Service Genie Z34

Service Manual
Part No. 36540

Rev C
August 2008
(before serial number 6291)
Introduction
First Edition Third Printing
Z-34/22
Z-34/22N
TM
TM
Important
Read, understand and obey the safety rules and
operating instructions in the Genie Z-34/22 &
Genie Z-34/22N Operators Manual before
attempting any maintenance or repair procedure.
This manual provides detailed scheduled
maintenance information for the machine owner
and user. It also provides troubleshooting and
repair procedures for qualified service
professionals.
Basic mechanical, hydraulic and electrical
skills are required to perform most procedures.
However, several procedures require specialized
skills, tools, lifting equipment and a suitable
workshop. In these instances, we strongly
recommend that maintenance and repair be
performed at an authorized Genie dealer
service center.
Genie Industries has endeavored to deliver the
highest degree of accuracy possible. However,
continuous improvement of our products is a Genie
policy. Therefore product specifications
are subject to change without notice.
Readers are encouraged to notify Genie of errors
and send in suggestions for improvement. All
communications will be carefully considered for
future printings of this and other manuals. Please
write to the technical publications team in care of
Genie Industries, PO Box 97030, Redmond WA
98073-9730 USA.
Copyright 1996 by Genie Industries

First Edition:
First Printing June, 1996

Second Printing February, 2000
First Edition:
Third Printing August, 2008
"Genie" and "Z" are registered trademarks of

Genie Industries in the U.S.A. and many other
countries.
Printed on recycled paper
Printed in U.S.A.
If you have any questions, please contact Genie

Industries.
Contact us:
http://www.genielift.com
e-mail: awp.techpub@terex.com
ii
Genie Z-34/22 & Genie Z-34/22N
Part No. 36540
Safety Rules
Danger
Failure to obey the instructions and safety rules
in this manual and the Genie Z-34/22 & Genie
Z-34/22N Operators Manual will result in death or
serious injury.
Many of the hazards identified in the
operators 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:
- manufacturers instructions and safety rules
- employers safety rules and worksite
regulations
- applicable governmental regulations
You have the appropriate tools, lifting
equipment and a suitable workshop.
Part No. 36540
iii
SAFETY RULES
Personal Safety
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.
Read each procedure thoroughly. This

manual and the decals on the machine,
use signal words to identify the following:
Safety alert symbolused to alert
personnel to potential personal
injury hazards. Obey all safety
messages that follow this symbol
to avoid possible injury or death.
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.
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.
Redused to indicate the

presence of an imminently
hazardous situation which, if not
avoided, will result in death or
serious injury.
Be sure that all tools and working areas

are properly maintained and ready for
use. Keep work surfaces clean and free of
debris that could get into machine components and
cause damage.
Orangeused to indicate the

presence of a potentially
avoided, could result in death or
serious injury.
Be sure any forklift, overhead crane or

other lifting or supporting device is fully
capable of supporting and stabilizing the
weight to be lifted. Use only chains or straps that
are in good condition and of ample capacity.
Yellow with safety alert symbol

used to indicate the presence of a
potentially hazardous situation
which, if not avoided, may cause
minor or moderate injury.
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.
Yellow without safety alert

symbolused to indicate the
avoided, may result in property
damage.
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.
Indicates special operation or

maintenance information.
iv
Part No. 36540
Theory of Operation
Power Source
Electrical System
The Genie Z-34/22 & Genie Z-34/22N are powered

by eight six-volt (315 AH) batteries, separated into
two groups of four. Each group of four batteries is
wired in series to produce 24V DC. The two battery
groups are then joined to produce 48V DC. The
drive system uses 48V DC and the control system
uses 24V DC.
Drive system
Hydraulic System
All machine functions are performed by the
hydraulic system. The hydraulic system is powered
by a single-section gear pump. When the pump is
activated, it supplies hydraulic fluid under pressure
to the function manifold, where the control valves
are located. To protect from over-pressurization of
the hydraulic system, the pump is provided with a
pressure relief valve, set at 3200 psi (221 bar).
Activating a machine function is accomplished by
actuating or moving a toggle switch and/or control
handle, which sends voltage to the appropriate
directional control valve. The directional valve
determines which direction the hydraulic fluid will
travel. The amount of hydraulic fluid volume is
determined by the proportional valve input voltage
from the boom function speed controller at the
platform controls. Each boom lift cylinder
incorporates a counterbalance valve to prevent
movement in the event of a hydraulic line failure.
Part No. 36540
All Z-34/22 and Z-34/22N machines utilize a DC

