Terex Z3413-9461 Installation and operating manual

Service and Repair Manual
Serial Number Range
Z-34/22 IC
from Z3413-9461
to
Z3415-
10688
This manual includes:
Repair
procedures
Fault Codes
Electrical and
Hydraulic Schematics
from Z3416F-10689 to
Z3416F-
11999
from Z34F-12000
For detailed maintenance
procedures, refer to the
appropriate Maintenance
Manual for your machine.
Part No. 1274592
Rev A
September 2016

Service and Repair Manual September 2016
Introduction
ii Z-34/22 IC Part No. 1274592
Intr oduct io n Intr oduct io n
Important
Read, understand and obey the safety rules and
operating instructions in the appropriate Operator's
Manual on your machine before attempting any
procedure.
This manual provides troubleshooting and repair
procedures for qualified service professionals.
Basic mechanical, hydraulic and electrical skills are
required to perform most procedures. However,
several procedures require specialized skills, tools,
lifting equipment and a suitable workshop. In these
instances, we strongly recommend that
maintenance and repair be performed at an
authorized Genie dealer service center.
Compliance
Machine Classification
Group B/Type 3 as defined by ISO 16368
Machine Design Life
Unrestricted with proper operation, inspection and
scheduled maintenance.
Technical Publications
Genie has endeavored to deliver the highest
degree of accuracy possible. However, continuous
improvement of our products is a Genie policy.
Therefore, product specifications are subject to
change without notice.
Readers are encouraged to notify Genie of errors
and send in suggestions for improvement. All
communications will be carefully considered for
future printings of this and all other manuals.
Contact Us:
Internet: www.genielift.com
E-mail: [e-mail]
Find a Manual for this Model
Go to http://www.genielift.com
Use the links to locate Service Manuals,
Maintenance Manuals, Service and Repair
Manuals, Parts Manuals and Operator's Manuals.
Copyright © 2015 by Terex Corporation
1274592 Rev A, September 2016
First Edition, First Printing
Genie is a registered trademark of Terex South Dakota, Inc. in
the U.S.A. and many other countries.
“Z” is a trademark of Terex South Dakota, Inc.

September 2016 Service and Repair Manual
Introduction
Part No. 1274592 Z-34/22 IC iii
Revision History
Revision Date Section Procedure / Page / Description
A 9/2016 Release
Reference Examples:
Electronic Version
Click on any content or procedure in the Table of Contents to view
the update.
Section – Repair Procedure, 4-2
Section – Fault Codes, All charts
Section – Schematics, Legends and schematics

Service and Repair Manual September 2016
Introduction
iv Z-34/22 IC Part No. 1274592
Serial Number Legend
To
August 31, 2016
1 Model
2 Model year
3 Facility code
4 Sequence number
5 Serial number (stamped on chassis)
6 Serial label (located under cover)
From September 1, 2016
1 Model
2 Facility code
3 Sequence number
4 Serial number (stamped on chassis)
5 Serial label (located under cover)

September 2016 Service and Repair Manual
Safety Rules
Part No. 1274592 Z-34/22 IC v
Section 1 Safet y Rul es
Danger
Failure to obey the instructions and safety rules in
this manual and the appropriate Operator's Manual
on your machine will result in death or serious
injury.
Many of the hazards identified in the operator's
manual are also safety hazards when maintenance
and repair procedures are performed.
Do Not Perform Maintenance
Unless:
You are trained and qualified to perform
maintenance on this machine.
You read, understand and obey:
•manufacturer's instructions and safety rules
•employer's safety rules and worksite
regulations
•applicable governmental regulations
You have the appropriate tools, lifting
equipment and a suitable workshop.

Service and Repair Manual September 2016
Safety Rules
vi Z-34/22 IC Part No. 1274592
Personal Safety
Any person working on or around a machine must
be aware of all known safety hazards. Personal
safety and the continued safe operation of the
machine should be your top priority.
Read each procedure thoroughly. This
manual and the decals on the machine,
use signal words to identify the following:
Safety alert symbol
—
used to alert
personnel
to potential personal
injury hazards. Obey all safety
messages that follow this symbol
to avoid possible injury or death.
Indicates a imminently hazardous
situation which, if not avoided, will
result in death or serious injury.
Indicates a potential
ly hazardous
situation which, if not avoided,
could result in death or serious
injury.
Indicates a potentially hazardous
situation which, if not avoided,
may cause minor or moderate
injury.
Indicates a potentially hazardous
situation which, if not
avoided,
may result in property damage.
Be sure to wear protective eye wear and
other protective clothing if the situation
warrants it.
Be aware of potential crushing hazards
such as moving parts, free swinging or
unsecured components when lifting or
placing loads. Always wear approved
steel
-toed shoes.
Workplace Safety
Any person working on or around a machine must
be aware of all known safety hazards. Personal
safety and the continued safe operation of the
machine should be your top priority.
Be
sure to keep sparks, flames and
lighted tobacco away from flammable and
combustible materials like battery gases
and engine fuels. Always have an
approved fire extinguisher within easy
reach.
Be sure that all tools and working areas
are properly mainta
ined and ready for
use. Keep work surfaces clean and free of
debris that could get into machine
components and cause damage.
Be sure any forklift, overhead crane or
other lifting or supporting device is fully
capable of supporting and stabilizing the
we
ight to be lifted. Use only chains or
straps that are in good condition and of
ample capacity.
Be sure that fasteners intended for one
time use (i.e., cotter pins and self
-locking
nuts) are not reused. These components
may fail if they are used a second
time.
Be sure to properly dispose of old oil or
other fluids. Use an approved container.
Please be environmentally safe.
Be sure that your workshop or work area
is properly ventilated and well lit.

