MP

WA

TE

RT

EM

P.

SE

ND

ER

WH

T/B

LK

#2

5E

.H.

WH

T

DISTRIBUTOR

G

-

+

COILB

LK

/WH

T

WN

T/R

ED

#2

6E

.H.

CR8

RP

MC

OIL

FL

AS

HIN

GB

EA

CO

NS

FU

EL

RE

LA

Y

FU

EL

RE

LA

Y

AN

TI-D

IES

EL

VA

LVE

LP

GS

OL

EN

OID

RP

MC

UT

OU

TC

OIL

RE

LA

Y

TU

RN

TA

BL

ER

OTA

TE

LE

FT

TU

RN

TA

BL

ER

OTA

TE

RIG

HT

CR4

BL

U/W

HT

#R

6-E

.H.

BL

U/R

ED

#R

7-E

.H.

CR7CR6

NO

CR7

CR3

FB

WH

T/B

LK

#5

-E.H

.

WH

T#

4-E

.H.

NO

CR1

TB22KS1

BL

K/R

ED

RE

D#

20

-E.H

.R

ED

TB20

CB1

10 AMP.

10 AMP.

TB27

OR

G/B

LK

-1

RED

TB41

TB9

TB28

TB23

P1RED

GRND

RED PLAT

RE

D

TS15

WH

T-2

RE

D/B

LK

-1

BL

K/R

ED

-3

RE

D-1

CB2

BL

K-2 P3

HORN

RE

D

TS1

P2 FS1

BLKRED

TB38

TS18

TB34TB33

TB24

1

10

56789

432

BL

K#

R1

-E.H

.

CR1

TB21

NO

CR2 CR2

KEY BYPASSIGN./FUEL ONENG. FAULT

GROUND

KEY PWR.BATTERY

START INPUTAUX. ON

IGN./STARTMODULE

START RELAYTACHOMETER

TS16

BL

K

BL

K/W

HT

-1

BL

K-1

TS17

BL

K/R

ED

RE

D/W

HT

#2

3-E

.H.

VAC

TB35

TB4

TB5

HIG

HR

PM

BL

U/W

HT

-1

BL

U/R

ED

-1

TB39

BL

K/R

ED

-1

WH

T/B

LK

-3

TS20

TS19

WH

T-3

TS2TS3

TS4 TS5TS6

CR3

WH

T#

21

-E.H

.

AU

XIL

IAR

YP

OW

ER

AU

XIL

IAR

YP

OW

ER

WHT

NO

TS27

LIFT/DRIVESELECT (OPTION)

SW

ING

LE

FT

RIG

HT

SW

ING

LE

FT

RIG

HT

EN

GIN

ES

PE

ED

HIG

HR

PM

GA

SF

UE

LL

P

GA

SF

UE

LL

P

EN

GIN

EC

HO

KE

EN

GIN

EC

HO

KE

EN

GIN

ES

TA

RT

EN

GIN

ES

TA

RT

STARTER

ES34GP1 D



Part No. 43037 Genie Z-34/22 IC 6 - 10

1

2

3

4

5

6

7

8


DE

CE

NT

AL

AR

M(O

PT

ION

AL

)

SE

CO

ND

AR

YB

OO

MU

P

SE

CO

ND

AR

YB

OO

MD

WN

PR

IMA

RY

BO

OM

DW

N

PR

IMA

RY

BO

OM

UP

BL

U#

10

-E.H

.

A3

BL

U/B

LK

#11

-E.H

.

RE

D/B

LK

#2

-E.H

.

RE

D#

1-E

.H.

PL

AT

FO

RM

LE

VE

LU

P

PL

AT

FO

RM

LE

VE

LD

WN

PR

IMA

RY

BO

OM

RE

TR

AC

T

PR

IMA

RY

BO

OM

EX

TE

ND

PL

AT

FO

RM

RO

TA

TE

BL

K/W

HT

#8

-E.H

.

BL

K#

7-E

.H.

OR

G/B

LK

#1

5-E

.H.

OR

G#

14

-E.H

.

DR

IVE

ED

C

BR

N-6

BR

N-7

BO

OM

UP

LIM

ITS

WIT

CH

BO

OM

EX

TE

ND

LIM

ITS

WIT

CH

BO

OM

FL

OW

CO

NT

RO

L

PL

AT

FO

RM

JIB

ST

EE

RR

IGH

T

ST

EE

RL

EF

T

MO

TO

RS

TR

OK

E

WH

T-6

WH

T-7

NC

LS1

NO

LS2

WH

T/R

ED

-E.H

.

TB40TB29

TB37

DR

IVE

EN

AB

LE

LIM

ITS

WIT

CH

GR

OU

ND

TB12

WHT#12-E.H.

NCNO

LS3

BL

K-3

TB10

TB11 TB2

TB1

BL

U/B

LK

-3

TS21

BL

U-3

BL

K/W

HT

-3

RE

D/B

LK

-3

TS22

RE

D-3

TB8

TB7

TB15

TB14

TB17

TB18

ORG-JIB

BLU-JIB

OR

G/B

LK

-3

TS23 TS24

OR

G-3

GR

N/B

LK

-3

TS25

BLK-JIB

GR

N-3

GR

N/B

LK

-1

GR

N-1

WHT-JIB

TS7 TS8 TS9 TS10

BR

N-J

IB

TS11 TS12

TB44

TB43

TB6

TB36 TB32 TB31

WH

T/R

ED

-3

TS26

OR

G-1

WH

T/B

LK

-1

WH

T/R

ED

-1

BL

U/B

LK

-1

RE

D/W

HT

-1

RED

BL

U-1

TB30 TB13

BL

U/R

ED

-3

BR

N-2

BL

U/W

HT

-3

WH

T-1

AOEM

CONTROL

FLOW

R

+

-

X

10

9

6

8

7

5

BP1

ROTARY

HORSE

POWER

LIMITER

BOARD

3

4

2

1

RE

D/W

HT

R2

25

0

HIG

H

RE

DL

OW

7

8

5

4

6

TS13

DP1

2

3

1

L1

TS14

5

R1

BL

K-5

BR

N-5

RE

D-5

WH

T-5

RE

D/W

HT

#2

5-E

.H.

BL

U/B

LK

#3

7-E

.H.

BL

U#

36

-E.H

.

WH

T/R

ED

#3

2-E

.H.

WH

T/B

LK

#3

1-E

.H.

LS4

NO

BR

N-8

WH

T-8

SE

CO

ND

AR

YU

PL

IMIT

SW

ITC

H

LS2

NC

CR9

CR10

CR9CR10

CUT-OUT (OPTION)

PLATFORM LEVEL

BL

K-6

RE

D-6

SE

CO

ND

AR

YB

OO

M

DO

WN

UP

PR

IMA

RY

BO

OM

DO

WN

UP

PR

IMA

RY

BO

OM

RE

TR

AC

T

EX

TE

ND

PL

AT

FO

RM

LE

VE

L

DO

WN

UP

PL

AT

FO

RM

RO

TA

TE

LE

FT

RIG

HT

JIB

BO

OM

DO

WN

UP

DR

IVE

EN

AB

LE

D.E.

JIB

BO

OM

DO

WN

UP

PL

AT

FO

RM

RO

TA

TE

LE

FT

RIG

HT

PL

AT

FO

RM

LE

VE

L

DO

WN

UP

PR

IMA

RY

BO

OM

RE

TR

AC

T

EX

TE

NDP

RIM

AR

YB

OO

M

DO

WN

UP

SE

CO

ND

AR

YB

OO

M

DO

WN

UP

ES34GP2D

BR

AK

ER

EL

EA

SE

Section 6 - SchematicsService Manual


Electrical Schematic, Gasoline/LPG Models(from serial number 869 to 1186)


6 - 11 Genie Z-34/22 IC Part No. 43037

1

2

3

4

5

6

7

8


RE

D/B

LK

#R

6-E

.H.

WH

T#

21

-E.H

.

RE

D-E

.H.

OR

G/B

LK

#4

1-E

.H.

RE

D/B

LK

#2

8-E

.H.

RE

D/W

HT

#2

3-E

.H.

RE

D#

27

-E.H

.

BL

K/R

ED

EX

CT.B

AT

TE

RY

-

+

RE

GU

LA

TO

R

SE

RV

ICE

HO

RN

RE

LA

Y

ALT

ER

NA

TO

R

CH

OK

ES

OL

EN

OID

RP

MS

OL

EN

OID

SE

RV

ICE

HO

RN

-

BA

T.

AU

XIL

IAR

YP

OW

ER

RE

LA

Y

AU

XIL

IAR

YP

UM

P

LE

VE

LS

EN

SO

R

STA

RT

ER

MO

TO

R

BL

K/R

ED

#R

4-E

.H.

BL

K/W

HT

#R

8-E

.H.

IND

.

BA

T.

STA

.

+

BL

K#

R5

-E.H

.

CR8 CR4

NOCR5 CR5

NOPR1 PR1

NO

CR6

BL

U/W

HT

#R

6-E

.H.

OPS1 WTS1

NO

IGN

ITIO

NS

YS

TE

M

OIL

PR

ES

SU

RE

SE

ND

ER

HO

UR

ME

TE

R

NC

CH

OK

ER

EL

AY

FU

EL

PU

MP

WA

TE

RT

EM

P.

SE

ND

ER

WH

T/B

LK

#2

5E

.H.

WH

T

DISTRIBUTOR

G

-

+

COIL

BL

K/W

HT

WN

T/R

ED

#2

6E

.H.

CR8

RP

MC

OIL

FL

AS

HIN

GB

EA

CO

NS

FU

EL

RE

LA

Y

FU

EL

RE

LA

Y

AN

TI-D

IES

EL

VA

LVE

LP

GS

OL

EN

OID

RP

MC

UT

OU

TC

OIL

RE

LA

Y

TU

RN

TA

BL

ER

OTA

TE

LE

FT

TU

RN

TA

BL

ER

OTA

TE

RIG

HT

CR4

BL

U/W

HT

#R

6-E

.H.

BL

U/R

ED

#R

7-E

.H.

CR7CR6

NO

CR7

CR3

FB

WH

T/B

LK

#5

-E.H

.

WH

T#

4-E

.H.

NO

CR1

TB22KS1

BL

K/R

ED

RE

D#

20

-E.H

.R

ED

TB20

CB1

10 AMP.

10 AMP.

TB27

OR

G/B

LK

-1

RED

TB41

TB9

TB28

TB23

P1RED

GRND

RED PLAT

RE

D

TS15

WH

T-2

RE

D/B

LK

-1

BL

K/R

ED

-3

RE

D-1

CB2

BL

K-2 P3

HORN

RE

D

TS1

P2 FS1

BLKRED

TB38

TS18

TB34TB33

TB24

1

10

56789

432

BL

K#

R1

-E.H

.

CR1

TB21

NO

CR2 CR2

KEY BYPASSIGN./FUEL ONENG. FAULT

GROUND

KEY PWR.BATTERY

START INPUTAUX. ON

IGN./STARTMODULE

START RELAYTACHOMETER

TS16

BL

K

BL

K/W

HT

-1

BL

K-1

TS17B

LK

/RE

D

RE

D/W

HT

#2

3-E

.H.

VAC

TB35

TB4

TB5

HIG

HR

PM

BL

U/W

HT

-1

BL

U/R

ED

-1

TB39

BL

K/R

ED

-1

WH

T/B

LK

-3

TS20

TS19

WH

T-3

TS2TS3

TS4 TS5TS6

CR3

WH

T#

21

-E.H

.

AU

XIL

IAR

YP

OW

ER

AU

XIL

IAR

YP

OW

ER

WHT

NO

TS27

LIFT/DRIVESELECT (OPTION)

SW

ING

LE

FT

RIG

HT

SW

ING

LE

FT

RIG

HT

EN

GIN

ES

PE

ED

HIG

HR

PM

GA

SF

UE

LL

P

GA

SF

UE

LL

P

EN

GIN

EC

HO

KE

EN

GIN

EC

HO

KE

EN

GIN

ES

TA

RT

EN

GIN

ES

TA

RT

STARTER

ES34GP1E

LOAD SENSE OPTION(SEE DETAIL BELOW)

RED/BLK

LOAD SENSE OPTION

LOAD SENSE PCB

WHT

3A

21 3

BRN

54 6 7

21 3 4

11

RED/BLK

CR11

8 9 10 12

P2RED

WHT

RE

D/W

HT

CR11

FS1

BLK

EN

GIN

ES

PE

ED



Part No. 43037 Genie Z-34/22 IC 6 - 12

1

2

3

4

5

6

7

8


DE

CE

NT

AL

AR

M(O

PT

ION

AL

)

SE

CO

ND

AR

YB

OO

MU

P

SE

CO

ND

AR

YB

OO

MD

WN

PR

IMA

RY

BO

OM

DW

N

PR

IMA

RY

BO

OM

UP

BL

U#

10

-E.H

.

A3

BL

U/B

LK

#11

-E.H

.

RE

D/B

LK

#2

-E.H

.

RE

D#

1-E

.H.

PL

AT

FO

RM

LE

VE

LU

P

PL

AT

FO

RM

LE

VE

LD

WN

PR

IMA

RY

BO

OM

RE

TR

AC

T

PR

IMA

RY

BO

OM

EX

TE

ND

PL

AT

FO

RM

RO

TA

TE

BL

K/W

HT

#8

-E.H

.

BL

K#

7-E

.H.

OR

G/B

LK

#1

5-E

.H.

OR

G#

14

-E.H

.

DR

IVE

ED

C

BR

N-6

BR

N-7

BO

OM

UP

LIM

ITS

WIT

CH

BO

OM

EX

TE

ND

LIM

ITS

WIT

CH

BO

OM

FL

OW

CO

NT

RO

L

PL

AT

FO

RM

JIB

ST

EE

RR

IGH

T

ST

EE

RL

EF

T

MO

TO

RS

TR

OK

E

WH

T-6

WH

T-7

NC

LS1

NO

LS2

WH

T/R

ED

-E.H

.

TB40TB29

TB37

DR

IVE

EN

AB

LE

LIM

ITS

WIT

CH

GR

OU

ND

TB12

WHT#12-E.H.

NCNO

LS3

BL

K-3

TB10

TB11 TB2

TB1

BL

U/B

LK

-3

TS21

BL

U-3

BL

K/W

HT

-3

RE

D/B

LK

-3

TS22

RE

D-3

TB8

TB7

TB15

TB14

TB17

TB18

ORG-JIB

BLU-JIB

OR

G/B

LK

-3

TS23 TS24

OR

G-3

GR

N/B

LK

-3

TS25

BLK-JIB

GR

N-3

GR

N/B

LK

-1

GR

N-1

WHT-JIB

TS7 TS8 TS9 TS10

BR

N-J

IB

TS11 TS12

TB44

TB43

TB6

TB36 TB32 TB31

WH

T/R

ED

-3

TS26

OR

G-1

WH

T/B

LK

-1

WH

T/R

ED

-1

BL

U/B

LK

-1

RE

D/W

HT

-1

RED

BL

U-1

TB30 TB13

BL

U/R

ED

-3

BR

N-2

BL

U/W

HT

-3

WH

T-1

AOEM

CONTROL

FLOW

R

+

-

X

10

9

6

8

7

5

BP1

ROTARY

HORSE

POWER

LIMITER

BOARD

3

4

2

1

RE

D/W

HT

R2

25

0

HIG

H

RE

DL

OW

7

8

5

4

6

TS13

DP1

2

3

1

L1

TS14

4

R1

BL

K-5

BR

N-5

RE

D-5

WH

T-5

RE

D/W

HT

#2

5-E

.H.

BL

U/B

LK

#3

7-E

.H.

BL

U#

36

-E.H

.

WH

T/R

ED

#3

2-E

.H.

WH

T/B

LK

#3

1-E

.H.

LS4

NO

BR

N-8

WH

T-8

SE

CO

ND

AR

YU

PL

IMIT

SW

ITC

H

LS2

NC

CR9

CR10

CR9CR10

CUT-OUT (OPTION)

PLATFORM LEVEL

BL

K-6

RE

D-6

SE

CO

ND

AR

YB

OO

M

DO

WN

UP

PR

IMA

RY

BO

OM

DO

WN

UP

PR

IMA

RY

BO

OM

RE

TR

AC

T

EX

TE

ND

PL

AT

FO

RM

LE

VE

L

DO

WN

UP

PL

AT

FO

RM

RO

TA

TE

LE

FT

RIG

HT

JIB

BO

OM

DO

WN

UP

DR

IVE

EN

AB

LE

D.E.