drive motor on each non-steer wheel. The two
motors are connected in series and are controlled
by a solid-state motor controller. The motor
controller regulates the amount of current applied
to the drive motors based upon the position of the
drive controller (joystick), which allows proportional
drive speed control.
Z-34/22 machines (before serial number 1734) and
Z-34/22N machines (before serial number 2227)
use series-wound DC drive motors and a solid
state motor controller designed for series motors. A
mechanical forward/reverse contactor provides
directional control of the drive motors. These
machines also have a proportional braking system,
which is active in the drive controller (joystick)
range between neutral position and half way to full
deflection in both drive directions. The drive
controller has a 0-5 V DC voltage output which
activates the motor controller, as well as a
proportional coil output for the brake system.
Z-34/22 machines (after serial number 1733) and
Z-34/22N machines (after serial number 2226) use
separately excited (Sepex) DC drive motors and a
Sepex motor controller. No forward/reverse
contactor is required in this system, as the
controller does the switching automatically. The
Sepex drive system utilizes regenerative braking,
which means that the drive motors are used to
slow down and stop the machine. The resulting
THEORY OF OPERATION
energy is then returned to the batteries.

Regenerative braking allows the use of a simple,
non-proportional parking brake which applies after
the machine has come to a stop, or if the
Emergency Stop button is pushed in to the OFF
position.
The Sepex motor controller also incorporates self
diagnostics. An LED on the motor controller will
flash a fault code when a fault is present to aid in
troubleshooting. Refer to the fault code chart in
Section Five.
Limit switches
There are two types of limit switches, which are
found in various locations on the machine: drive
speed limit switches and a drive enable limit
switch.
The function of a drive speed limit switch is to limit
the raised machine drive speed to 0.6 miles per
hour (1 km/h) when either the primary or
secondary boom is raised more than 2 feet (0.6 m)
OR when the primary boom is extended more than
12 inches (30 cm).
The function of the drive enable limit switch is to
limit the ability of the machine to drive when the
boom is rotated outside the area between the nonsteer wheels.
Machine Controls
The Z-34/22 and Z-34/22N machines are equipped
with operational controls which are found in two
locations: the ground controls, located opposite the
hydraulic tank side of the machine, and the
platform controls, located in the platform. All lift and
drive functions are available at the platform
controls. Only boom functions are available at the
ground controls. Moving a boom function toggle
switch in the direction indicated on the control
panel decal will determine which boom function will
operate and its direction of travel.
The platform controls incorporates a rotary boom
function speed controller which, by varying the
position of the controller, controls the amount of
voltage to the boom function proportional valve.
This controller determines the speed at which the
function will operate.
The drive controller (joystick) is fitted with a
potentiometer that communicates the drive
controller position with the motor controller. A
thumb rocker switch on the top of the drive
controller is used for steering.
Washing electronic components is not suggested.
Instead, use compressed air to remove debris.
Component damage hazard. Avoid
shock or impact to the motor
controller. Internal damage may
not be visible from the outside.
vi
Part No. 36540
Table of Contents
Introduction
Important Information ...................................................................................................... ii
Section One
Safety Rules
General Safety Rules ..................................................................................................... iii
Theory of Operation ....................................................................................................... v
Section Two
Specifications
Machine Specifications ............................................................................................. 2 - 1
Performance Specifications ...................................................................................... 2 - 2
Hydraulic Specifications ............................................................................................ 2 - 3
Hydraulic Hose and Fitting Torque Specifications ..................................................... 2 - 4
SAE and Metric Fastener Torque Chart ..................................................................... 2 - 5
Section Three
Scheduled Maintenance Inspections

Introduction ............................................................................................................... 3 - 1
Table A ..................................................................................................................... 3 - 2
Table B ..................................................................................................................... 3 - 2
Table C ..................................................................................................................... 3 - 4
Table D ..................................................................................................................... 3 - 4
Maintenance Inspection Report ................................................................................. 3 - 5
Section Four
Scheduled Maintenance Procedures

Introduction ............................................................................................................... 4 - 1
Part No. 36540
A-1
Inspect the Operators and Safety Manuals ..................................................... 4 - 2
A-2
Inspect the Decals and Placards ..................................................................... 4 - 2
A-3
Inspect for Damage and Loose or Missing Parts ............................................. 4 - 3
A-4
Check the Hydraulic Oil Level ......................................................................... 4 - 3
vii
TABLE OF CONTENTS
Section Four
Scheduled Maintenance Procedures, continued