September 2016
Table of Contents
Part No. 1274592 Z-34/22 IC vii
Introduction Introduction ........................................................................................................... ii
Important Information .............................................................................................ii
Find a Manual for this Model..................................................................................ii
Revision History..................................................................................................... iii
Serial Number Legend ..........................................................................................iv
Section 1 Safety Rules .......................................................................................................... v
General Safety Rules .............................................................................................v
Section 2 Specifications ....................................................................................................... 1
Machine Specifications...........................................................................................1
Machine Component Weights................................................................................2
Performance Specifications....................................................................................2
Hydraulic Specification...........................................................................................3
Hydraulic Component Specifications......................................................................5
Machine Torque Specifications..............................................................................6
Kubota WG-972 Engine Specifications..................................................................7
GM .998L Engine Specifications............................................................................8
Kubota D1105 Engine Specifications.....................................................................9
Perkins 403D-11 Engine Specifications...............................................................10
Perkins 403F-11 Engine Specifications ...............................................................11
Hydraulic Hose and Fitting Torque Specifications ...............................................12
Torque Procedure ................................................................................................13
SAE and Metric Fasteners Torque Charts ...........................................................15

September 2016
Table of Contents
viii Z-34/22 IC Part No. 1274592
Section 3 Repair Procedures ............................................................................................. 16
Introduction ..........................................................................................................16
Platform Controls ............................................................................................... 18
1-1 Drive Joystick.................................................................................................18
How to Adjust the Drive Joystick....................................................................18
1-2 Boom Function Speed Controller Adjustments..............................................20
Boom Function Speed Controller Adjustments...............................................20
Platform Components ....................................................................................... 22
2-1 Platform Leveling Slave Cylinder...................................................................22
How to Remove the Platform Leveling Slave Cylinder...................................22
How to Bleed the Leveling Slave Cylinder......................................................22
2-2 Platform Rotator.............................................................................................23
How to Remove the Platform Rotator.............................................................23
How to Bleed the Platform Rotator.................................................................24
2-3 Platform Overload System.............................................................................25
How to Calibrate the Platform Overload System (if equipped).......................25
Jib Boom Components ...................................................................................... 26
3-1 Jib Boom........................................................................................................26
How to Remove the Jib Boom........................................................................26
3-2 Jib Boom Bell Crank ......................................................................................27
How to Remove the Jib Boom Bell Crank ......................................................27
3-3 Jib Boom Lift Cylinder....................................................................................27
How to Remove the Jib Boom Lift Cylinder....................................................27

September 2016
Table of Contents
Part No. 1274592 Z-34/22 IC ix
Primary Boom Components .............................................................................. 29
4-1 Cable Track....................................................................................................29
How to Repair the Primary Boom Cable Track...............................................29
4-2 Primary Boom.................................................................................................29
How to Shim the Primary Boom......................................................................29
How to Remove the Primary Boom.................................................................30
How to Disassemble the Primary Boom .........................................................32
4-3 Primary Boom Lift Cylinder ............................................................................33
How to Remove the Primary Boom Lift Cylinder.............................................33
4-4 Primary Boom Extension Cylinder .................................................................34
How to Remove the Primary Boom Extension Cylinder..................................34
4-5 Platform Leveling Master Cylinder.................................................................36
How to Remove the Platform Leveling Master Cylinder .................................36
Secondary Boom Components ......................................................................... 38
5-1 Secondary Boom............................................................................................39
How to Disassemble the Secondary Boom.....................................................39
5-2 Secondary Boom Lift Cylinders......................................................................42
How to Remove the Secondary Boom Lift Cylinders......................................42
Engines ................................................................................................................ 44
6-1 Kubota Diesel Models ....................................................................................44
Timing Adjustment ..........................................................................................44
How to Check the Glow Plugs.........................................................................44
RPM Adjustment .............................................................................................44
How to Remove the Flex Plate........................................................................45
How to Install the Flex Plate............................................................................45
Coolant Temperature and Oil Pressure Switches...........................................45

September 2016
Table of Contents
x Z-34/22 IC Part No. 1274592
6-2 Kubota Gasoline / LPG Models .....................................................................46
Choke Adjustment ..........................................................................................46
Timing Adjustment..........................................................................................46
Carburetor Adjustment....................................................................................46
RPM Adjustment.............................................................................................46
How to Remove the Flex Plate.......................................................................47
How to Install the Flex Plate...........................................................................47
Coolant Temperature and Oil Pressure Switches ..........................................47
6-3 Perkins Diesel Models ...................................................................................48
Timing Adjustment..........................................................................................48
RPM Adjustment.............................................................................................48
How to Remove the Flex Plate.......................................................................49
How to Install the Flex Plate...........................................................................49
Coolant Temperature and Oil Pressure Switches ..........................................49
6-4 GM .998L Models ..........................................................................................50
Timing Adjustment..........................................................................................50
How to Remove the Flex Plate.......................................................................51
How to Install the Flex Plate...........................................................................51
Hydraulic Pumps ................................................................................................ 52
7-1 Auxiliary Pump...............................................................................................52
How to Test the Auxiliary Pump......................................................................52
How to Remove the Auxiliary Pump...............................................................52
7-2 Function Pump...............................................................................................53
How to Test the Function Pump .....................................................................53
How to Removet the Function Pump..............................................................53
7-3 Drive Pump....................................................................................................54
How to Remove the Drive Pump ....................................................................54
How to Prime the Drive Pump ........................................................................54