JIB

BO

OM

DO

WN

UP

PL

AT

FO

RM

RO

TA

TE

LE

FT

RIG

HT

PL

AT

FO

RM

LE

VE

L

DO

WN

UP

PR

IMA

RY

BO

OM

RE

TR

AC

T

EX

TE

NDP

RIM

AR

YB

OO

M

DO

WN

UP

SE

CO

ND

AR

YB

OO

M

DO

WN

UP

ES34GP2E

BR

AK

ER

EL

EA

SE



Ground Control Box Wiring Diagram,Diesel Models (before serial number 869)


Ground Control Box Wiring Diagram,Diesel Models(before serial number 869)


6 - 13 Genie Z-34/22 IC Part No. 43037

1

2

3

4

5

6

7

8


ES34D4C

RED-S.P.1RED-3 PRI. BOOM UPRED-M.H.

BRN-GRD.-R4-85

RED-27D

RED-R2-30

WHT-R2-86

WHT-24D10

9

8

7

6

5

4

BLK-33B

BLK-R1-86

ORG/BLK-41D

3

2

1

D C

ENG. FAULT

IGN./FUEL ON

KEY BYPASS

KEY PWR.

BATTERY

GROUND

AUX. ON

START INPUT

TACHOMETER

START RELAY

MODULE

IGN./START

B A

ORG/RED-1

ORG/BLK-1

ORG-1

BLU/RED-1

BLU/WHT-1

BLU/BLK-1

BLU-1

BLK/RED-1

BLK/WHT-1

BLK-1

WHT/BLK-1

WHT-1

R/W-1

WHT/RED-1

RED-1

WHT-2

BLK-2

WHT-E.H.

WHT-E.H.

RED/BLK-1

GRN/WHT-3

GRN/BLK-3

ORG/RED-3

ORG-3

ORG/BLK-3

GRN-3

BLU-3

BLU/BLK-3

BLU/WHT-3

BLK-3

BLK/WHT-3

BLK/RED-3

BLU/RED-3

RED/WHT-3

WHT-3

WHT/BLK-3

RED/BLK-3

WHT/RED-3 W/R-M.H.

WHT/BLK-M.H.

RED/BLK-M.H.

WHT-M.H.

BLK/WHT-M.H.

BK/RD-CR5

BLK-M.H.

ORG/BLK-M.H.

ORG-M.H.

WHT-E.H.

WHT-5

WHT-CR2

RED-E.H.

WT/RD-E.H.

RED-E.H.

WT/RD-E.H.

WT/BK-E.H.

RD/WT-M.H.

WT-10-ISM

BLK-CR5

WT/BK-E.H.

RD/WT-E.H.

RD/BK-M.H.

RED-5

BU/BK-M.H.

BLU-M.H.

BK-3-ISM

OG/BK-E.H.

WHT-7

DRV. ENA.

HORN

BOOM FUNCTION F.C.

BOOM EXTEND

SEC. BOOM DN

SEC. BOOM UP

12V BATT. SUPPLY

BOOM RETRACT

PLAT. LEVEL. UP

PLAT. LEVEL DN.

PLAT. ROT. L.

PLAT. ROT. R.

DRV. ENA. LT.

IGNITION PWR.

PRI. BOOM DOWN

TURN. ROT. R

TURN. ROT. L

BU/BK-S.P.11

6

2

5

4

3

10

7

9

8

WT/RD-S.P.

WHT-S.P.

RD/BK-S.P.

RD/WT-S.P.

WT/BK-S.P.

BLU-S.P.

BLK-S.P.

BK/WT-S.P.

16

15

14

12

13

21

20

19

18

17

ORG-S.P.

OG/BK-S.P.

BLK-5

RED-S.P.

GRN-S.P.

GR/BK-S.P.

L.P.

GAS

PULSE PICKUP

LIMIT SWITCH

STEER LEFT

START

RPM

2WD/4WD

E.D.C.

E.D.C.

BRAKE

AUX. PWR.

KEYSWITCH PWR.

PWR. TO PLAT.

TILT ALARM

GLOW PLUG

WARNING SENDER

OIL PRESSURE SENDER

WATER TEMP. SENDER

STEER RIGHT

32

RD-4-ISM

25

26

24

23

22

29

30

31

27

28

RED-S.P.

BLK-S.P.

WHT-S.P.

WT/BK-S.P.

WT/RD-S.P.

BK/RD-CR3

37

36

33

34

35

BLK-CR3

42

40

41

38

39

BLK-S.P.

BK/RD-S.P.

WHT-6

GRN/WHT-1

GRN-1

JIB DOWN

JIB UP

45

44

43

RED-CR17

OG/BK-2ISM

WHT-SP-DB

WHT/RED-26A

WHT-21A

BRN (GROUND)

WHT/BLK-25A

HM

-

+

NC

NC

NO NO

#5

CABLE

HARNESS

ENGINE/MANIFOLD

#3

CABLE

2

CABLE

#1

#7

CABLE

CABLE

#6

CABLEWHT-23A

BLK-22A

RED-27A

BLK/RED-35A

GRN-17A

GRN/BLK-18A

BLK/WHT-8A

BLK-7A

RED-1A

RED/BLK-2A

BLU-10A

BLU/BLK-11A

WHT-4A

WHT/BLK-5A

WHT/RED-3A

RED-20A

GRN-43A

GRN/BLK-44A

ORG-14A

ORG/BLK-15A

RED-R1#30

BLK/WHT-34A

BLK-33A

GRN/BLK-1 GR/BK-S.P.

GRN-S.P.

VOLTAGE OIL PRESSURE COOLANT TEMP.BRNBLK-7

BRN-2

47

46 BRN-8BRN-5 BRN

BRN-E.H.

GROUND

GROUND

BLK/RED-R4-E.H.

WHT-9 ISM

RED-6 ISM

BLK-1-ISM

RED-CB2

BLK-22D

BLK/RED-9D

BLK-R1-E.H.

BLK-R5-M.H.

5

WHT-21D

1 2 3

BLK/RED-35D

BLK-33D

BLK/WHT-34D

BLK/WHT-R8-E.H.

8

4

P1

KS1

TS15

TS23

TS22

TS21

TS20

TS25

TS24

TS26

CB1TS19

TS16TS17

CB2

KS1

TS15

TS16

TS25

TS19

P1

LABEL

TS22

TS23

TS20

CB1

CB2

HM

R1

TS24

BOOM EXTEND/RETRACT SWITCH

CIRCUIT BREAKER, ENGINE, 10A

CIRCUIT BREAKER, CONTROLS, 10A

PRIMARY BOOM UP/DOWN SWITCH

PLATFORM ROTATE SWITCH

TURNTABLE ROTATE SWITCH

RESISTOR, 5 OHM, BOOM FUNCTIONS

HOUR METER

PLATFORM LEVEL SWITCH

DESCRIPTION

AUXILIARY SWITCH

KEY SWITCH

ENGINE RPM SWITCH

EMERGENCY STOP BUTTON

ENGINE START SWITCH

TS17 ENGINE GLOW PLUG SWITCH

TS21 SECONDARY BOOM UP/DOWN SWITCH

TS26 JIB UP/DOWN SWITCH

R1

BRN-6

WHT-8

BLK-6

BLK-6

ORG/BLK-TB15B

ORG-TB14B

10 9

BRN-GRD

RED-6

ORG/BLK-E.H.

ORG-E.H.

PLATFORM LEVEL CUT-OUT OPTION

CABLE

#8

BK/WT-S.P.BK/WT-CR8

BLU/BLK-M.H.

BLU-M.H.

WHT-TB23B

BRN-5 ISM

ENGINE HARNESSEH

MANIFOLD HARNESSMH

(OPT)

(OPT)

Ground Control Box Wiring Diagram,Diesel Models



Part No. 43037 Genie Z-34/22 IC 6 - 14

1

2

3

4

5

6

7

8


ES34D5E

RED-S.P.1RED-3 PRI. BOOM UPRED-M.H.

BRN-GRD.-R4-85

RED-27D

RED-R2-30

WHT-R2-86

WHT-24D10

9

8

7

6

5

4

BLK-33B

BLK-R1-86

ORG/BLK-41D

3

2

1

D C

ENG. FAULT

IGN./FUEL ON

KEY BYPASS

KEY PWR.

BATTERY

GROUND

AUX. ON

START INPUT

TACHOMETER

START RELAY

MODULE

IGN./START

B A

ORG/RED-1

ORG/BLK-1

ORG-1

BLU/RED-1

BLU/WHT-1

BLU/BLK-1

BLU-1

BLK/RED-1

BLK/WHT-1

BLK-1

WHT/BLK-1

WHT-1

R/W-1

WHT/RED-1

RED-1

WHT-2

BLK-2

WHT-E.H.

WHT-E.H.

RED/BLK-1

GRN/WHT-3

GRN/BLK-3

ORG/RED-3

ORG-3

ORG/BLK-3

GRN-3

BLU-3

BLU/BLK-3

BLU/WHT-3

BLK-3

BLK/WHT-3

BLK/RED-3

BLU/RED-3

RED/WHT-3

WHT-3

WHT/BLK-3

RED/BLK-3

WHT/RED-3 W/R-M.H.

WHT/BLK-M.H.

RED/BLK-M.H.

WHT-M.H.

BLK/WHT-M.H.

BK/RD-CR5

BLK-M.H.

ORG/BLK-M.H.

ORG-M.H.

WHT-E.H.

WHT-5

WHT-CR2

RED-E.H.

WT/RD-E.H.

RED-E.H.

WT/RD-E.H.

WT/BK-E.H.

RD/WT-M.H.

WT-10-ISM

BLK-CR5

WT/BK-E.H.

RD/WT-E.H.

RD/BK-M.H.

RED-5

BU/BK-M.H.

BLU-M.H.

BK-3-ISM

OG/BK-E.H.

WHT-7

DRV. ENA.

HORN

BOOM FUNCTION F.C.

BOOM EXTEND

SEC. BOOM DN

SEC. BOOM UP

12V BATT. SUPPLY

BOOM RETRACT

PLAT. LEVEL. UP

PLAT. LEVEL DN.

PLAT. ROT. L.

PLAT. ROT. R.

DRV. ENA. LT.

IGNITION PWR.

PRI. BOOM DOWN

TURN. ROT. R

TURN. ROT. L

BU/BK-S.P.11

6

2

5

4

3

10

7

9

8

WT/RD-S.P.

WHT-S.P.

RD/BK-S.P.

RD/WT-S.P.

WT/BK-S.P.

BLU-S.P.

BLK-S.P.

BK/WT-S.P.

16

15

14

12

13

21

20

19

18

17

ORG-S.P.

OG/BK-S.P.

BLK-5

RED-S.P.

GRN-S.P.

GR/BK-S.P.

L.P.

GAS

PULSE PICKUP

LIMIT SWITCH

STEER LEFT

START

RPM

2WD/4WD

E.D.C.

E.D.C.

BRAKE

AUX. PWR.

KEYSWITCH PWR.

PWR. TO PLAT.

TILT ALARM

GLOW PLUG

WARNING SENDER

OIL PRESSURE SENDER

WATER TEMP. SENDER

STEER RIGHT

32

RD-4-ISM

25

26

24

23

22

29

30

31

27

28

RED-S.P.

BLK-S.P.

WHT-S.P.

WT/BK-S.P.

WT/RD-S.P.

BK/RD-CR3

37

36

33

34

35

BLK-CR3

42

40

41

38

39

BLK-S.P.

BK/RD-S.P.

WHT-6

GRN/WHT-1

GRN-1

JIB DOWN

JIB UP

45

44

43

RED-CR17

OG/BK-2ISM

WHT-SP-DB

WHT/RED-26A

WHT-21A

BRN (GROUND)

WHT/BLK-25A

HM

-

+

NC

NC

NO NO

#5

CABLE

HARNESS

ENGINE/MANIFOLD

#3

CABLE

2

CABLE

#1

#7

CABLE

CABLE

#6

CABLEWHT-23A

BLK-22A

RED-27A

BLK/RED-35A

GRN-17A

GRN/BLK-18A

BLK/WHT-8A

BLK-7A

RED-1A

RED/BLK-2A

BLU-10A

BLU/BLK-11A

WHT-4A

WHT/BLK-5A

WHT/RED-3A

RED-20A

GRN-43A

GRN/BLK-44A

ORG-14A

ORG/BLK-15A

RED-R1#30

BLK/WHT-34A

BLK-33A


GRN-S.P.

VOLTAGE OIL PRESSURE COOLANT TEMP.BRNBLK-7

BRN-2

47

46 BRN-8BRN-5 BRN

BRN-E.H.

GROUND

GROUND

BLK/RED-R4-E.H.

WHT-9 ISM

RED-6 ISM

BLK-1-ISM

RED-CB2

BLK-22D

BLK/RED-9D

BLK-R1-E.H.

BLK-R5-M.H.

5

WHT-21D

1 2 3

BLK/RED-35D

BLK-33D

BLK/WHT-34D

BLK/WHT-R8-E.H.

8

4

P1

KS1

TS15

TS23

TS22

TS21

TS20

TS25

TS24

TS26

CB1TS19

TS16TS17

CB2

KS1

TS15

TS16

TS25

TS19

P1

LABEL

TS22

TS23

TS20

CB1

CB2

HM

R1

TS24








HOUR METER


DESCRIPTION

AUXILIARY SWITCH

KEY SWITCH

ENGINE RPM SWITCH


ENGINE START SWITCH

TS17 ENGINE GLOW PLUG SWITCH



R1

BRN-6

WHT-8

BLK-6

BLK-6

ORG/BLK-TB15B

ORG-TB14B

10 9

BRN-GRD

RED-6

ORG/BLK-E.H.

ORG-E.H.


CABLE

#8

BK/WT-S.P.BK/WT-CR8

BLU/BLK-M.H.

BLU-M.H.

WHT-TB23B

BRN-5 ISM

ENGINE HARNESSEH

MANIFOLD HARNESSMH

(OPT)

(OPT)


Ground Control Box Wiring Diagram,Diesel Models


Ground Control Box Wiring Diagram,Gasoline/LPG Models(before serial number 869)


Ground Control Box Wiring Diagram,Gasoline/LPG Models(before serial number 869)


6 - 15 Genie Z-34/22 IC Part No. 43037

1

2

3

4

5

6

7

8


ES34GP4C

RED-S.P.1RED-3 PRIMARY BOOM UPRED-M.H.

RED-27D

RED-R2-30

WHT-R2-86

WHT-24D10

9

8

7

6

5

4

BLK-33B

BLK-R1-86

ORG/BLK-41D

3

2

1

D C

ENG. FAULT

IGN./FUEL ON

KEY BYPASS

KEY PWR.

BATTERY

GROUND

AUX. ON

START INPUT

TACHOMETER

START RELAY

IGN./STARTMODULE

B A

ORG/RED-1

ORG/BLK-1

ORG-1

BLU/RED-1

BLU/WHT-1

BLU/BLK-1

BLU-1

BLK/RED-1

BLK/WHT-1

BLK-1

WHT/BLK-1

WHT-1

R/W-1

WHT/RED-1

RED-1

WHT-2

BLK-2

WHT-E.H.

WHT-E.H.

RED/BLK-1

GRN/WHT-3

GRN/BLK-3

ORG/RED-3

ORG-3

ORG/BLK-3

GRN-3

BLU-3

BLU/BLK-3

BLU/WHT-3

BLK-3

BLK/WHT-3

BLK/RED-3

BLU/RED-3

RED/WHT-3

WHT-3

WHT/BLK-3

RED/BLK-3

WHT/RED-3 W/R-M.H.

WHT/BLK-M.H.

RED/BLK-M.H.

WHT-M.H.

BLK/WHT-M.H.

BK/RD-CR5

BLK-M.H.

ORG/BLK-M.H.

ORG-M.H.

WHT-E.H.

WHT-5

WHT-CR2

RED-E.H.

WT/RD-E.H.

RED-E.H.

WT/RD-E.H.

WT/BK-E.H.

RD/WT-E.H.

WT-10-ISM

BLK-CR5

WT/BK-E.H.

RD/WT-E.H.

RD/BK-M.H.

RED-5

BU/BK-M.H.

BLU-M.H.

BK-3-ISM

OG/BK-E.H.

BU/WT-CR6

WHT-7

DRIVE ENABLE

HORN

BOOM FUNCTION FLOW CONTROL

BOOM EXTEND

SECONDARY BOOM DOWN

SECONDARY BOOM UP

12V BATTERY SUPPLY

BOOM RETRACT

PLATFORM LEVEL UP

PLATFORM LEVEL DOWN

PLATFORM ROTATE LEFT

PLATFORM ROTATE RIGHT

DRIVE ENABLE LIGHT

IGNITION POWER

PRIMARY BOOM DOWN

TURNTABLE ROTATE RIGHT

TURNTABLE ROTATE LEFT

BU/BK-S.P.11

6

2

5

4

3

10

7

9

8

WT/RD-S.P.