A-5
Check for Hydraulic Leaks ............................................................................... 4 - 4
A-6
Test the Platform and Ground Controls ............................................................ 4 - 5
A-7
Test the Auxiliary Power Operation ................................................................. 4 - 7
A-8
Test the Tilt Sensor ......................................................................................... 4 - 8
A-9
Test the Limit Switches ................................................................................... 4 - 8
A-10 Test the Lift/Drive Select Switch (if equipped) ............................................... 4 - 11

A-11 Perform 30 Day/50 Hour Service ................................................................... 4 - 11
B-1
Check the Batteries ....................................................................................... 4 - 12
B-2
Inspect the Electrical Wiring .......................................................................... 4 - 13
B-3
Inspect the Tires and Wheels (including lug nut torque) ................................. 4 - 14
B-4
Confirm the Proper Brake Configuration ......................................................... 4 - 14
B-5
Check the Oil Level in the Drive Hubs ........................................................... 4 - 15
B-6
Test the Key Switch ...................................................................................... 4 - 16
B-7
Test the Emergency Stop Buttons ................................................................. 4 - 16
B-8
Test the Ground Control Override .................................................................. 4 - 17
B-9
Test the Platform Self-leveling ...................................................................... 4 - 17
B-10 Test the Horn ................................................................................................ 4 - 18

B-11 Test the Foot Switch ..................................................................................... 4 - 18
B-12 Test the Drive Enable System ....................................................................... 4 - 19
B-13 Test the Drive Brakes .................................................................................... 4 - 20
B-14 Test the Drive Speed - Stowed Position ........................................................ 4 - 21
B-15 Test the Drive Speed - Raised or Extended Position ..................................... 4 - 22
B-16 Test the Alarm Package (if equipped) ............................................................ 4 - 23
viii
Part No. 36540
TABLE OF CONTENTS
Section Four
Scheduled Maintenance Procedures, continued

B-17 Test the Turntable Rotation Stop ................................................................... 4 - 24
B-18 Check the Electrical Contactors .................................................................... 4 - 25
B-19 Perform Hydraulic Oil Analysis ...................................................................... 4 - 25
B-20 Replace the Hydraulic Tank Return Filter ....................................................... 4 - 26
Section Five
C-1
Check the Primary Boom Wear Pads ............................................................ 4 - 28
C-2
Check the Turntable Rotation Bearing Bolts .................................................. 4 - 28
C-3
Check the Free-wheel Configuration .............................................................. 4 - 30
C-4
Grease the Turntable Rotation Bearing and Worm Drive Gear ........................ 4 - 31
C-5
Replace the Drive Hub Oil ............................................................................. 4 - 31
C-6
Bleed the Platform Rotator ............................................................................ 4 - 32
D-1
Test or Replace the Hydraulic Oil .................................................................. 4 - 33
D-2
Grease the Steer Axle Wheel Bearings - 2WD Models ................................... 4 - 35
Troubleshooting Flow Charts

Introduction .............................................................................................................. 5 - 1
Fault Code Chart
(Z-34/22 after serial number 1733 and
Z-34/22N after serial number 2226) .................................................................. 5 - 3
Part No. 36540
All Functions Will Not Operate ......................................................................... 5 - 7
Lift Pump Motor Will Not Operate .................................................................. 5 - 10
Auxiliary Pump Motor Will Not Operate .......................................................... 5 - 17
All Functions Inoperative, Power Unit Starts and Runs .................................. 5 - 20
All Lift and Steer Functions Inoperative, Drive Function Operational .............. 5 - 21
Ground Controls Inoperative, Platform Controls Operate Normally ................. 5 - 25
ix
TABLE OF CONTENTS
Section Five
Troubleshooting Flow Charts, continued

7
Platform Controls Inoperative, Ground Controls Operate Normally

(Z-34/22 before serial number 1734 and
Z-34/22N before serial number 2227) ............................................................. 5 - 27
Platform Controls Inoperative, Ground Controls Operate Normally

Z-34/22N after serial number 2226) ................................................................ 5 - 31
Primary Boom Up Function Inoperative ......................................................... 5 - 34
10
Primary Boom Down Function Inoperative ..................................................... 5 - 38
11
Secondary Boom Up Function Inoperative ..................................................... 5 - 42
12
Secondary Boom Down Function Inoperative ................................................ 5 - 46
13
Primary Boom Extend Function Inoperative ................................................... 5 - 50
14
Primary Boom Retract Function Inoperative .................................................. 5 - 55
15
Turntable Rotate Left Function Inoperative .................................................... 5 - 60
16
Turntable Rotate Right Function Inoperative .................................................. 5 - 65
17
All Platform Level Functions Inoperative ....................................................... 5 - 69
18
Platform Level Up Function Inoperative ......................................................... 5 - 71
19
Platform Level Down Function Inoperative ..................................................... 5 - 76
20
Platform Rotate Left Function Inoperative ...................................................... 5 - 80
21
Platform Rotate Right Function Inoperative ................................................... 5 - 84
22
Jib Boom Up Function Inoperative ................................................................. 5 - 88
23
Jib Boom Down Function Inoperative ............................................................. 5 - 91
24
Steer Left Function Inoperative

25
Steer Left Function Inoperative

Part No. 36540
TABLE OF CONTENTS
Section Five

26
Steer Right Function Inoperative

27
Steer Right Function Inoperative

28
All Drive Functions Inoperative, All Other Functions Operate Normally

Z-34/22N before serial number 2227) ............................................................ 5 - 100
28A Brake Function Inoperative

29
All Drive Functions Inoperative, All Other Functions Operate Normally

Z-34/22N after serial number 2226) ............................................................... 5 - 110
29A Motor Controller Fault Code 21: Throttle Fault

29B Motor Controller Fault Code 32: Main Contactor Welded
29C Motor Controller Fault Code 34: Missing Main Contactor OR
Main Contactor Did Not Close
30
Part No. 36540
Brake Release Function Inoperative

xi
TABLE OF CONTENTS
Section Five
xii

31
Drive Forward Function Inoperative .............................................................. 5 - 120

Z-34/22N before serial number 2227)
32
Drive Reverse Function Inoperative .............................................................. 5 - 121

33
Machine Will Not Drive At Full Speed

34
Machine Will Not Drive At Full Speed

35
Machine Drives At Full Speed With Platform Raised Or Extended

36
Machine Drives At Full Speed With Platform Raised Or Extended

37
Drive Enable System Is Malfunctioning

38
Drive Enable System Is Malfunctioning

Z-34/22N after serial number 2226) ..................................................... 5 - 129
39
Remote Brake Release Inoperative

Z-34/22 before serial number 3578 and
Part No. 36540
TABLE OF CONTENTS
Section Six
Schematics
Introduction ............................................................................................................... 6 - 1
Electrical Components .............................................................................................. 6 - 2
Load Sensor Option Diagram
Z-34/22N before serial number 2227) ......................................................................... 6 - 4
(Z-34/22 from serial number 1734 to 2060 and
Z-34/22N from serial number 2227 to 2870) ............................................................... 6 - 5
Power Cable Diagram
Power Cable Diagram
Z-34/22N after serial number 4260) ........................................................................... 6 - 8
Abbreviations Legend ................................................................................................ 6 - 9
Electrical Symbols Legend ...................................................................................... 6 - 10
Hydraulic Symbols Legend ...................................................................................... 6 - 11
Part No. 36540
xiii
TABLE OF CONTENTS
Section Six
Schematics, continued
Electrical Schematic
Z-34/22N from serial number 2227 to 2447) ............................................................. 6 - 17
Z-34/22N after serial number 5619) ......................................................................... 6 - 25
Electrical Schematic - CE Models
xiv
Part No. 36540
TABLE OF CONTENTS
Section Six
Ground Control Panel Legend
Ground Control Panel Wiring Diagram
Ground Control Terminal Strip Wiring Diagram
Platform Control Box Wiring Diagram
Z-34/22N before serial number 2227) ....................................................................... 6 - 36
Part No. 36540
xv
TABLE OF CONTENTS
Section Six
Hydraulic Schematic
Hydraulic Schematic
Hydraulic Schematic
Hydraulic Schematic
Hydraulic Schematic
xvi
Part No. 36540
TABLE OF CONTENTS
Section Seven
Repair Procedures
Introduction ............................................................................................................... 7 - 1
Platform Controls
1-1
Controllers ....................................................................................................... 7 - 2
1-2
Foot Switch ..................................................................................................... 7 - 9
1-3
Toggle Switches ............................................................................................ 7 - 10
Platform Components
2-1
Platform ........................................................................................................ 7 - 11
2-2
Platform Leveling Slave Cylinder ................................................................... 7 - 11
2-3
Platform Rotator ............................................................................................ 7 - 13
Jib Boom Components