WHT-S.P.

RD/BK-S.P.

RD/WT-S.P.

WT/BK-S.P.

BLU-S.P.

BLK-S.P.

BK/WT-S.P.

16

15

14

12

13

21

20

19

18

17

ORG-S.P.

OG/BK-S.P.

BLK-5

RED-S.P.

GRN-S.P.

GR/BK-S.P.

L.P.

GAS

PULSE PICKUP

LIMIT SWITCH

STEER LEFT

ENGINE START

RPM

2WD/4WD

E.D.C.

E.D.C.

BRAKE

AUILIARY POWER

KEYSWITCH POWER

POWER TO PLATFORM

TILT ALARM

GLOW PLUG

WARNING SENDER

OIL PRESSURE SENDER

WATER TEMP. SENDER

STEER RIGHT

32

RD-4-ISM

25

26

24

23

22

29

30

31

27

28

RED-S.P.

BLK-S.P.

WHT-S.P.

WT/BK-S.P.

WT/RD-S.P.

BK/RD-CR3

37

36

33

34

35

BLK-CR3

42

40

41

38

39

BLK-S.P.

BK/RD-S.P.

WHT-6

BU/WT-S.P.

BU/RD-S.P.

GRN/WHT-1

GRN-1

JIB DOWN

JIB UP

45

44

43

RED-CR17

OG/BK-2ISM

WHT-SP-DB

WHT/RED-26A

WHT-21A

BRN (GROUND)

WHT/BLK-25A

HM

-

+

NC

NC

NO NO

CABLE #3

ENGINE/MANIFOLDHARNESS

CABLE #2

CABLE #1

CABLE #5

CABLE #6

CABLE #7WHT-23A

BLK-22A

RED-27A

BLK/RED-35A

GRN-17A

GRN/BLK-18A

BLK/WHT-8A

BLK-7A

RED-1A

RED/BLK-2A

BLU-10A

BLU/BLK-11A

WHT-4A

WHT/BLK-5A

WHT/RED-3A

RED-20A

GRN-43A

GRN/BLK-44A

ORG-14A

ORG/BLK-15A

RED-R1#30

BLU/RED-39A

BLU/WHT-38A

BLK/WHT-34A

BLK-33A


GRN-S.P.

VOLTAGEGAUGE

OIL PRESSUREGAUGE

COOLANT TEMPERATUREGAUGE

BRNBLK-7

BRN-2

47

46 BRN-8BRN-5 BRN

BRN-E.H.

GROUND

GROUND

BLU/RED-CR7

BLU/RED-39D

BLU/RED-R7-E.H.

BLK/RED-R4-E.H.

WHT-9 ISM

RED-6 ISM

BLK-1-ISM

RED-CB2

BLK-22D

BLK/RED-9D

BLK-R1-E.H.

BLK-R5-M.H. BLU/WHT-R6-E.H.

RED/BLK-R6-E.H.

BLU/WHT-38D

CR6 CR7

WHT-21D

CR1 CR2 CR3

BLK/RED-35D

BLK-33D

BLK/WHT-34D

BLK/WHT-R8-E.H.

CR8

CR4

P1

KS1

TS15

TS23

TS22

TS21

TS20

TS25

TS24

TS26

CB1TS19

TS16

TS18

TS17

CB2

KS1

TS15

TS16

TS18

TS25

TS19

P1

LABEL

TS22

TS23

TS20

CB1

CB2

HM

R1

TS24








HOUR METER


ENGINE FUEL SELECT SWITCH

DESCRIPTION

AUXILIARY SWITCH

KEY SWITCH

ENGINE RPM SWITCH


ENGINE START SWITCH

TS17 ENGINE CHOKE SWITCH



R1

BRN-6

WHT-8

BLK-6

BLK-6

ORG/BLK-TB15B

ORG-TB14B

CR10 CR9

BRN-GRD

RED-6

ORG/BLK-E.H.

ORG-E.H.


CABLE #8

BLK/WHT-CR8

RD/WT-M.H.

BLU/BLK-M.H.

BLU-M.H.

BRN-5 ISM

ENGINE HARNESSEH

MANIFOLD HARNESSMH

(OPT)

(OPT)

CR5

BRN-GRD -R4-85

Ground Control Box Wiring Diagram,Gasoline/LPG Models



Part No. 43037 Genie Z-34/22 IC 6 - 16

1

2

3

4

5

6

7

8


ES34GP5E

RED-S.P.1RED-3 PRIMARY BOOM UPRED-M.H.

RED-27D

RED-R2-30

WHT-R2-86

WHT-24D10

9

8

7

6

5

4

BLK-33B

BLK-R1-86

ORG/BLK-41D

3

2

1

D C

ENG. FAULT

IGN./FUEL ON

KEY BYPASS

KEY PWR.

BATTERY

GROUND

AUX. ON

START INPUT

TACHOMETER

START RELAY

IGN./STARTMODULE

B A

ORG/RED-1

ORG/BLK-1

ORG-1

BLU/RED-1

BLU/WHT-1

BLU/BLK-1

BLU-1

BLK/RED-1

BLK/WHT-1

BLK-1

WHT/BLK-1

WHT-1

R/W-1

WHT/RED-1

RED-1

WHT-2

BLK-2

WHT-E.H.

WHT-E.H.

RED/BLK-1

GRN/WHT-3

GRN/BLK-3

ORG/RED-3

ORG-3

ORG/BLK-3

GRN-3

BLU-3

BLU/BLK-3

BLU/WHT-3

BLK-3

BLK/WHT-3

BLK/RED-3

BLU/RED-3

RED/WHT-3

WHT-3

WHT/BLK-3

RED/BLK-3

WHT/RED-3 W/R-M.H.

WHT/BLK-M.H.

RED/BLK-M.H.

WHT-M.H.

BLK/WHT-M.H.

BK/RD-CR5

BLK-M.H.

ORG/BLK-M.H.

ORG-M.H.

WHT-E.H.

WHT-5

WHT-CR2

RED-E.H.

WT/RD-E.H.

RED-E.H.

WT/RD-E.H.

WT/BK-E.H.

RD/WT-E.H.

WT-10-ISM

BLK-CR5

WT/BK-E.H.

RD/WT-E.H.

RD/BK-M.H.

RED-5

BU/BK-M.H.

BLU-M.H.

BK-3-ISM

OG/BK-E.H.

BU/WT-CR6

WHT-7

DRIVE ENABLE

HORN

BOOM FUNCTION FLOW CONTROL

BOOM EXTEND

SECONDARY BOOM DOWN

SECONDARY BOOM UP

12V BATTERY SUPPLY

BOOM RETRACT

PLATFORM LEVEL UP

PLATFORM LEVEL DOWN

PLATFORM ROTATE LEFT

PLATFORM ROTATE RIGHT

DRIVE ENABLE LIGHT

IGNITION POWER

PRIMARY BOOM DOWN

TURNTABLE ROTATE RIGHT

TURNTABLE ROTATE LEFT

BU/BK-S.P.11

6

2

5

4

3

10

7

9

8

WT/RD-S.P.

WHT-S.P.

RD/BK-S.P.

RD/WT-S.P.

WT/BK-S.P.

BLU-S.P.

BLK-S.P.

BK/WT-S.P.

16

15

14

12

13

21

20

19

18

17

ORG-S.P.

OG/BK-S.P.

BLK-5

RED-S.P.

GRN-S.P.

GR/BK-S.P.

L.P.

GAS

PULSE PICKUP

LIMIT SWITCH

STEER LEFT

ENGINE START

RPM

2WD/4WD

E.D.C.

E.D.C.

BRAKE

AUILIARY POWER

KEYSWITCH POWER

POWER TO PLATFORM

TILT ALARM

GLOW PLUG

WARNING SENDER

OIL PRESSURE SENDER

WATER TEMP. SENDER

STEER RIGHT

32

RD-4-ISM

25

26

24

23

22

29

30

31

27

28

RED-S.P.

BLK-S.P.

WHT-S.P.

WT/BK-S.P.

WT/RD-S.P.

BK/RD-CR3

37

36

33

34

35

BLK-CR3

42

40

41

38

39

BLK-S.P.

BK/RD-S.P.

WHT-6

BU/WT-S.P.

BU/RD-S.P.

GRN/WHT-1

GRN-1

JIB DOWN

JIB UP

45

44

43

RED-CR17

OG/BK-2ISM

WHT-SP-DB

WHT/RED-26A

WHT-21A

BRN (GROUND)

WHT/BLK-25A

HM

-

+

NC

NC

NO NO

CABLE #3

ENGINE/MANIFOLDHARNESS

CABLE #2

CABLE #1

CABLE #5

CABLE #6

CABLE #7WHT-23A

BLK-22A

RED-27A

BLK/RED-35A

GRN-17A

GRN/BLK-18A

BLK/WHT-8A

BLK-7A

RED-1A

RED/BLK-2A

BLU-10A

BLU/BLK-11A

WHT-4A

WHT/BLK-5A

WHT/RED-3A

RED-20A

GRN-43A

GRN/BLK-44A

ORG-14A

ORG/BLK-15A

RED-R1#30

BLU/RED-39A

BLU/WHT-38A

BLK/WHT-34A

BLK-33A


GRN-S.P.

VOLTAGEGAUGE

OIL PRESSUREGAUGE

COOLANT TEMPERATUREGAUGE

BRNBLK-7

BRN-2

47

46 BRN-8BRN-5 BRN

BRN-E.H.

GROUND

GROUND

BLU/RED-CR7

BLU/RED-39D

BLU/RED-R7-E.H.

BLK/RED-R4-E.H.

WHT-9 ISM

RED-6 ISM

BLK-1-ISM

RED-CB2

BLK-22D

BLK/RED-9D

BLK-R1-E.H.

BLK-R5-M.H. BLU/WHT-R6-E.H.

RED/BLK-R6-E.H.

BLU/WHT-38D

CR6 CR7

WHT-21D

CR1 CR2 CR3

BLK/RED-35D

BLK-33D

BLK/WHT-34D

BLK/WHT-R8-E.H.

CR8

CR4

P1

KS1

TS15

TS23

TS22

TS21

TS20

TS25

TS24

TS26

CB1TS19

TS16

TS18

TS17

CB2

KS1

TS15

TS16

TS18

TS25

TS19

P1

LABEL

TS22

TS23

TS20

CB1

CB2

HM

R1

TS24








HOUR METER


ENGINE FUEL SELECT SWITCH

DESCRIPTION

AUXILIARY SWITCH

KEY SWITCH

ENGINE RPM SWITCH


ENGINE START SWITCH

TS17 ENGINE CHOKE SWITCH



R1

BRN-6

WHT-8

BLK-6

BLK-6

ORG/BLK-TB15B

ORG-TB14B

CR10 CR9

BRN-GRD

RED-6

ORG/BLK-E.H.

ORG-E.H.


CABLE #8

BLK/WHT-CR8

RD/WT-M.H.

BLU/BLK-M.H.

BLU-M.H.

BRN-5 ISM

ENGINE HARNESSEH

MANIFOLD HARNESSMH

(OPT)

(OPT)

CR5

BRN-GRD -R4-85




Platform Control Box Wiring Diagram,Diesel Models


Platform Control Box Wiring Diagram,Diesel Models


6 - 17 Genie Z-34/22 IC Part No. 43037

1

2

3

4

5

6

7

8

A B C D E F G H I J K L M N O

ES34D3E

CA

BL

E#

3C

AB

LE

#1

JIB

F.S

.11

0

TILT

AL

AR

M

RED/BLK-1

NO

NC

NC

NO

NC

NC

BR

N#

2-H

PL

RE

D/W

HT

-3

WH

T#

1-H

PL

WH

T-2

BL

K-F

.S.

BL

K-2

BL

K/R

ED

-3

WH

T/R

ED

#3

2-1

BL

U#

36

-1

BL

U/B

LK

#3

7-1

WH

T#

30

-1

WH

T/B

LK

#3

1-1

OR

G#

40

-1

OR

G/B

LK

#4

1-1

RE

D/W

HT

#2

9-1

RE

D#

27

-1

BL

U/R

ED

-3

WH

T/R

ED

-3

OR

G/B

LK

-3

OR

G-3

RE

D/B

LK

-3

RE

D-3

GR

N/B

LK

-3

GR

N-3

BL

K/W

HT

-3

BL

K-3

WH

T/B

LK

-3

WH

T-3

BL

U/B

LK

-3

BL

U-3

GR

N/B

LK

#4

4-1

GR

N#

43

-1

BL

U/W

HT

-3

BL

K/R

ED

#3

5-1

BL

K/W

HT

#3

4-1

BL

K#

33

-1

RE

D-F

.S.

BL

K-J

IB

WH

T-J

IB

BL

UE

-JIB

BR

N-J

IB

OR

G-J

IB

BP

1

+A - X R

1 32 54 76 8

RE

D#

10

-HP

L1

0 9 8 567 34

HORSE POWER LIMITER

2 1B

RN

-2

WH

T-F

S

25

0

P3

TS

1

TS

14

TS

6T

S7

TS

8

TS

9

TS

11

TS

10 T

S1

2

DP1

TS

13

TS

5

TS

3T

S2

P2

L1

TS14

TS13

DP1

BP1

TS1

TS2

TS3

P2

LABEL

TS7

TS6

TS8

TS9

TS10

TS11

TS12

TS5



EXTEND/RETRACT SWITCH

SECONDARY BOOM UP/DOWN SWITCH


JIB UP/DOWN SWITCH

DRIVE ENABLE SWITCH

DRIVE HIGH/LOW OUTPUT SWITCH


RPM SWITCH

START SWITCH

DESCRIPTION

BOOM FUNCTION SPEED CONTROLLER

DRIVE CONTROLLER

GLOW PLUG SWITCH


AUXILIARY SWITCH

P3 HORN BUTTON

R2

250 OHM RESISTERR2

L1 DRIVE ENABLE LIGHT

REMOVE THIS WIRE WHEN LOAD SENSE OPTION IS REQUIRED.

CA

BL

E#

2

ORG/RED#42-1

ORG/RED-3

GRN/WHT#45-1

SPARE WIRES

RED-JIB

Platform Control Box Wiring Diagram,Gasoline/LPG Models


Part No. 43037 Genie Z-34/22 IC 6 - 18

1

2

3

4

5

6

7

8

O N M L K J I H G F E D C B A

ES34GP3E

CA

BL

E#

3C

AB

LE

#1

JIB

F.S

.11

0

TILT

AL

AR

M

RED/BLK-1

NO

NC

NC

NO

NC

NC

BR

N#

2-H

PL

RE

D/W

HT

-3

WH

T#

1-H

PL

WH

T-2

BL

K-F

.S.

BL

K-2

BL

K/R

ED

-3

WH

T/R

ED

#3

2-1

BL

U#

36

-1

BL

U/B

LK

#3

7-1

WH

T#

30

-1

WH

T/B

LK

#3

1-1

OR

G#

40

-1

OR

G/B

LK

#4

1-1

RE

D/W

HT

#2

9-1

RE

D#

27

-1

BL

U/R

ED

-3

WH

T/R

ED

-3

OR

G/B

LK

-3

OR

G-3

RE

D/B

LK

-3

RE

D-3

GR

N/B

LK

-3

GR

N-3

BL

K/W

HT

-3

BL

K-3

WH

T/B

LK

-3

WH

T-3

BL

U/B

LK

-3

BL

U-3

GR

N/B

LK

#4

4-1

GR

N#

43

-1

BL

U/W

HT

-3

BL

U/R

ED

#3

9-1

BL

U/W

HT

#3

8-1

BL

K/R

ED

#3

5-1

BL

K/W

HT

#3

4-1

BL

K#

33

-1

RE

D-F

.S.

BL

K-J

IB

WH

T-J

IB

BL

UE

-JIB

BR

N-J

IB

OR

G-J

IB

BP

1

+A - X R

1 32 54 76 8

RE

D#

10

-HP

L1

0 9 8 567 34

HORSE POWER LIMITER

2 1B

RN

-2

WH

T-F

S

25

0

P3

TS

1

TS

14

TS

6T

S7

TS

8

TS

9

TS

11

TS

10 T

S1

2

DP1

TS

13

TS

4T

S5

TS

3T

S2

P2

L1

TS14

TS13

DP1

BP1

TS1

TS2

TS4

TS3

P2

LABEL

TS7

TS6

TS8

TS9

TS10

TS11

TS12

TS5



EXTEND/RETRACT SWITCH

SECONDARY BOOM UP/DOWN SWITCH

FUEL SELECT SWITCH


JIB UP/DOWN SWITCH

DRIVE ENABLE SWITCH

DRIVE HIGH/LOW OUTPUT SWITCH


RPM SWITCH

START SWITCH

DESCRIPTION

BOOM FUNCTION SPEED CONTROLLER

DRIVE CONTROLLER

CHOKE SWITCH


AUXILIARY SWITCH

P3 HORN BUTTON

R2

250 OHM RESISTERR2

L1 DRIVE ENABLE LIGHT

REMOVE THIS WIRE WHEN LOAD SENSE OPTION IS REQUIRED.