3-1
Jib Boom ....................................................................................................... 7 - 16
3-2
Jib Boom Bell Crank ...................................................................................... 7 - 17
3-3
Jib Boom Lift Cylinder ................................................................................... 7 - 18
Primary Boom Components

4-1
Plastic Cable Track ....................................................................................... 7 - 19
4-2
Primary Boom ............................................................................................... 7 - 19
4-3
Primary Boom Lift Cylinder ............................................................................ 7 - 23
4-4
Extension Cylinder ........................................................................................ 7 - 25
4-5
Platform Leveling Master Cylinder ................................................................. 7 - 26
Secondary Boom Components
Part No. 36540
5-1
Secondary Boom ........................................................................................... 7 - 29
5-2
Secondary Boom Lift Cylinder ....................................................................... 7 - 33
xvii
TABLE OF CONTENTS
Section Seven
Repair Procedures, continued

Ground Controls
6-1
Control Relays ............................................................................................... 7 - 34
6-2
Toggle Switches, See 1-3, Toggle Switches .................................................. 7 - 36
6-3
Wago Components ...................................................................................... 7 - 36
Hydraulic Pumps
7-1
Auxiliary Pump .............................................................................................. 7 - 37
7-2
Main Function Pump ..................................................................................... 7 - 38
Manifolds
xviii
8-1
Function Manifold Components

Z-34/22N before serial number 935) ............................................................... 7 - 40
8-2

Z-34/22N from serial number 935 to 2226) ..................................................... 7 - 42
8-3

8-4
Valve Adjustments - Function Manifold ......................................................... 7 - 46
8-5
Jib Boom / Platform Rotate Manifold Components

8-6

(Z-34/22 from serial number 1734 to 2005
Z-34/22N from serial number 2227 to 2771) ................................................... 7 - 52
8-7

8-8
Steer / Brake Manifold Components

8-9

(Z-34/22 from serial number 781 to 1733
Z-34/22N from serial number 1030 to 2226) ................................................... 7 - 55
Part No. 36540
TABLE OF CONTENTS
Section Seven
Repair Procedures, continued

Hydraulic Tank
9-1
Hydraulic Tank .............................................................................................. 7 - 56
Turntable Rotation Components

10-1 Turntable Rotation Hydraulic Motor ................................................................ 7 - 58
Steering Axle Components
11-1 Yoke and Hub ................................................................................................ 7 - 59
11-2 Steering Cylinder ........................................................................................... 7 - 61
11-3 Tie Rod .......................................................................................................... 7 - 61
Non-steering Axle Components
12-1 Drive Motor .................................................................................................... 7 - 62
12-2 Drive Hub ...................................................................................................... 7 - 62
Motor Controller
13-1 Motor Controller
Part No. 36540
xix
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xx
Part No. 36540
Section 2 Specifications
Specifications
Machine Specifications
Tires and wheels, Z-34/22
Stowed dimensions
Z-34/22N
Z-34/22
Length
18 ft 7 in
5.7 m
18 ft 6 in
5.6 m
Width
4 ft 10 in
1.5 m
5 ft 8 in
1.7 m
Height
6 ft 7 in
2m
6 ft 7 in
2m
11,500 lbs
5216 kg
10,500 lbs
4763 kg
5 3/4 in
14.6 cm
6 in
15.2 cm
Machine Weight
Tire size
Tire ply rating
Tire contact area
Overall tire diameter
Wheel diameter
Wheel width
9-14.5 LT
Tread 8
Sidewall 6
43.5 sq in
280 sq cm
28 in
37 cm
14.5 in
45 cm
7 in
18 cm
Tires and wheels, Z-34/22N

Tire size (solid rubber)
Ground clearance
22 x 7 x 17.75 in
56 x 18 x 45 cm
Load range
7600 lbs
3447 kg
Tire contact area
35 sq in
226 sq cm
22 in
56 cm
17.75 in
45 cm
7 in
18 cm
Platform dimensions
Length
56 in
142 cm
Width
30 in
76 cm
500 lbs
227 kg
Overall tire diameter

Wheel diameter
Maximum capacity
Wheel width
Operational dimensions
Height, platform maximum
34 ft 4 in
10.5 m
34 ft 8 in
10.6 m
Wheel lugs
Front
Rear
Height, working maximum
40 ft 4 in
12.3 m
40 ft 8 in
12.4 m
Lug nut torque
Horizontal reach, maximum
22 ft 4 in
6.8 m
22 ft 4 in
6.8 m
6 ft 2 in
1.9 m
6 ft 2 in
1.9 m
Turning radius
(outside)
12 ft 9 in
3.9 m
13 ft 1 in
4m
Turning radius
(inside)
6 ft
1.8 m
5 ft 8 in
1.7 m
Turntable rotation (degrees)
355
355
Platform rotation (degrees)
160
160
8 @ 5/8-18
9 @ 5/8-18
125 ft-lbs
169.5 Nm
Fluid Capacities
Turntable tailswing
Wheelbase

Z-34/22N before serial number 1116:
Hydraulic tank capacity
Hydraulic system
(including tank)
Z-34/22 after serial number 808 and
Z-34/22N after serial number 1115:
Hydraulic system
(including tank)
5 gallons
18.9 liters
7 gallons
26.5 liters
4 gallons
15.1 liters
6 gallons
22.7 liters
Continuous improvement of our products is a

Genie policy. Product specifications are subject to
change without notice.
Part No. 36540
2-1
SPECIFICATIONS
Performance Specifications
Drive speeds (maximum) Z-34/22
Drive speed, stowed
4 mph
6.4 km/h
35:1 torque hubs
40 ft/6.8 sec 12.2 m/6.8 sec
Drive speed, stowed
49:1 torque hubs
3.1 mph
5 km/h
40 ft/9.1 sec 12.2 m/9.1 sec
(after serial number 1733)

Drive speed, stowed
3.7 mph
6 km/h
47:1 torque hubs
40 ft/7.5 sec 12.2 m/7.5 sec
Drive speed,
0.6 mph
1 km/h
booms raised or extended 40 ft/40 sec 12.2 m/40 sec
Drive speeds (maximum) Z-34/22N
Drive speed, stowed
3.4 mph
35:1 torque hubs
40 ft/8 sec
Drive speed, stowed
49:1 torque hubs
Drive speed, stowed
47:1 torque hubs
5.5 km/h
12.2 m/8 sec
2.8 mph
4.5 km/h
40 ft/10 sec 12.2 m/10 sec
3.1 mph
40 ft/9 sec
5 km/h
12.2 m/9 sec
Drive speed,
0.6 mph
1 km/h
Gradeability (boom stowed)
Z-34/22 (before serial number 1734)
49:1 drive hubs
35:1 drive hubs
35%
30%
Z-34/22 (after serial number 1733)

47:1 drive hubs
30%
Z-34/22N (before serial number 2227)

49:1 drive hubs
35:1 drive hubs
25%
20%
Z-34/22N (after serial number 2226)

47:1 drive hubs
30%
2-2
Boom function speeds, maximum

from platform controls (with 500 lbs in platform)
Z-34/22N before serial number 2227
Jib boom up
30 to 40 seconds
Jib boom down
15 to 25 seconds
Primary boom up
25 to 35 seconds
Primary boom down
15 to 25 seconds
Primary boom extend
25 to 35 seconds
Primary boom retract
15 to 25 seconds
Secondary boom up
15 to 25 seconds
Secondary boom down
10 to 15 seconds
Turntable rotate - 355
50 to 70 seconds
Platform rotate - 160
5 to 10 seconds
Platform level up
10 to 20 seconds
Platform level down
10 to 20 seconds
Boom function speeds, maximum

from platform controls (with 500 lbs in platform)
Z-34/22N after serial number 2226
Jib boom up
23 to 29 seconds
Jib boom down
20 to 26 seconds
Primary boom up
15 to 21 seconds
Primary boom down
12 to 18 seconds
Primary boom extend
21 to 27 seconds
Primary boom retract
12 to 18 seconds
Secondary boom up
16 to 22 seconds
Secondary boom down
12 to 18 seconds
Turntable rotate - 355
57 to 63 seconds
Platform rotate - 160
17 to 23 seconds
Platform level up
10 to 20 seconds
Platform level down
10 to 20 seconds
Part No. 36540
SPECIFICATIONS
Hydraulic Specifications
Auxiliary pump
Dexron equivalent
Hydraulic fluid
Displacement
Lift pump
Type
Type
Fixed displacement gear pump