CA

BL

E#

2

ORG/RED#42-1

ORG/RED-3

GRN/WHT#45-1

SPARE WIRES

RED-JIB





Hydraulic Schematic, 2WD Models(before serial number 674)

6 - 19 Genie Z-34/22 IC Part No. 43037

1

2

3

4

5

6

7

8


B PORT

M3

BRAKE/2 SPEEDMANIFOLD

LEFTREARBRAKE

M1

T3

0.070inch

CHARGE PRESSURE

0.025inch

T P

RIGHTREARBRAKE

T2 T1

M2

M4

250PSI

TANK (18 GALLONS)

A PORT

0.085 inch

2WDTRACTIONMANIFOLD STEERING

CYLINDER

25 PSI

M

AUXILIARYPUMP0.5 GPM

DRIVE PUMP

3500PSI

320PSI

E

B

3500PSI

A

LIFT/STEERPUMP

3.0 GPM

CHARGE PRESSURE

A

B

S2

S1

T3

L1

T1

P1

BRAKE

2 SPD

150-175 PSI

150-175 PSI

CP

A

BD

C

B

A

5PSI



Part No. 43037 Genie Z-34/22 IC 6 - 20

1

2

3

4

5

6

7

8


JIB BOOM

PLATFORM ROTATE

2500 PSI3:1

0.025 inch

2500 PSI3:1

PRIMARY BOOM EXTENSION

1800 PSI

PRIMARY BOOM

1400 PSI

0.032 inch

1600 PSI

SECONDARY BOOM

3000 PSI1.5:1

1750 PSI

TURNTABLE ROTATE

5.9 CU. IN./REV

1750 PSI

3000 PSI

3:1

3000 PSI8:1

MASTER

PLATFORM LEVEL SLAVE CYLINDER

0.030 inch

.050

S1

T1

T2

P2

T3 T4

3200 PSI

S2

.8 GPM

G1

P1

P1

T3

S1

S2

0.1 GPM

T1

C1 C2 M1 M2 C6 C7 C8

J1 J2 PR1 PR2

A

E

B

C

D

W

M

F G

H

I J K

L

N O

X

P Q R S T U V A B C D

E

2500 PSI3:1

3000 PSI3:1

C3 C4 C5




Hydraulic Schematic, 2WD Models(from serial number 674 to 1029)

6 - 21 Genie Z-34/22 IC Part No. 43037

1

2

3

4

5

6

7

8


B PORT

M3


LEFTREARBRAKE

M1

T3

0.070inch

CHARGE PRESSURE

0.025inch

T P

RIGHTREARBRAKE

T2 T1

M2

M4

250PSI

TANK (18 GALLONS)

A PORT


CYLINDER

25 PSI

M


DRIVE PUMP

3500PSI

320PSI

E

B

3500PSI

A

LIFT/STEERPUMP

3.0 GPM

CHARGE PRESSURE

A

B

S2

S1

T3

L1

T1

P1

BRAKE

2 SPD

150-175 PSI

150-175 PSI

CP

A

BD

C

B

A

5PSI



Part No. 43037 Genie Z-34/22 IC 6 - 22

1

2

3

4

5

6

7

8


JIB BOOM

PLATFORM ROTATE

2500 PSI3:1

0.025 inch

2500 PSI3:1


1800 PSI

PRIMARY BOOM

1400 PSI

0.032 inch

1600 PSI

SECONDARY BOOM

3000 PSI1.5:1

TURNTABLE ROTATE

5.9 CU. IN./REV

3000 PSI3:1

3000 PSI8:1

MASTER


0.030 inch

.050

S1

T1

T2

P2

T3 T4

3200 PSI

S2

.8 GPM

G1

P1

P1

T3

S1

S2

0.1 GPM

T1

C1 C2 M1 M2 C6 C7 C8

J1 J2 PR1 PR2

A

E

B

C

D

W

M

F G HI

J K

L

N O

X


E

2500 PSI3:1

3000 PSI3:1

C3 C4 C5

1500 PSI3:1





6 - 23 Genie Z-34/22 IC Part No. 43037

1

2

3

4

5

6

7

8


B PORT

M3


LEFTREARBRAKE

M1

T3

0.070inch

CHARGE PRESSURE

0.025inch

T P

RIGHTREARBRAKE

T2 T1

M2

M4

250PSI

TANK (18 GALLONS)

A PORT


CYLINDER

25 PSI

M


DRIVE PUMP

3500PSI

320PSI

E

B

3500PSI

A

LIFT/STEERPUMP

3.0 GPM

CHARGE PRESSURE

A

B

S2

S1

T3

L1

T1

P1

BRAKE

2 SPD

150-175 PSI

150-175 PSI

CP

A

BD

C

B

A

5PSI



Part No. 43037 Genie Z-34/22 IC 6 - 24

1

2

3

4

5

6

7

8

JIB BOOM

PLATFORM ROTATE

2500 PSI3:1

3000 PSI3:1


1800 PSI

PRIMARY BOOM

1400 PSI

0.032 inch

1600 PSI

SECONDARY BOOM

3000 PSI1.5:1

TURNTABLE ROTATE

5.9 CU. IN./REV

3000 PSI3:1

3000 PSI8:1

MASTER


0.025 inch

.050

S1

T1

T2

P2

T3 T4

3200 PSI

S2

.8 GPM

G1

P1

P1

T3

S1

S2

0.1 GPM

T1

C1 C2 M1 M2 C6 C7 C8

J1 J2 PR1 PR2

A

E

B

C

D

W

M

F G HI

J K

L

N O

X

P Q R S T U V A B C DE

2500 PSI3:1

3000 PSI3:1

C3 C4 C5

1500 PSI3:1

0.025 inch

0.028inch

F






6 - 25 Genie Z-34/22 IC Part No. 43037

1

2

3

4

5

6

7

8


T1

M3


REARLEFT

M1

T3

0.070inch

CHARGE PRESSURE

0.025inch

T P

REARRIGHT

M2

HYDRAULIC TANK

0.085 inch4WDTRACTIONMANIFOLD

STEERING

25PSI

M


DRIVE PUMP

320 PSI

E

B

3500 PSI

A

LIFT/STEERPUMP3.0 GPM

CHARGE PRESSURE

A

B

S2

S1

T3

L1

T1

P1

BRAKE

2 SPD

150-175 PSI

150-175 PSI

P

M6

M5

M7

FRONTLEFT

FRONTRIGHT

0.052inch

33%67%

0.070 inch

250PSI

A PORT

T2

M4

CP

B PORT

M8

5PSI

AB

C

D

E

C

HI

J

F

G

3500 PSI

A

B



Part No. 43037 Genie Z-34/22 IC 6 - 26

1

2

3

4

5

6

7

8


JIB BOOM

PLATFORM ROTATE

2500 PSI3:1

0.025 inch

2500 PSI3:1


1800 PSI

PRIMARY BOOM

1400 PSI

0.032 inch

1600 PSI

SECONDARY BOOM

3000 PSI1.5:1

1750 PSI

TURNTABLE ROTATE

5.9 CU. IN./REV

1750 PSI

3000 PSI

3:1

3000 PSI8:1

MASTER


0.030 inch

.050

S1

T1

T2

P2

T3 T4

3200 PSI

S2

.8 GPM

G1

P1

P1

T3

S1

S2

0.1 GPM

T1

C1 C2 M1 M2 C6 C7 C8

J1 J2 PR1 PR2

A

E

B

C

D

W

M

F G

H

I J K

L

N O

X


E

2500 PSI3:1

3000 PSI3:1

C3 C4 C5





6 - 27 Genie Z-34/22 IC Part No. 43037

1

2

3

4

5

6

7

8


T1

M3


REARLEFT

M1

T3

0.045inch

CHARGE PRESSURE

0.025inch

T P

REARRIGHT

M2

HYDRAULIC TANK

4WDTRACTIONMANIFOLD

STEERING

25PSI

M


DRIVE PUMP

320 PSI

E

B

3500 PSI

A


CHARGE PRESSURE

A

B

S2

S1

T3

L1

T1

P1

BRAKE

2 SPD

150-175 PSI

150-175 PSI

P

M6

M5

M7

FRONTLEFT

FRONTRIGHT

0.052inch

33%67%

0.052 inch

250PSI

A PORT

T2

M4

CP

B PORT

M8

5PSI

AB

C

D

E

C

HI

J

F

G

3500 PSI

A

B



Part No. 43037 Genie Z-34/22 IC 6 - 28

1

2

3

4

5

6

7

8


JIB BOOM

PLATFORM ROTATE

2500 PSI3:1

0.025 inch

2500 PSI3:1


1800 PSI

PRIMARY BOOM

1400 PSI

0.032 inch

1600 PSI

SECONDARY BOOM

3000 PSI1.5:1

TURNTABLE ROTATE

5.9 CU. IN./REV

3000 PSI3:1

3000 PSI8:1

MASTER


0.030 inch

.050

S1

T1

T2

P2

T3 T4

3200 PSI

S2

.8 GPM

G1

P1

P1

T3

S1

S2

0.1 GPM

T1

C1 C2 M1 M2 C6 C7 C8

J1 J2 PR1 PR2

A

E

B

C

D

W

M

F G HI

J K

L

N O

X


E

2500 PSI3:1

3000 PSI3:1

C3 C4 C5

1500 PSI3:1





6 - 29 Genie Z-34/22 IC Part No. 43037

1

2

3

4

5

6

7

8


T1

M3


REARLEFT

M1

T3

0.045inch

CHARGE PRESSURE

0.025inch

T P

REARRIGHT

M2

HYDRAULIC TANK

4WDTRACTIONMANIFOLD

STEERING

25PSI

M


DRIVE PUMP

320 PSI

E

B

3500 PSI

A


CHARGE PRESSURE

A

B

S2

S1

T3

L1

T1

P1

BRAKE

2 SPD

150-175 PSI

150-175 PSI

P

M6

M5

M7

FRONTLEFT

FRONTRIGHT

0.052inch

33%67%

0.052 inch

250PSI

A PORT

T2

M4

CP

B PORT

M8

5PSI

AB

C

D

E

C

HI

J

F

G

3500 PSI

A

B



Part No. 43037 Genie Z-34/22 IC 6 - 30

1

2

3

4

5

6

7

8


JIB BOOM

PLATFORM ROTATE

2500 PSI3:1

3000 PSI3:1


1800 PSI

PRIMARY BOOM

1400 PSI

0.032 inch

1600 PSI

SECONDARY BOOM

3000 PSI1.5:1

TURNTABLE ROTATE

5.9 CU. IN./REV

3000 PSI3:1

3000 PSI8:1

MASTER


0.025 inch

.050

S1

T1

T2

P2

T3 T4

3200 PSI

S2

.8 GPM

G1

P1

P1

T3

S1

S2

0.1 GPM

T1

C1 C2 M1 M2 C6 C7 C8

J1 J2 PR1 PR2

A

E

B

C

D

W

M

F G HI

J K

L

N O

X

P Q R S T U V A B C DE

2500 PSI3:1

3000 PSI3:1

C3 C4 C5

1500 PSI3:1

0.025 inch

0.028inch

F



Part No. 43037 Genie Z-34/22 IC 7 - 1

Service Manual - First Edition Section 7 - Repair Procedures


Symbols Legend





Indicates that a specific result is expected afterperforming a series of steps.

Repair Procedures

About This SectionMost of the procedures in this section should onlybe performed by a trained service professionalin a suitably equipped workshop. Select theappropriate repair procedure after troubleshootingthe problem.

Perform disassembly procedures to the pointwhere repairs can be completed. Then tore-assemble, perform the disassembly steps inreverse order.

Observe and Obey:

Repair procedures shall be completed by aperson trained and qualified on the repair of thismachine.



Before Repairs Start:

Read, understand and obey the safety rulesand operating instructions in theGenie Z-34/22 IC Operator's Manual.

Be sure that all necessary tools and parts areavailable and ready for use.

Read each procedure completely and adhere tothe instructions. Attempting shortcuts mayproduce hazardous conditions.

Unless otherwise specified, perform each repairprocedure with the machine in the followingconfiguration:



· Turntable rotated with the boom betweenthe non-steer wheels


· Wheels chocked



Identifysymptoms

Troubleshoot

Performrepair


solved

problemstill exists

Inspectand test

7 - 2 Genie Z-34/22 IC Part No. 43037

Service Manual - First EditionSection 7 - Repair Procedures

Platform Controls

2 Open the control box lid and locate thehorsepower limiter board.

Electrocution hazard. Contactwith electrically charged circuitsmay result in death or seriousinjury. Remove all rings, watchesand other jewelry.

a horsepower limiter board

3 Connect the black(-) lead from a DC volt meterto the no. 2 terminal, and the red(+) lead to theno. 10 terminal.

Horsepower limiter boarda "A" potentiometer: maximum voltage

output to the controller in thestowed position

b "B" potentiometer: maximum voltageoutput to the drive controller in theboom raised position

c "C" potentiometer: reaction rate orhow fast the voltage output reacts tothe change in engine rpm

1-1Horsepower Limiter BoardThe horsepower limiter board is responsible forgoverning drive pump output. It senses engine rpmfrom the alternator. The horsepower limiter boardsenses drops in rpm normally due to increaseddrive resistance (rough terrain or incline) anddecreases voltage to the drive controller which inturn decreases voltage to the drive pump therebyreducing pump output to maintain optimum enginerpm and horsepower. Three adjustments arerequired for optimum performance.

How to Adjust the HorsepowerLimiter Board

The engine rpm must becorrect before performing thisprocedure. See MaintenanceProcedure B-10, Check andAdjust the Engine RPM.

Do not adjust the horsepowerlimiter board unless the staticbattery voltage is above 12V DCand the alternator is operatingproperly with 12.5 to 14.5V DCoutput.

Kubota Gasoline/LPG models:Perform this procedure in gasolinemode.

1 Remove the fasteners from the platformcontrol box lid.

a

12V DC or greatergroundengine rpm sensornot usednot usedlow drive speed limit switchnot usednot usednot usedoutput to drive controller

b

a

c

Part No. 43037 Genie Z-34/22 IC 7 - 3


PLATFORM CONTROLS

12 Disconnect the volt meter.

13 Raise the primary boom above the drive limitswitch.

a drive limit switch

14 Drive the machine for 40 feet (12 m) andrecord the elapsed time. Repeat this step inthe opposite drive direction.

15 Adjust the "B" potentiometer to obtain thecorrect raised drive speed of 1 foot per second(30.5 cm per second).

16 Close the platform control box lid and installthe fasteners.

Drive speed specificationsStowed position, high range

2WD 4WDKubota Gas/LPG Models 40 ft6.1 sec 40 ft/6.8 sec

12.2 m/6.1 sec 12.2 m/6.8 sec

Kubota Diesel Models 40 ft/6.1 sec 40 ft/6.8 sec12.2 m/6.1 sec 12.2 m/6.8 sec

Booms raised or 40 feet/40 secondsextended, high range 12 meters/40 secondsAll models


5 Move the engine idle control switch to footswitch activated high idle (rabbit and foot switchsymbol).

6 Press down the foot switch and adjust the"A" potentiometer counterclockwise to increasevoltage or clockwise to decrease voltage.

"A" potentiometer specifications - all models

Voltage setting 8.5 V DC

7 Move the engine idle control switch to low idle(turtle symbol).

8 Press down the foot switch and then adjustthe "C" potentiometer to obtain a 0V DC voltagereading.

9 Move the engine idle control switch to footswitch activated high idle (rabbit and foot switchsymbol). Move the drive select switchto high range (machine on level groundsymbol).

10 Press down the foot switch and re-adjust the"A" potentiometer to the previous voltagesetting in step 6.

11 Be sure that the boom is in the stowed position,then drive the machine and observe how theengine rpm reacts to drive control handlemovement. If the engine surges or hunts, adjustthe "C" potentiometer counterclockwise untilsurging is minimized.

Under an extreme load, anexcessive counterclockwiseadjustment to the "C"potentiometer will causethe engine to stall. The "C"potentiometer adjustment is acompromise between enginestability (surging) and enginerpm droop.

a

7 - 4 Genie Z-34/22 IC Part No. 43037


PLATFORM CONTROLS

Boom Function SpeedController Adjustments


Do not adjust the controllersunless the static battery supplyvoltage is above 12V DC.

1 Turn the key switch to platform control and pullthe Emergency Stop button to the ON position atboth the ground and platform controls.

2 Open the platform control box lid and locate theboom function speed controller.

a black wireb diodec white/red wired boom function speed controllere max-out adjustable trimpotf threshold adjustable trimpot

3 Locate the diode between the black wire fromthe boom function speed controller and thewhite/red wire.

4 Connect the red (+) lead from a volt meter tothe wire connector of the white/red wire next tothe diode. Connect the black (-) lead to ground.

5 Turn the boom function speed controller to theCREEP position.

6 Set the threshold: Press down the foot switch,then move the primary boom switch to theUP position until the voltage reading appears.Adjust the voltage to 5.00 to 6.00V DC. Turn thethreshold trimpot adjustment screw clockwise toincrease the voltage or counterclockwise todecrease the voltage.

7 Turn the boom function speed controller tothe 9 position.

8 Set the max-out: Press down the foot switch,then move the primary boom switch to theUP position. Adjust the voltage to 8.5 to9.0V DC. Turn the max-out trimpot adjustmentscrew clockwise to increase the voltage orcounterclockwise to decrease the voltage.

Boom function speedcontroller specifications

Threshold 5.00 to 6.00V DC

Max-out 8.5 to 9.0V DC

1-2Diodes

How to Test a Diode1 Connect the leads from an ohmmeter to each

end of the diode.

2 Re-connect the leads from the ohmmeter to theopposite ends (from step 1) of the diode. Thediode should have resistance in one directionand not the other.

a

b

c

d

e

f

Part No. 43037 Genie Z-34/22 IC 7 - 5


PLATFORM CONTROLS

1-3Foot Switch

How to Test the Foot Switch1 Turn the key switch to the OFF position and

separate the wiring quick disconnect plug fromthe platform toe board.

2 Do not press down the foot switch. Connect theleads from an ohmmeter or continuity tester toeach wire combination listed below and checkfor continuity.

Test Desired result

red to black continuity(zero Ω)

red to white no continuity(infinite Ω)

black to white no continuity

Do not use the color of theconnector as a guide for thesetests. Use the actual wire colorto identify which connector touse for testing.

3 Press down the foot switch. Connect the leadsfrom an ohmmeter or continuity tester to eachwire combination listed below and check forcontinuity.

Test Desired result

red to black no continuity(infinite Ω)

red to white no continuity

black to white continuity(zero Ω)

7 - 6 Genie Z-34/22 IC Part No. 43037


PLATFORM CONTROLS

Right

Single poledouble throw(SPDT)

Double poledouble throw(DPDT)

CenterLeft

1

2

3

4 5 6

1 2 3

1

2

3 1

2

3

1 2 3 1 2 3

1 2 3 1 2 3 1 2 3

4 5 6 4 5 6

1-4Toggle Switches

Toggle switches used for single function switchingare single pole double throw (SPDT) switches.Dual function switching requires a double poledouble throw (DPDT) switch.

How to Test a Toggle SwitchContinuity is the equivalent of 0 to3 ohms. A simple continuity testermay not accurately test the switch.

This procedure covers fundamental switch testingand does not specifically apply to all varieties oftoggle switches.

1 Turn the key switch to the OFF position. Tagand disconnect all wiring from the toggle switchto be tested.

2 Connect the leads of an ohmmeter to the switchterminals in the following combinations listedbelow to check for continuity.

Test Desired result

Left position

terminal 1 to 2, 3, 4, 5 & 6 no continuity(infinite Ω)

terminal 2 to 3 continuity(zero Ω)

terminal 2 to 4, 5 & 6 no continuity


terminal 4 to 5 & 6 no continuity

terminal 5 to 6 continuity

Center position There are no terminalcombinations that will

produce continuity(infinite Ω)

Right position


terminal 1 to 3, 4, 5 & 6 no continuity(infinite Ω)

terminal 2 to 3, 4, 5 & 6 no continuity


terminal 4 to 5 continuity

terminal 4 to 6 no continuity

terminal 5 to 6 no continuity

Part No. 43037 Genie Z-34/22 IC 7 - 7


Platform Components

2-1Platform

How to Remove the Platform1 Separate the foot switch wiring quick disconnect

plug from the platform toeboard.

2 Remove the platform control box mountingfasteners, then lower the control box.

If your machine is equipped withan air line to platform option, theair line must be disconnected fromthe platform before removal.

3 Place blocks under the platform railing forsupport. Then carefully lower the platform ontothe blocks.

4 Remove the platform mounting fasteners andremove the platform.

Do not overtighten the platformmounting fasteners duringinstallation.

2-2Platform Leveling Slave Cylinder

The slave cylinder and the rotator pivot are thetwo primary supports for the platform. The slavecylinder keeps the platform level through theentire range of primary boom motion. It operates ina closed-circuit hydraulic loop with the mastercylinder. The slave cylinder is equipped withcounterbalance valves to prevent movement inthe event of a hydraulic line failure.

How to Remove the SlaveCylinder

Before cylinder removal isconsidered, bleed the slavecylinder to be sure there is noair in the closed loop.

1 Extend the boom until the slave cylinderbarrel-end pivot pin is accessible.

2 Raise the boom slightly and place blocks underthe platform. Then lower the boom until theplatform is resting on the blocks.

3 Remove the pin retainer fastener fromthe rod-end pivot pin.

4 Remove the external retaining ring from thebarrel-end pivot pin.

5 Use a soft metal drift and drive the rod-endpivot pin out.

6 Use a soft metal drift and drive the barrel-endpivot pin out.

7 Carefully pull the cylinder out of the boom.

8 Disconnect and tag the hydraulic hoses fromthe slave cylinder and connect them togetherwith a connector. Cap the fittings on thecylinder.


7 - 8 Genie Z-34/22 IC Part No. 43037


PLATFORM COMPONENTS

How to Bleed the Slave Cylinder1 Raise the jib boom to a horizontal position.

2 Move the platform level switch up and downthrough two platform leveling cycles to removeany air that might be in the system.

2-3Platform Rotator

The platform rotator is a hydraulically-activatedhelical gear assembly used to rotate the platform160 degrees.

How to Remove thePlatform Rotator1 Remove the platform. See 2-1,

How to Remove the Platform.

2 Tag, disconnect and plug the hydraulic hosesfrom the platform rotator manifold.


3 Support the platform mounting weldment, but donot apply any lifting pressure.

4 Remove the six mounting bolts from theplatform mounting weldment, then remove thecenter bolt and slide the platform mountingweldment off of the platform rotator.

5 Support the platform rotator. Do not applyany lifting pressure.

6 Remove the pin retainers from the jib boom andleveling links to platform rotator pivot pins. Donot remove the pins.

7 Support the jib boom and leveling links.

8 Use a soft metal drift to drive both pins out, thenremove the platform rotator from the machine.

Part No. 43037 Genie Z-34/22 IC 7 - 9


PLATFORM COMPONENTS

How to Bleed the PlatformRotator1 Connect a clear hose to the top bleed valve.

Place the other end of the hose in a containerto collect any discharge.

a clear hoseb top bleed valvec bottom bleed valved container

2 Open the top bleed valve, but do not remove it.


position.

4 Hold the platform rotate switch to the right forapproximately 5 seconds, then release it.Repeat three times.

Crushing hazard. Keep handsclear of the platform pivotweldment during rotation.

5 Hold the platform rotate switch to the left forapproximately 5 seconds, then release it.

6 Fully rotate the platform to the left and continueholding the platform rotate switch until air stopscoming out of the bleed valve. Immediatelyrelease the platform rotate switch and close thebleed valve.

7 Rotate the platform to the right until it iscentered.

8 Connect the clear hose to the bottom bleedvalve and open the valve.

9 Rotate the platform to the right and continueholding the platform rotate switch until air stopscoming out of the bleed valve.

Crushing hazard. Keep handsclear of the platform pivotweldment during rotation.

10 Close the bleed valve and remove the hose.

11 Turn the key switch to the OFF position andclean up any hydraulic oil that may have spilled.


position.

13 Rotate the platform full left and right and inspectthe bleed valves for leaks.

b

c

d

a

7 - 10 Genie Z-34/22 IC Part No. 43037


Jib Boom Components

3-1Jib Boom

How to Remove the Jib BoomPerform this procedure with theboom in the stowed position.

1 Remove the platform. See 2-1,How to Remove the Platform.

2 Remove the platform mounting weldmentand the platform rotator. See 2-3, How toRemove the Platform Rotator.

3 Tag, disconnect and plug the jib boom liftcylinder hydraulic hoses.


4 Remove the job boom manifold cover.

5 Remove the mounting fasteners from the jibboom manifold.

6 Remove the cable cover from the side of thejib boom.

7 Support the jib boom with an overhead crane.

8 Remove the pin retainer from the jib boompivot pin. Use a soft metal drift to remove thepin, then remove the jib boom from theprimary boom.

Crushing hazard. The jib boom willfall when the pin is removedif it is not properly supported.

9 Remove the pin retainers from the jib boomlift cylinder rod-end pivot pin. Do not remove thepin.

10 Remove both of the jib boom leveling links fromthe primary boom.

11 Support the jib boom lift cylinder with anoverhead crane.

12 Use a soft metal drift to remove the jib boom liftcylinder rod-end pivot pin, then remove the jibboom lift cylinder from the primary boom.

Crushing hazard. The jib boomlift cylinder will fall when the pinis removed if it is not properlysupported.

Part No. 43037 Genie Z-34/22 IC 7 - 11


3-2Jib Boom Lift Cylinder

How to Remove the Jib BoomLift Cylinder


1 Raise the jib boom slightly and place blocksunder the platform mounting weldment. Thenlower the jib boom until the platform is restingon the blocks.

2 Disconnect and plug the jib boom lift cylinderhydraulic hoses.


3 Remove the pin retainers from the jib boomlift cylinder rod-end pivot pin. Do not remove thepin.

4 Use a soft metal drift to tap the rod-end pivotpin half way out. Then lower the leveling link tothe ground. Tap the pin the other direction andlower the opposite leveling link. Do not removethe pin.

JIB BOOM COMPONENTS

5 Support the jib boom lift cylinder with anoverhead crane.

6 Remove the pin retainer from the jib boom liftcylinder barrel-end pivot pin. Use a soft metaldrift to remove the barrel-end pin.

7 Use a soft metal drift to remove the jib boom liftcylinder rod-end pin. Remove the cylinder fromthe machine.

Crushing hazard. The jib boom liftcylinder will fall when it is removedif it is not properly supported.

7 - 12 Genie Z-34/22 IC Part No. 43037


JIB BOOM COMPONENTS

3-3Jib Boom / Platform Rotate Manifold Components(before serial number 1030)The jib boom/platform rotate manifold is mounted to the jib boom.

Index SchematicNo. Description Item Function Torque

1 2 position 3 way spool valve ............. A ........... Jib up ................................................8-10 ft-lbs / 11-14 Nm

2 2 position 3 way spool valve ............. D ........... Platform rotate right ..........................8-10 ft-lbs / 11-14 Nm

3 Orifice, 0.030 in (0.76 mm) ................ E ........... Platform rotate circuit

4 2 position 3 way spool valve ............. C ........... Platform rotate left .............................8-10 ft-lbs / 11-14 Nm

5 2 position 3 way spool valve ............. B ........... Jib down ............................................8-10 ft-lbs / 11-14 Nm

Plug Torque Specifications

Description Hex Size Torque

SAE No. 2 1/8 50 in-lbs / 6 Nm

SAE No. 4 3/16 13 ft-lbs / 18 Nm

SAE No. 6 1/4 18 ft-lbs / 24 Nm

SAE No. 8 5/16 50 ft-lbs / 68 Nm

SAE No. 10 9/16 55 ft-lbs / 75 Nm

SAE No. 12 5/8 75 ft-lbs / 102 Nm

How to Check the Resistanceof a Valve Coil1 Turn the key switch to the OFF position and

disconnect the wires from the valve coil tobe tested.

2 Coils with 2 terminals: Connect the leads fromthe ohmmeter to the valve coil terminals.

Coils with 1 terminal: Connect the positivelead from the ohmmeter to the valve coilterminal, then connect the negative lead fromthe ohmmeter to the internal ring of the valvecoil.

Valve coil specification

2 position 3 way valve, 10V 5.5 to 6.5Ω

Part No. 43037 Genie Z-34/22 IC 7 - 13


JIB BOOM COMPONENTS

3-4Jib Boom / Platform Rotate Manifold Components(after serial number 1029)The jib boom/platform rotate manifold is mounted to the jib boom.


1 2 position 3 way spool valve ............. A ........... Jib up ................................................8-10 ft-lbs / 11-14 Nm

2 2 position 3 way spool valve ............. D ........... Platform rotate right ..........................8-10 ft-lbs / 11-14 Nm

3 2 position 3 way spool valve ............. C ........... Platform rotate left .............................8-10 ft-lbs / 11-14 Nm

4 Orifice, 0.025 in (0.64 mm) ................ E ........... Platform rotate circuit

5 Orifice, 0.028 in (0.71 mm) ................ F ........... Platform rotate and jib boom circuit

6 2 position 3 way spool valve ............. B ........... Jib down ............................................8-10 ft-lbs / 11-14 Nm




SAE No. 4 3/16 13 ft-lbs / 18 Nm

SAE No. 6 1/4 18 ft-lbs / 24 Nm

SAE No. 8 5/16 50 ft-lbs / 68 Nm

SAE No. 10 9/16 55 ft-lbs / 75 Nm

SAE No. 12 5/8 75 ft-lbs / 102 Nm


disconnect the wires from the valve coil tobe tested.



Valve coil specification

2 position 3 way valve, 10V 5.5 to 6.5Ω

6

2

4

1

3

5

7 - 14 Genie Z-34/22 IC Part No. 43037


4-1Plastic Cable Track

The primary boom cable track guides the cablesand hoses running up the boom. It can be repairedlink by link without removing the cables and hosesthat run through it. Removing the entire primaryboom cable track is only necessary whenperforming major repairs that involve removing theprimary boom.

How to Repair the Plastic CableTrack

Component damage hazard. Theprimary boom cable track can bedamaged if it is twisted.

a link separation pointb lower clip

1 Use a slotted screwdriver to pry down on thelower clip.

2 Repeat step 1 for each link.

3 To remove a single link, open the lower clipand then use a screw driver to pry the link tothe side.

4-2Primary Boom

How to Shim the Primary BoomMeasure each wear pad. Replacethe pad if it is less than 0.41 inch(1 cm) thick. If the pad is morethan 0.41 inch (1 cm) thick,perform the following procedure.

1 Extend the boom until the wear pads areaccessible.

2 Loosen the wear pad mounting fasteners.

3 Install the new shims under the wear pad toobtain zero clearance and zero drag.

4 Tighten the mounting fasteners.

5 Extend and retract the boom through an entirecycle. Check for tight spots that could causescraping or binding.

Always maintain squarenessbetween the outer and inner boomtubes.

How to Remove thePrimary Boom

Bodily injury hazard. Thisprocedure requires specific repairskills, lifting equipment and asuitable workshop. Attempting thisprocedure without these skills andtools may cause death or seriousinjury and significant componentdamage. Dealer service is stronglyrecommended.


1 Remove the platform. See 2-1,How to Remove the Platform.

2 Remove the platform rotator. See 2-3, How toRemove the Platform Rotator.

Primary Boom Components

a

b

Part No. 43037 Genie Z-34/22 IC 7 - 15


3 Remove the jib boom. See 3-1,How to Remove the Jib Boom.

4 Support the slave cylinder.

5 Remove the external retaining ring from theslave cylinder barrel-end pivot pin.

6 Use a soft metal drift and drive the slavecylinder barrel-end pin out.

7 Remove the slave cylinder from the primaryboom.

8 Support the cable track with an overhead crane.

9 Remove the hose/cable cover from the pivotend of the boom.

10 Remove the cable track mounting fasteners,then remove the cable track from theboom and lay it off to the side.

Component damage hazard.The boom cable trackcan be damaged if it is twisted.

11 Remove the turntable end cover.

12 Remove the retaining bolt from the mastercylinder rod-end pivot pin. Use a soft metal driftto remove the pin. Pull the cylinder back andsecure it from moving.

13 Remove the drive speed limit switchmounted on the side of the pivot end ofthe boom. Do not disconnect the wiring.

14 Tag, disconnect and plug the extension cylinderhydraulic hoses. Cap the fittings on thecylinder.


15 Attach an overhead 5 ton crane to the centerpoint of the boom.

16 Attach a similar lifting device to the lift cylinder.

17 Use the crane to lift the primary boom to ahorizontal position.

18 Place support blocks under the cylinder, acrossthe secondary boom.

19 Remove the pin retaining fastener from theboom lift cylinder rod-end pin. Use a soft metaldrift to remove the pin.

Crushing hazard. The boom liftcylinder will fall unless it isproperly supported.

20 Lower the rod-end of the lift cylinder ontosupport blocks. Protect the cylinder rod fromdamage.

21 Remove the hose clamp brackets from theunderside of the primary boom.

22 Remove the hose clamp from the side of theprimary boom.

23 Remove the limit switch cam mounting fastener.

Note the position of the cambefore removing it.

24 Remove the pin retaining fastener from theboom pivot pin.

25 Remove the boom pivot pin with a soft metaldrift, then carefully remove the boom from themachine.

Crushing hazard. If the overheadcrane is not properly attached,the boom may becomeunbalanced and fall when it isremoved from the machine.

PRIMARY BOOM COMPONENTS

7 - 16 Genie Z-34/22 IC Part No. 43037



How to Disassemblethe Primary Boom

Complete disassembly of theboom is only necessaryif the outer or inner boom tubesmust be replaced. The extensioncylinder can be removed withoutcompletely disassembling theboom. See 4-4, How to Removethe Extension Cylinder.

1 Remove the boom. See 4-2,How to Remove the Primary Boom.

2 Place blocks under the extension cylinder forsupport.

3 Remove the retaining fasteners from theextension cylinder barrel-end pivot pin. Use asoft metal drift to remove the pin.

4 Remove and label the location of the wear padsfrom the top side of the boom tube, at theplatform end of the boom.

Pay careful attention to thelocation and amount of shimsused with each wear pad.

5 Carefully rotate the base end of the extensioncylinder until the pin mounting bore is in avertical position.

6 Support the extension tube with an overheadcrane at the platform end of the boom.

Crushing hazard. The boom tubeswill fall when they are removedfrom the boom if they are notproperly supported.

7 Support and slide the number 2 extension tubeout of the number 1 primary boom tube. Placethe number 2 boom tube on blocks for support.

During removal, the overheadcrane strap will need to becarefully adjusted for properbalancing.

8 Remove the retaining rings from the extensioncylinder rod-end pivot pin at the platform end ofthe number 2 extension tube. Use a soft metaldrift to remove the pin.

9 Support and slide the extension cylinder out ofthe base end of the number 2 boom tube. Placethe extension cylinder on blocks for support.

During removal, the overheadcrane strap will need to becarefully adjusted for properbalancing.

10 Remove and label the wear pads from theextension cylinder.

Pay careful attention to thelocation of each wear pad.

Part No. 43037 Genie Z-34/22 IC 7 - 17



4-3Primary Boom Lift Cylinder

The lift cylinder raises and lowers the primaryboom. The lift cylinder is equipped withcounterbalance valves to prevent movement in theevent of a hydraulic line failure.

How to Remove the PrimaryBoom Lift Cylinder

Bodily injury hazard. Thisprocedure requires specific repairskills, lifting equipment and asuitable workshop. Attempting thisprocedure without these skills andtools may result in death orserious injury and significantcomponent damage. Dealerservice is strongly recommended.

1 Raise the primary boom enough to access theprimary boom lift cylinder rod-end pivot pin.

2 Attach an overhead crane to the primary boomfor support. Do not lift it.

3 Place a block of wood across the uppersecondary boom to support the cylinder whenthe rod-end pin is removed. Support thecylinder with a lifting device.

4 Raise the secondary boom enough to accessthe primary boom lift cylinder barrel-endpivot pin.

5 Remove the rear turntable cover.

6 Place a 4x4 inch block between the lowercompression arms and the cross member of theupper secondary boom. Carefully lower thesecondary boom onto the block.

Crushing hazard. Keep handsaway from the block and allmoving parts when lowering thesecondary boom.

7 Remove the pin retainer from the primary boomlift cylinder rod-end pin. Then use a soft metaldrift to remove the pin.

8 Lower the rod end of the cylinder onto theblocks that were placed on the uppersecondary boom.

9 Remove the pin retainer from the uppercompression arm pivot pin (same side ofmachine as the primary boom lift cylinderbarrel-end pivot pin retainer).

10 Place a rod through the compression arm pivotpin and twist to remove.

11 Swing the compression arm up out of the way.Secure it from moving.

12 Tag, disconnect and plug the primary boom liftcylinder hydraulic hoses.


13 Support the primary boom lift cylinder withstraps or ropes to restrict it from swingingfreely.

14 Remove the pin retainer from the pivot pin atthe barrel-end of the primary boom lift cylinder.Do not remove the pivot pin.

7 - 18 Genie Z-34/22 IC Part No. 43037



15 Use the overhead crane to lift the primary boom1 inch (2.5 cm). This will relieve pressure on thebarrel-end pivot pin.

16 Place a rod through the barrel-end pivot pin andtwist to remove the pin.

Crushing hazard. When the barrel-end pivot pin is removed, theprimary boom lift cylinder willswing down if it is not properlysupported.

17 Attach an overhead crane or similar liftingdevice to the rod-end of the primary boom liftcylinder. Carefully loosen the straps and allowthe primary boom lift cylinder to slowly swingdown.

18 Carefully remove the cylinder from the machine.

4-4Extension Cylinder

The extension cylinder extends and retracts theprimary boom extension tube. The extensioncylinder is equipped with counterbalance valves toprevent movement in the event of a hydraulic linefailure.

How to Remove theExtension Cylinder


1 Raise the primary boom to the horizontalposition. Then extend the boom 3 to 4 feet(7.6 to 10 m) until the extension cylinderrod-end pivot pins are accessible.

2 Remove the snap rings from the extensioncylinder rod-end pivot pins. Then use a softmetal drift to remove the pins.


4 Raise the secondary boom until the mastercylinder rod-end pivot pin is accessible.

5 Remove the drive limit switch from the base ofthe primary boom. Do not disconnect the wiring.

6 Remove the retaining bolt from the mastercylinder rod end pivot pin, then use a soft metaldrift to remove the pin.

7 Manually retract the master cylinder and push ittoward the platform end of the boom (to obtainenough clearance for the extension cylinderremoval).

Part No. 43037 Genie Z-34/22 IC 7 - 19



8 Disconnect and plug the extension cylinderhydraulic hoses. Cap the fittings on thecylinder.


9 Remove the retaining bolt from the extensioncylinder pivot pin, then use a soft metal drift toremove the pin.

10 Carefully pull out and properly support theextension cylinder from the primary boom.

Crushing hazard. The cylinder willfall if it is not properly supportedwhen it is pulled out of theextension tube.

To make installation of theextension cylinder easier, be surethat the cylinder rod is extended3 to 4 feet (1 m).

4-5Platform Leveling MasterCylinder

The master cylinder acts as a pump for the slavecylinder. It is part of the closed circuit hydraulicloop that keeps the platform level through theentire range of primary boom motion. The mastercylinder is located inside the upper mid-pivot at thepivot end of the primary boom.

How to Remove the PlatformLeveling Master Cylinder


Before cylinder removal isconsidered, bleed the cylinder tobe sure that there is no air in theclosed loop. See 2-2, How toBleed the Slave Cylinder.


2 Raise the secondary boom until the mastercylinder barrel-end pivot pin is above theturntable counterweights.

3 Raise the primary boom until the mastercylinder rod-end pivot pin is accessible.

4 Attach an overhead crane to the pivot end ofthe primary boom. Do not lift it.

7 - 20 Genie Z-34/22 IC Part No. 43037


5 Secure the upper secondary boom to the pivotend of the primary boom with a strap (this willprevent the upper secondary boom from fallingwhen the master cylinder barrel-end pin isremoved from the cylinder).

6 Tag, disconnect and plug the master cylinderhydraulic hoses. Cap the fittings on thecylinder.


7 Tie a strap around the lug on the rod end of themaster cylinder, then secure the strap to theprimary boom (use this strap to lower thecylinder out of the upper mid-pivot).

8 Remove the pin retainer from the mastercylinder rod-end pivot pin. Then use a softmetal drift to remove the pin.

9 Remove the pin retainer from the mastercylinder barrel-end pivot pin. Then use a softmetal 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 toremove the cylinder. The pin should remain inone side of the upper secondary boom andupper mid-pivot.

Crushing hazard. The uppersecondary boom and the uppermid-pivot will fall if the pivot pin iscompletely removed.

10 Use the strap around the rod-end lug to lowerthe cylinder out of the machine.


Part No. 43037 Genie Z-34/22 IC 7 - 21



7 - 22 Genie Z-34/22 IC Part No. 43037


Secondary Boom Components

Secondary Booma upper mid-pivotb upper compression armc lower mid-pivotd compression linke lower secondary boomf lower compression armg turntable pivoth upper secondary boom

a b

d

e

f

g

f

h

b

c

Part No. 43037 Genie Z-34/22 IC 7 - 23


9 Pull the cables out of the platform control box.

10 Pull all of the electrical cables out of the plasticcable track. Do not pull out the hydraulic hoses.

11 Remove the hose clamps from the bottom sideof the primary boom.

12 Tag, disconnect and plug the platform rotatorhydraulic hoses at the union, located on thebottom side of the primary boom.


13 Remove the hose clamp from the side of theprimary boom at the pivot end.

14 Remove the drive speed limit switchmounted on the side of the pivot end ofthe primary boom. Do not disconnect the wiring.

15 Remove the limit switch cam mounting fastenerfrom the primary boom pivot pin then removethe limit switch. Do not disconnect the wiring.

Note the position of the cambefore removing it.

16 Attach a strap from an overhead crane to thepivot end of the primary boom.

17 Carefully lift the secondary and primary boomassembly until the master and primary liftcylinder hydraulic hoses are accessible.

18 Remove the cable covers from the top of theupper secondary boom.

19 Tag, disconnect and plug the primary boom liftcylinder and master cylinder hydraulic hoses.


SECONDARY BOOM COMPONENTS

5-1Secondary Boom

How to Disassemble theSecondary Boom

Bodily injury hazard. Theprocedures in this section requirespecific repair skills, liftingequipment and a suitableworkshop. Attempting thisprocedure without these skills andtools may result in death orserious injury and significantcomponent damage. Dealerservice is required.

Follow the disassembly steps to the point requiredto complete the repair. Then re-assemble thesecondary boom by following the disassemblysteps in reverse order.


2 Place a lifting device under the front of theplatform.


4 Remove the cable cover from the side of the jibboom.

5 Remove the wire loom from the cables at theplatform control box.

6 Locate the 4 cables from the primary boomcable track to the platform control box. Numbereach cable and its entry location at the platformcontrol box.

7 Open the platform control box.

8 Label and disconnect each wire of the 4 cablesin the platform control box.


7 - 24 Genie Z-34/22 IC Part No. 43037


20 Lower the booms to the stowed position.

21 Pull all the cables and hoses through the uppermid-pivot.

Component damage hazard.Cables and hoses can beirreparably damaged if they arekinked or pinched.

22 Position the strap from the overhead craneapproximately two feet from the platform end ofthe primary boom. Measure from the end of theprimary boom tube.

23 Remove the pin retainers from the uppermid-pivot to upper compression arm pivot pins.Use a soft metal drift to remove the pins.

24 Swing the compression arms down and out ofthe way. Secure them from moving.

25 Remove the pin retainers from the uppermid-pivot to upper secondary boom pivot pin.Use a soft metal drift to remove the pin.

26 Carefully remove the entire primary boomassembly from the machine (primary boomassembly, jib boom assembly, platform, mastercylinder, primary lift cylinder and upper mid-pivot).

Crushing hazard. If the overheadcrane is not properly attached, theprimary boom assembly maybecome unbalanced and fall whenit is removed from the machine.Do not remove the assembly frommachine until it is properlybalanced.

27 Place the entire assembly onto a structurecapable of supporting it.

28 Remove the pin retainers from the uppercompression arm pivot pins. Do not remove thepins.

29 Position the lifting strap from an overhead craneat the center of the control box side uppercompression arm, then remove it from themachine. Repeat this step for the engine sideupper compression arm.

Crushing hazard. If the overheadcrane is not properly attached, theupper compression arm maybecome unbalanced and fall whenit is removed from the machine.

30 Remove the pin retainer from the rod end of thesecondary boom lift cylinder. Use a soft metaldrift to remove the pin. Secure the cylinder frommoving.

31 Remove the pin retainer from the lower pivot pinon the compression link. Use a soft metal driftto remove the pin.

32 Attach the strap from an overhead crane to theupper secondary boom.

33 Remove the pin retainer from the uppersecondary boom to lower mid-pivot pivot pin.Use a soft metal drift to remove the pin.

34 Remove the upper secondary boom withcompression link from the machine.

Crushing hazard. If the overheadcrane is not properly attached, theupper secondary boom withcompression link may becomeunbalanced and fall when it isremoved from the machine.

35 Remove the drive speed limit switchmounted on the inside of the lower mid-pivot.Do not disconnect the wiring.

36 Remove the cable covers from the top of thelower secondary boom. Pull all the cables andhoses to the back of the turntable.

37 Remove the LPG hose from the tank and thenremove the LPG tank. (this is to access thebarrel-end mounting pin).


Part No. 43037 Genie Z-34/22 IC 7 - 25



38 Disconnect the battery cables from the batterythen remove the battery hold down and battery.(this is to access the barrel-end mounting pin).

39 Remove the retaining fasteners from thesecondary boom lift cylinder barrel-end pivotpins.

40 Attach the strap from the crane to the lug on therod-end of the secondary boom lift cylinder.

41 Tag, disconnect and plug the hydraulic hosesfrom the secondary boom lift cylinder. Cap thefittings on the cylinder.


42 Use a slide hammer to remove the barrel-endpins (access the pins from the access holes inthe bulkheads, one on each side). Then removethe cylinder from the machine.

Crushing hazard. If the overheadcrane is not properly attached, thesecondary boom lift cylinder maybecome unbalanced and fall whenit is removed from the machine.

43 Attach the strap from the crane to the lowermid-pivot.

44 Remove the pin retainers from the lowermid-pivot to lower compression arm pivot pins.Use a slide hammer and remove the pin.

45 Remove the pin retainers from the lowermid-pivot to lower secondary boom pivot pins.Use a soft metal drift to remove the pin.

46 Remove the lower mid-pivot from the machine.

Crushing hazard. If the overheadcrane is not properly attached, thelower mid-pivot may becomeunbalanced and fall when it isremoved from the machine.

47 Attach the strap from the crane to the controlbox side lower compression arm.

48 Remove the pin retainer from the lowercompression arm to turntable pivot pin. Use aslide hammer and remove the pin. Remove thearm from the machine. Repeat for the engineside lower compression arm.

Crushing hazard. If the overheadcrane is not properly attached, thelower compression arms maybecome unbalanced and fall whenit is removed from the machine.

49 Attach the strap from the crane to the lowersecondary boom.

50 Remove the pin retainer from the lowersecondary boom to turntable pivot pin. Use asoft metal drift to remove the pin.

51 Remove the lower secondary boom from themachine.

Crushing hazard. If the overheadcrane is not properly attached, thelower secondary boom maybecome unbalanced and fall whenit is removed from the machine.

7 - 26 Genie Z-34/22 IC Part No. 43037



5-2Secondary Boom Lift Cylinder

The secondary boom lift cylinder raises andlowers the secondary boom. The secondaryboom lift cylinder is equipped with counterbalancevalves to prevent movement in the event of ahydraulic line failure.

How to Remove the SecondaryBoom Lift Cylinder


1 Rotate the turntable to the side until the boom iscentered between the steer and non-steer tires.

2 Raise the primary boom to full height. Do notextend it.

3 Attach the strap from an overhead crane to thelug on the rod-end of the secondary boom liftcylinder.

4 From the bottom side of the cylinder, removethe retaining fasteners from the secondaryboom lift cylinder barrel-end pivot pins.

5 Use a slide hammer to remove the barrel-endpins (access the pins from the access holes inthe bulkheads, one on each side).

6 Remove the pin retainer from the secondaryboom lift cylinder rod-end pivot pin. Then use asoft metal drift to remove the pin.

7 Carefully lower the cylinder down through thesecondary boom, enough to access thehydraulic hoses. Do not pinch the hoses.

8 Disconnect and plug the hydraulic hoses fromthe secondary boom lift cylinder. Cap thecylinder fittings.


9 Remove the cylinder through the top of thesecondary boom.

Part No. 43037 Genie Z-34/22 IC 7 - 27


Kubota D-905 Engine

6-1Timing Adjustment

Complete information to perform this procedure isavailable in the Kubota D-905 Workshop Manual(Kubota code number: 97897-02432). Genie partnumber 31742.

6-2Glow Plugs

How to Check the Glow PlugsSee the scheduled maintenance procedure B-9,Check The Glow Plugs - Kubota Diesel Models.

6-3Engine RPM

RPM AdjustmentSee the scheduled maintenance procedure B-10,Check and Adjust the Engine RPM.

6-4Flex Plate

The flex plate acts as a coupler between theengine and the pump. It is bolted to the engineflywheel and has a splined center to drivethe pump.

How to Remove the Flex Plate1 Support the drive pump with an appropriate

lifting device. Then remove all of the pumpmounting plate to engine bell housing bolts.

2 Carefully pull the pump away from the engineand secure it from moving.

3 Remove the flex plate mounting fasteners, thenremove the flex plate from the engine.

How to Install the Flex Plate1 Install the flex plate onto the flywheel with the

raised spline away from the flywheel.

a pumpb pump shaftc pump couplerd flex platee flywheel

2 Install the coupler onto the pump shaft with theset screw towards the pump. Leave a 1/32 inch(0.8 mm) gap between the coupler and pumpend plate.

3 Apply Loctite® removable thread sealant to thecoupler set screw. Torque the set screw to36 ft-lbs (49 Nm).

Component damage hazard. Donot force the drive pump duringinstallation or the flex plate teethmay become damaged.

b ea c d

7 - 28 Genie Z-34/22 IC Part No. 43037


KUBOTA D-905 ENGINE

6-5Water Temperature and OilPressure Gauges

The water temperature gauge is an electricalgauge. The sending unit has limit contacts that arefactory set. The contacts will close at 230o F(109o C). When the contacts close, the engine willshut off to prevent damage and will not start untilthe temperature drops below the contact point.Temperature will be indicated when the key is onand the Emergency Stop Button is pulled out to theON position.

Component damage hazard.Do not crank the engine withthe over-temperature light on.

The oil pressure gauge is an electrical gauge. Thesending unit has limit contacts that are factory set.The contacts will close at 8 psi (0.55 bar). Whenthe contacts close, the engine will shut off toprevent damage. Oil pressure will be indicatedwhen the engine is running.

Component damage hazard.Do not crank the engine with thelow oil pressure light on.

Part No. 43037 Genie Z-34/22 IC 7 - 29


7-1Choke Adjustments

The manual choke is solenoid operated and is onlyoperational in the gasoline mode. This choke willnot operate in propane mode.

Choke adjustments are affectedby climate. Richer adjustment willbe necessary in colder climates,leaner adjustment in warmerclimates.

7-2Timing Adjustment

Complete information to perform this procedure isavailable in the Kubota WG-750 Workshop Manual(Kubota number: 97897-00643). Genie partnumber 52492.

7-3Carburetor Adjustment

Complete information to perform this procedure isavailable in the Kubota WG-750 Workshop Manual(Kubota number: 97897-00643). Genie partnumber 52492.

7-4RPM Adjustment

See the scheduled maintenance procedure B-10,Check and Adjust the Engine RPM.

7-5Flex Plate

The flex plate acts as a coupler between theengine and the pump. It is bolted to the engineflywheel and has a splined center to drivethe pump.

Flex Plate Removal1 Support the drive pump with an appropriate

lifting device. Then remove all of the pumpmounting plate to engine bell housing bolts.

2 Carefully pull the pump away from the engineand secure it from moving.

3 Remove the flex plate mounting fasteners, thenremove the flex plate from the engine.

How to Install the Flex Plate1 Install the flex plate onto the flywheel with the

raised spline against the flywheel.


b ea c d

a pumpb pump shaftc pump couplerd flex platee flywheel

7 - 30 Genie Z-34/22 IC Part No. 43037


2 Install the coupler onto the pump shaft with theset screw towards the pump. Leave a 1/32 inch(0.8 cm) gap between the coupler and pumpend plate.

3 Apply removable Loctite® thread sealant to thecoupler set screw. Torque the set screw to36 ft-lbs (49 Nm).

Component damage hazard. Donot force the drive pump duringinstallation or the flex plate teethmay become damaged.

7-6Water Temperature and OilPressure Gauges

The water temperature gauge is an electricalgauge. The sending unit has limit contacts that arefactory set. The contacts will close at 230o F(109o C). When the contacts close, the engine willshut off to prevent damage and will not start untilthe temperature drops below the contact point.Temperature will be indicated when the key is onand the Emergency Stop Button is pulled out to theON position.

Component damage hazard.Do not crank the engine withthe over-temperature light on.

The oil pressure gauge is an electrical gauge. Thesending unit has limit contacts that are factory set.The contacts will close at 8 psi (0.55 bar). Whenthe contacts close, the engine will shut off toprevent damage. Oil pressure will be indicatedwhen the engine is running.

Component damage hazard.Do not crank the engine with thelow oil pressure light on.

KUBOTA WG-750 ENGINE

Part No. 43037 Genie Z-34/22 IC 7 - 31


KUBOTA WG-750 ENGINE

a b

d c

7-7Vacuum Switch

How to Test the Vacuum Switch

a ohmmeterb common terminal (SOL.)c vacuum switchd normally open terminal (ING.)

1 Connect the leads from an ohmmeter orcontinuity tester to the common and normallyopen terminals.

Result: There should be no continuity(infinite Ω).

2 Apply mild suction to the vacuum port.

Result: The switch should close and show fullcontinuity (zero Ω).

Component damage hazard. Donot short vacuum switch terminalsto ground.

7 - 32 Genie Z-34/22 IC Part No. 43037


8-1Control Relays

Relays used for dual function switching are doublepole double throw (DPDT) relays.

How to Test a Single Pole DoubleThrow Relay

Electrocution hazard. Contact withelectrically charged circuits maycause death or serious injury.Remove all rings, watches andother jewelry.

This procedure covers fundamental relay testingand does not specifically apply to all varietiesof relays.

1 Turn the key switch to the OFF position andremove the key.

2 Label and then disconnect all the wiring fromthe relay to be tested.

3 Connect the leads from an ohmmeter to eachterminal combination and check for continuity.Terminals 85 and 86 represent the coil andshould not be tested in any other combination.

Test Desired result

terminal 85 to 86 85 to 95Ω

terminal 87 to 87a & 30 no continuity(infinite Ω)

terminal 87a to 30 continuity(zero Ω)

4 Connect 12V DC to terminal 85 and a groundwire to terminal 86, then test the followingterminal combinations.

Test Desired result

terminal 87a to 87 & 30 no continuity(infinite Ω)


Ground Controls

Relay Schematic

Terminal Numbers

Part No. 43037 Genie Z-34/22 IC 7 - 33


GROUND CONTROLS

8-2Toggle Switches

See 1-4, Toggle Switches.

8-3Wago® Components

How to Remove a Wago®

ComponentElectrocution hazard. Contact withelectrically charged circuits maycause death or serious injury.Remove all rings, watches andother jewelry.

A small screwdriver is providedand should be used whenremoving a Wago® component.This screwdriver is located in theoperator’s manual storage box inthe platform.

1 Label the wiring from the component to beremoved.

2 Use the provided screwdriver to push in andrelease the wire from the component.

3 Locate the removal tab on the bottom or topside of the component.

4 Use the provided screwdriver to gently pry upon the tab of the component and remove it.

7 - 34 Genie Z-34/22 IC Part No. 43037


Hydraulic Pumps

9-1Auxiliary Pump

How to Test the Auxiliary Pump1 Disconnect and plug the high pressure

hydraulic hose from the auxiliary pump.


2 Connect a 0 to 5000 psi (0 to 350 bar) pressuregauge to the high pressure port on the pump.

3 Turn the key switch to ground control and pullthe Emergency Stop button to the ON position.

4 Activate any function using auxiliary power.

Result: If the pressure gauge reads 2800 psi(193 bar), immediately stop. The pump is good.

Result: If pressure fails to reach 2800 psi(193 bar), the pump is bad and will need to beserviced or replaced.

5 Remove the pressure gauge and reconnect thehydraulic hose.

How to Remove the AuxiliaryPump1 Tag, disconnect and cap the hydraulic hoses

from the pump.


2 Remove the pump mounting bolts. Carefullyremove the pump.

9-2Lift/Steer Pump

How to Test the Lift/Steer Pump1 Disconnect and plug the high pressure

hydraulic hose from the lift/steer pump.


2 Connect a 0 to 5000 psi (0 to 350 bar) pressuregauge to the high pressure port on the pump.

3 Kubota Gasoline/LPG models: Remove thehigh tension lead from the center of the ignitioncoil.


4 Turn the key switch to ground control and pullthe Emergency Stop button to the ON position.

5 Kubota Diesel models: Hold the manual fuelshutoff valve clockwise to the CLOSED position.

Both models: Observe the pressure gaugewhile cranking the engine. Immediately stopcranking if the pressure reaches or exceeds3000 psi (206 bar).

Component damage hazard.Hydraulic pressure in excess of3000 psi (206 bar) will causesevere component damage.

Result: If the pressure gauge reads 3000 psi(206 bar), immediately stop cranking theengine. The pump is good.

Result: If pressure fails to reach 3000 psi(206 bar), the pump is bad and will need to beserviced or replaced.

Part No. 43037 Genie Z-34/22 IC 7 - 35


6 Remove the pressure gauge and reconnect thehydraulic hose.

7 Kubota Gasoline/LPG models: Reconnect thehigh tension lead to the ignition coil.

How to Remove the Lift/SteerPump1 Disconnect and cap the hydraulic hoses from

the pump.


2 Remove the pump mounting bolts. Carefullyremove the pump.

9-3Drive Hydraulic Pump

The drive hydraulic pump is a bi-directionalvariable displacement piston pump. The pumpoutput is controlled by the electronic displacementcontroller (EDC), located on the pump. The onlyadjustment that can be made to the pump is theneutral or null adjustment. Any internal service tothe pump should only be performed at anauthorized Sundstrand-Sauer service center.

How to Remove the DriveHydraulic Pump

Component damage hazard. Thework area and surfaces where thisprocedure will be performed mustbe clean and free of debris thatcould get into the hydraulic systemand cause severe componentdamage. Dealer service isrecommended.

1 Disconnect the electrical connection at theelectronic displacement controller (EDC)located on the drive pump.

2 Tag,disconnect and plug the hydraulic hoses onthe pump.


3 Support the pump and remove the two drivepump mounting bolts. Carefully remove thepump.

HYDRAULIC PUMPS

7 - 36 Genie Z-34/22 IC Part No. 43037


How to Prime the Pump1 Connect a 0 to 6000 psi (0 to 414 bar) pressure

gauge to the test port on the drive pump.

2 Kubota Gasoline/LPG models: Remove thehigh tension lead from the center of the ignitioncoil.


Kubota Diesel models: Hold the manual fuelshutoff valve clockwise to the CLOSED position.

3 Crank the engine with the starter motor for 15seconds, wait 15 seconds, then crank theengine an additional 15 seconds or until thepressure reaches 320 psi (22 bar).

HYDRAULIC PUMPS

Part No. 43037 Genie Z-34/22 IC 7 - 37



7 - 38 Genie Z-34/22 IC Part No. 43037


Function Manifold

10-1Function Manifold ComponentsThe function manifold is mounted to the turntable under the ground controls.


1 Counterbalance valve ........................ F ........... Platform level up ...............................35-40 ft-lbs (47-54 Nm)

2 Counterbalance valve ........................ G ........... Platform level down ..........................35-40 ft-lbs (47-54 Nm)

3 Relief valve, 1750 psi (121 bar)(before serial number 674) ................ H ........... Turntable rotate left ...........................25-30 ft-lbs (34-41 Nm)

Counterbalance valve,1500 psi (103 bar)(after serial number 673) ................... H ........... Turntable rotate left ...........................35-40 ft-lbs (47-54 Nm)

4 Relief valve, 1750 psi (121 bar)(before serial number 674) ................ I ............ Turntable rotate right ........................25-30 ft-lbs (34-41 Nm)

Counterbalance valve,1500 psi (103 bar)(after serial number 673) ................... I ............ Turntable rotate right ........................35-40 ft-lbs (47-54 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) ......... K ........... Primary boom down ..........................25-30 ft-lbs (34-41 Nm)

7 Relief valve, 1800 psi (124 bar) ........ L ........... Primary Boom extend .......................25-30 ft-lbs (34-41 Nm)

8 Proportional solenoid valve ............... D ........... System flow regulating circuit ...........10-12 ft-lbs (14-16 Nm)

9 3 position 4 way spool valve ............. E ........... Steer left/right ....................................10-12 ft-lbs (14-16 Nm)

10 Flow regulator valve 0.1 gpm ............ W .......... Differential sensing circuit .................10-12 ft-lbs (14-16 Nm)

11 Differential sensing valve .................. C ........... All functions .......................................10-12 ft-lbs (14-16 Nm)

12 Diagnostic fitting ............................................... Testing

13 Priority flow regulator valve 1.0 gpm . A ........... Steering .............................................10-12 ft-lbs (14-16 Nm)

14 Relief valve, 3200 psi (221 bar) ........ B ........... System relief .....................................25-30 ft-lbs (34-41 Nm)

15 2 position 3 way solenoid valve ......... V ........... Primary boom retract ........................8-10 ft-lbs (11-14 Nm)

16 2 position 3 way solenoid valve ......... S ........... Primary boom up ...............................8-10 ft-lbs (11-14 Nm)




SAE No. 4 3/16 13 ft-lbs / 18 Nm

SAE No. 6 1/4 18 ft-lbs / 24 Nm


SAE No. 8 5/16 50 ft-lbs / 68 Nm

SAE No. 10 9/16 55 ft-lbs / 75 Nm

SAE No. 12 5/8 75 ft-lbs / 102 Nm

Part No. 43037 Genie Z-34/22 IC 7 - 39


FUNCTION MANIFOLD

7 - 40 Genie Z-34/22 IC Part No. 43037


FUNCTION MANIFOLD

Function Manifold Components, continuedThe function manifold is mounted to the turntable under the ground controls.


17 2 position 3 way solenoid valve ......... Q ........... Secondary boom up ..........................8-10 ft-lbs (11-14 Nm)

18 2 position 3 way solenoid valve ......... P ........... Turntable rotate left ...........................8-10 ft-lbs (11-14 Nm)

19 2 position 3 way solenoid valve ......... M .......... Platform level up ...............................8-10 ft-lbs (11-14 Nm)

20 2 position 3 way solenoid valve ......... U ........... Primary boom extend ........................8-10 ft-lbs (11-14 Nm)

21 2 position 3 way solenoid valve ......... T ........... Primary boom down ..........................8-10 ft-lbs (11-14 Nm)

22 2 position 3 way solenoid valve ......... R ........... Secondary boom down .....................8-10 ft-lbs (11-14 Nm)

23 2 position 3 way solenoid valve ......... O ........... Turntable rotate right ........................8-10 ft-lbs (11-14 Nm)

24 2 position 3 way solenoid valve ......... N ........... Platform level down ..........................8-10 ft-lbs (11-14 Nm)

25 Orifice, 0.050 in (1.27 mm) ................ X ........... Turntable rotate circuit

Part No. 43037 Genie Z-34/22 IC 7 - 41


FUNCTION MANIFOLD

7 - 42 Genie Z-34/22 IC Part No. 43037


10-2Valve Adjustments -Function Manifold

How to Adjust the Primary BoomDown Relief Valve1 Connect a 0 to 3000 psi (0 to 206 bar) pressure

gauge to the test port on the function manifold.


3 With the engine in high rpm, hold down theprimary boom down switch with the primaryboom fully lowered, and observe the pressurereading on the pressure gauge.

4 Turn the machine off. Hold the relief valve andremove the cap (item 6, function manifold).

5 Adjust the internal hex socket. Turn it clockwiseto increase the pressure or counterclockwise todecrease the pressure. Then install the reliefvalve cap.

Tip-over hazard. Do not adjustthe relief valves higher thanspecified.

6 Repeat steps 2 through 5 and recheck the valvepressure.

Primary boom down relief valve specifications

Pressure 1400 psi97 bar

FUNCTION MANIFOLD

How to Adjust the TurntableRotate Relief Valves(before serial number 674)


1 Connect a 0 to 3000 psi (0 to 206 bar) pressuregauge to the test port on the function manifold.


3 With the engine in high rpm, hold the turntablerotate right switch with the turntable rotated tothe right (until it is against the rotation stop),and observe the pressure reading on thepressure gauge.


If adjusting the turntable rotate left,hold switch to the left and adjustthe left relief valve (item 3,function manifold).




Turntable rotate relief valve specifications


Part No. 43037 Genie Z-34/22 IC 7 - 43


FUNCTION MANIFOLD

How to Adjust the Primary BoomExtend Relief Valve




3 With the engine in high rpm, hold the primaryboom extend switch with the primary boom fullyextended, and observe the pressure reading onthe pressure gauge.





Primary boom extend relief valve specifications


How to Adjust the SecondaryBoom Down Relief Valve




3 With the engine in high rpm, hold down thesecondary boom down switch with thesecondary boom fully lowered, and observe thepressure reading on the pressure gauge.





Secondary boom down relief valve specifications


7 - 44 Genie Z-34/22 IC Part No. 43037


FUNCTION MANIFOLD


disconnect the wires from the valve coil to betested.



Valve coil specifications

2 position 3 way solenoid valve, 10V 5.5 - 6.5Ω

Proportional solenoid valve, 12V 4 - 5.2Ω

Part No. 43037 Genie Z-34/22 IC 7 - 45


Fuel and Hydraulic Tanks

11-1Fuel Tank

How to Remove the Fuel TankExplosion and fire hazard. Enginefuels are combustible. Remove thefuel tank in an open, well-ventilated area away from heaters,sparks, flames and lightedtobacco. Always have anapproved fire extinguisher withineasy reach.

Explosion and fire hazard. Whentransferring fuel, connect agrounding wire between themachine and pump or container.

1 Raise the secondary boom so the uppermid-pivot is approximately 12 feet (3.7 m) offthe ground.

2 Turn the LPG shutoff valve to the CLOSED

position on the LPG tank.

3 Remove the LPG hose from the tank and thenremove the tank from the machine.

4 Remove the mounting fasteners from the LPGbottle bracket then remove the bracket from themachine.

5 Turn the manual fuel shutoff valve to the CLOSED

position on the fuel tank.

6 Kubota Gasoline/LPG models: Disconnect,drain and plug the fuel hose.

Kubota Diesel models: Disconnect, drain andplug the supply and return fuel hoses. Cap thefuel return fitting on the fuel tank.

7 Remove the mounting fasteners from the tankstrap on the underside of the tank mountingtray.

8 Use an appropriate lifting device to remove thetank from the machine.

Clean the fuel tank and inspectfor rust and corrosion beforeinstalling.

11-2Hydraulic Tank

The primary functions of the hydraulic tank are tocool, clean and deaereate the hydraulic fluid duringoperation. It utilizes internal suction strainers forthe pump supply suction lines and has an externalreturn line filter.

How to Remove theHydraulic Tank

Component damage hazard. Thework area and surfaces where thisprocedure will be performed mustbe clean and free of debris thatcould get into the hydraulic systemand cause severe componentdamage. Dealer service isrecommended.

1 Remove the fuel tank. See 11-1, How toRemove the Fuel Tank.

2 Locate the drain hose on the bottom of thehydraulic tank and drain the oil into a suitablecontainer.

Burn hazard. Contact with hot oilmay cause severe burns.


3 Remove the hoses from the return filter.

4 Remove the suction hoses from the bottom ofthe tank.

5 Remove the mounting fasteners from the tankstraps.

6 Use an appropriate lifting device to remove thetank from the machine.

Clean the hydraulic tank andinspect for rust and corrosionbefore installing.

7 - 46 Genie Z-34/22 IC Part No. 43037


12-1Rotation Hydraulic Motor

The rotation hydraulic motor is the only serviceablecomponent of the turntable rotation assembly. Theworm gear may not be removed from the housing.In order to remove the housing, the turntable hasto be removed.

How to Remove the TurntableRotation Motor

Do not allow the turntable to rotateuntil the hydraulic motor isinstalled.

1 Tag, disconnect and plug the hydraulic hosesfrom the turntable rotation motor. Cap thefittings on the motor.


2 Remove the turntable rotation motor mountingbolts, then remove the motor.

Turntable Rotation Components

Part No. 43037 Genie Z-34/22 IC 7 - 47


2WD Steer Axle Components

13-1Yoke and Hub

How to Remove the Yokeand Hub1 Remove the cotter pin and the clevis pin from

both the steering cylinder and the tie rod.

a axleb pin retaining fastenerc king pind yokee hubf clevis pin and cotter ping steering cylinderh tie rod

2 Loosen the wheel lug nuts. Do notremove them.

3 Block the non-steer wheels, and then center alifting jack under the steering axle.

4 Raise the machine 6 inches (15 cm) and placeblocks under the drive chassis for support.

5 Remove the lug nuts, then the tire andwheel assembly.

6 Remove the pin retaining fasteners from theupper and lower king pins.

7 Attach a strap from a lifting device to theyoke/hub assembly for support.

8 Place a rod through the king pin and twist toremove the pins.

Crushing hazard. The yoke/hubassembly will fall when the kingpins are removed if it is notproperly supported.

Always use a new cotter pin wheninstalling a clevis pin.

Specifications Lubricated Dry

Lug nut torque 94 ft-lbs 125 ft-lbs127 Nm 169 Nm

How to Remove theHub and Bearings1 Loosen the wheel lug nuts. Do not remove

them.

2 Block the non-steer wheels and place a liftingjack under the steer axle.

3 Raise the machine and place blocks underthe drive chassis for support.

4 Remove the lug nuts. Then remove the tireand wheel assembly.

5 Remove the dust cap, cotter pin andslotted nut.

6 Pull the hub off the spindle. The washer andouter bearing should fall loose from the hub.

7 Place the hub on a flat surface and gently prythe bearing seal out of the hub. Remove therear bearing.

a

b

d

c

e

g

h

f

f

7 - 48 Genie Z-34/22 IC Part No. 43037


How to Install theHub and Bearings

When replacing a wheel bearing,both the inner and outer bearings,including the pressed-in races,must be replaced.

1 Be sure that both bearings are packedwith grease.

2 Place the large inner bearing into the rearof the hub.

3 Press the bearing seal evenly into the hubuntil it is flush.

4 Apply a small amount of grease onto the yokespindle.

5 Slide the hub onto the yoke spindle.

Component damage. Do notapply excessive force or damageto the lip of the seal may occur.

6 Place the outer bearing into the hub.

7 Install the washer and slotted nut.

8 Tighten the slotted nut to 35 foot-pounds(47 Nm).

9 Loosen the slotted nut, then re-tighten to8 foot-pounds (11 Nm).

10 Install a new cotter pin. Bend the cotter pinto lock it.

11 Install the dust cap, then the tire and wheelassembly. Torque the wheel lug nuts to125 foot-pounds (169.5 Nm).

2WD STEER AXLE COMPONENTS

13-2Steer Cylinder

How to Remove a Steer Cylinder1 Tag, disconnect and plug the hydraulic hoses

from the steering cylinder. Cap the fittings.


2 Remove the cotter pin. Then removethe clevis pin from each end of the steercylinder.

3 Remove the steer cylinder.


13-3Tie Rod

How to Remove the Tie Rod1 Remove the cotter pin, then remove the clevis

pin from each end of the tie rod.

2 Remove the tie rod.


Part No. 43037 Genie Z-34/22 IC 7 - 49


14-1Yoke and Hub

How to Remove the Yoke and HubThe yoke installation utilizes bushings and a thrustwasher that require periodic replacementdepending upon the application. The drive motormust be removed before the torque hub and yokecan be removed.

1 Loosen the wheel lug nuts. Do not removethem.

2 Block the non-steer wheels, and then center alifting jack under the steer axle.

3 Raise the machine 6 inches (15 cm) and placeblocks under the chassis.

4 Remove the lug nuts, then the tire and wheelassembly.

5 Remove the cotter pin, then the clevis pin fromboth the steering cylinder and the tie rodweldment.

a axleb king pinc pin retainerd yokee torque hubf cotter and clevis ping steering cylinderh tie rod

6 Tag, disconnect and cap the hydraulic hosesfrom the drive motor and plug them. Cap thedrive motor hydraulic fittings.


7 Remove the drive motor mounting fasteners.Slide the drive motor shaft out of the torque huband then remove it.

8 Remove the retaining fasteners from the kingpins. Do not remove the pins.

9 Attach a strap from a lifting device to theyoke/torque hub assembly and support it.

10 Use a soft metal drift to drive the king pins downand out.

Crushing hazard. The yoke/torquehub assembly will fall when theking pins are removed if it is notproperly supported.

11 Place the yoke/torque hub assembly on a flatsurface with the torque hub down. Remove thebolts that secure the yoke to the torque hub.

Specifications Lubricated Dry

Lug nut torque 94 ft-lbs 125 ft-lbs127 Nm 169 Nm

4WD Steer Axle Components

g

h

f

a

b

d

c

e

7 - 50 Genie Z-34/22 IC Part No. 43037


14-2Steer Cylinder

How to Remove a Steer Cylinder1 Tag, disconnect and plug the hydraulic hoses

from the steer cylinder. Cap the fittings.


2 Remove the cotter pin. Then removethe clevis pin from each end of the steercylinder.

3 Remove the steer cylinder.


4WD STEER AXLE COMPONENTS

14-3Tie Rod

How to Remove the Tie Rod1 Remove the cotter pin, then remove the clevis

pin from each end of the tie rod.

2 Remove the tie rod.


Part No. 43037 Genie Z-34/22 IC 7 - 51


Brake and Two Speed Manifold

15-1Brake and Two Speed Manifold ComponentsThe Brake and Two Speed Manifold is located under the drive chassis cover at the non-steer end.


1 2 position 3 way solenoid valve ......... A ........... Brake .................................................8-10 ft-lbs / 11-14 Nm

2 2 position 3 way solenoid valve ......... B ........... 2 Speed .............................................8-10 ft-lbs / 11-14 Nm

2

1

7 - 52 Genie Z-34/22 IC Part No. 43037


Non-steer Axle Components

16-1Drive Motor

Component damage hazard.Repairs to the drive motorshould only be performed by anauthorized Sundstrand-Sauerdealer.

How to Remove a Drive MotorA drive motor can only be removed from the insideof the chassis.

Component damage hazard.The work area and surfaceswhere this procedure will beperformed must be clean andfree of debris that could get intothe hydraulic system and causesevere component damage.Dealer service is recommended.

1 Tag, disconnect and cap the hydraulic hosesfrom the drive motor and plug them.

Bodily injury hazard. Sprayinghydraulic oil can penetrate andburn skin. Loosen hydraulicconnections very slowly toallow the oil pressure todissipate gradually. Do notallow oil to squirt or spray.

2 Remove the drive motor mounting bolts.

3 Guide the drive motor shaft out of the brake andthen remove the drive motor.

16-2Torque Hub

How to Remove a DriveTorque HubThe drive motor must be removed in order toaccess the torque hub mounting bolts.

1 Remove the drive motor. See 16-1,How to Remove a Drive Motor.

2 Disconnect the hydraulic hose from the brakeand plug it. Then remove the hydraulic fittingand the bleed valve.

Bodily injury hazard. Sprayinghydraulic oil can penetrate andburn skin. Loosen hydraulicconnections very slowly toallow the oil pressure todissipate gradually. Do notallow oil to squirt or spray.

3 Chock the steer wheels.

4 Loosen the wheel lug nuts. Do not removethem.

5 Center a lifting jack under the non-steer axle.Raise the machine and place blocks under thechassis for support.

6 Remove the wheel lug nuts, then the tire andwheel assembly.

7 Place a second lifting jack under the torquehub for support.

8 Remove the bolts that attach the torque hubto the chassis, then remove the torque hub.

Crushing hazard. The torquehub will fall if it is not properlysupported when the mountingbolts are removed.

Torque specifications

Lug nuts 125 ft-lbs169.5 Nm

Drive torque hub mounting bolts 210 ft-lbs285 Nm

Part No. 43037 Genie Z-34/22 IC 7 - 53



7 - 54 Genie Z-34/22 IC Part No. 43037


2WD Drive Manifold

17-12WD Drive Manifold ComponentsThe drive manifold is mounted inside the drive chassis at the non-steer end.


1 Shuttle valve 3 position 4 way ........... A ........... Charge pressure circuitthat gets hot oil out of low pressureside of drive pump and allows lowpressure flow path for brakerelease and 2-speed motor shift ... 15-18 ft-lbs / 20-24 Nm

2 Relief valve, 210 psi (14.5 bar) ......... B ........... Charge pressure circuit ................. 15-18 ft-lbs / 20-24 Nm


4 Flow divider/combiner valve .............. C ........... Controls flow to drive motorsin forward and reverse .................. 25-30 ft-lbs / 34-41 Nm

5 Orifice 0.070 in (1.78 mm) ................. D ........... Drive circuit

Part No. 43037 Genie Z-34/22 IC 7 - 55


2WD DRIVE MANIFOLD


Description Hex size Torque


SAE No. 4 3/16 13 ft-lbs / 18 Nm

SAE No. 6 1/4 18 ft-lbs / 24 Nm

SAE No. 8 5/16 50 ft-lbs / 68 Nm

SAE No. 10 9/16 55 ft-lbs / 75 Nm

SAE No. 12 5/8 75 ft-lbs / 102 Nm

17-2Valve Adjustments

How to Adjust the ChargePressure Relief Valve1 Connect a 0 to 600 psi (0 to 414 bar) pressure

gauge to the test port located on the drivemanifold.



3 Drive the machine slowly in either direction andobserve the pressure reading on the pressuregauge.

4 Turn the engine off. Hold the relief valve andremove the cap (index 2).

5 Adjust the internal hex socket. Turn it clockwiseto increase the pressure or counterclockwiseto decrease the pressure. Then install thevalve cap.

6 Restart the engine. Drive the machine in eitherdirection and recheck the valve pressure.

7 Turn the engine off, then remove the pressuregauge.

Relief valve specifications

Pressure 210 psi 14.5 bar

7 - 56 Genie Z-34/22 IC Part No. 43037


18-14WD Drive Manifold ComponentsThe drive manifold is mounted inside the drive chassis at the non-steer end.



2 Directional control valve .................... H ........... Diverts all flow to steer enddrive motors when in high range.......25-30 ft-lbs / 34-41 Nm

3 Flow divider/combiner valve .............. E ........... Controls flow to flowdivider/combiner valves 5 and 6 .......25-30 ft-lbs / 34-41 Nm

4 Orifice, plug 0.052 in (1.32 mm) ........ G ........... Drive circuit, steer end

5 Flow divider/combiner valve .............. F ........... Controls flow to steer enddrive motors in forwardand reverse .......................................25-30 ft-lbs / 34-41 Nm

6 Flow divider/combiner valve .............. D ........... Controls flow to non-steer enddrive motors in forwardand reverse .......................................25-30 ft-lbs / 34-41 Nm

7 Orifice, plug 0.070 in (1.78 mm) ........ C ........... Drive circuit, steer end

8 Check valve ....................................... I ............ Direction control circuit .....................15-18 ft-lbs / 20-24 Nm

9 Relief valve, 210 psi (14.5 bar) ......... B ........... Charge pressure circuit .....................15-18 ft-lbs / 20-24 Nm

10 Pilot operated check valve ................ J ............ Smoothes the shiftfrom low to high range ......................15-18 ft-lbs / 20-24 Nm

11 Shuttle valve 3 position 3 way ........... A ........... Charge pressure circuitthat gets hot oil out of low pressureside of drive pump and allows lowpressure flow path for brakerelease and 2-speed motor shift .......15-18 ft-lbs / 20-24 Nm

4WD Drive Manifold

Part No. 43037 Genie Z-34/22 IC 7 - 57


4WD DRIVE MANIFOLD

7 - 58 Genie Z-34/22 IC Part No. 43037


4WD DRIVE MANIFOLD


Description Hex size Torque


SAE No. 4 3/16 13 ft-lbs / 18 Nm

SAE No. 6 1/4 18 ft-lbs / 24 Nm

SAE No. 8 5/16 50 ft-lbs / 68 Nm

SAE No. 10 9/16 55 ft-lbs / 75 Nm

SAE No. 12 5/8 75 ft-lbs / 102 Nm

18-2Valve Adjustments

How to Adjust the ChargePressure Relief Valve1 Connect a 0 to 600 psi (0 to 41 bar) pressure

gauge to the test port located on the drivemanifold.



3 Drive the machine slowly in either directionand observe the pressure reading on thepressure gauge.

4 Turn the engine off. Hold the relief valve andremove the cap (index 2).

5 Adjust the internal hex socket. Turn it clockwiseto increase the pressure or counterclockwiseto decrease the pressure. Then install thevalve cap.

6 Restart the engine. Drive the machine in eitherdirection and recheck the valve pressure.

7 Turn the engine off, then remove thepressure gauge.

Relief valve specifications

Pressure 210 psi 14.5 bar

Dis

trib

ute

d B

y:

California Proposition 65

WARNINGThe 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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Documents

Service Manual - Genie liftmanuals.gogenielift.com/Parts And Service Manuals/data...Part No. 43037 Genie Z-34/22 IC Service Manual - First Edition Table of Contents v Introduction