0.75 gpm
2.8 l/min
Fixed displacement gear pump
Displacement
per revolution
0.153 cu in
2.5 cc
Displacement
(2500 psi/172 bar)
1.6 gpm
6 l/min
Hydraulic reservoir
return line filter
10 micron with 25 psi

(1.7 bar) bypass
Function manifold
Function relief
valve pressure
Primary boom down relief
Z-34/22
Z-34/22N
3200 psi
221 bar
1400 psi
1600 psi
97 bar
110 bar
1400 psi
1600 psi
97 bar
110 bar
Secondary boom down relief

valve pressure
1600 psi
110 bar
Primary boom extend relief

valve pressure
Z-34/22
(from serial number 2901 to 3215
Z-34/22N
(from serial number 3533 to 3766)
1800 psi
124 bar
1800 psi
2800 psi
124 bar
193 bar
1800 psi
2800 psi
124 bar
193 bar
Turntable rotate relief valve pressures

Z-34/22
1750 psi 121 bar
(from serial number 674 to 1733) Not adjustable
1100 psi
76 bar
Z-34/22N
(from serial number 935 to 2226)
Part No. 36540
1750 psi 121 bar

Not adjustable
1100 psi
76 bar
2-3
SPECIFICATIONS
Hydraulic Hose and Fitting Torque Specifications

Your machine is equipped with Parker Seal-Lok O-ring face seal fittings and hose ends. Machines that
utilize Parker Seal-Lok O-ring face seal hoses and fittings require that the fittings and hose ends be
torqued to specification when they are removed and installed, or when new hoses or fittings are installed.
Hydraulic Hose and Fitting Torque Specifications

SAE O-ring Boss Port - tube fitting
SAE Dash
Installing
Size
into...
ft. lbs.
-4
Aluminum
11
Steel
16
-6
Aluminum
23
Steel
35
-8
Aluminum
40
Steel
60
-10
Aluminum
69
Steel
105
-12
Aluminum
93
Steel
140
-16
Aluminum
139
Steel
210
-20
Aluminum
172
Steel
260
-24
Aluminum
208
Steel
315
Nm
14.9
21.7
31.2
47.5
54.2
81.3
93.6
142.4
126.1
190
188.5
284.7
233.2
352.5
282
427.1
Seal-Lok - hose end

SAE Dash
Size
ft. lbs.
-4
18
-6
27
-8
40
-10
63
-12
90
-16
120
-20
140
-24
165
Nm
24.4
36.6
54.2
85.4
122
162.7
190
223.7
Torque Procedure
1 Replace the O-ring. The O-ring must be
replaced anytime the seal has been broken.
The O-ring cannot be re-used if the fitting or
hose end has been tightened beyond finger
tight.
The O-rings used in the Parker
Seal Lok fittings and hose ends
are custom size O-rings. They are
not standard SAE size O-rings.
They are available in the O-ring
field service kit
(Genie part number 49612).
3 Be sure that the face seal O-ring is seated and

retained properly.
4 Position the tube and nut squarely on the face
seal end of the fitting and tighten the nut finger
tight.
5 Tighten the nut or fitting to the appropriate
torque per given size, as shown in the table
above.
6 Operate all machine functions and inspect the
hoses and fittings and related components to
be sure that there are no leaks.
2 Lubricate the O-ring before installation.
2-4
Part No. 36540
SPECIFICATIONS
SAE FASTENER TORQUE CHART

This chart is to be used as a guide only unless noted elsewhere in this manual
SIZE
Grade 5
THREAD
LUBED
20
28
1/4
5/16
3/8
7/16
1/2
9/16
5/8
3/4
7/8
1
1 1/8
1 1/4
1 1/2
LUBED
DRY
DRY
in- lbs
Nm
in- lbs
Nm
in- lbs
Nm
in- lbs
Nm
in- lbs
Nm
80
90
9
10.1
100
120
11.3
13.5
110
120
12.4
13.5
140
160
15.8
18
130
140
14.7
15.8
LUBED
18
24
16
24
14
20
13
20
12
18
11
18
10
16
9
14
8
12
7
12
7
12
6
12
A574 High Strength

Black Oxide Bolts
LUBED
Grade 8
DRY
LUBED
DRY
LUBED
f t - lbs
Nm
f t - lbs
Nm
f t - lbs
Nm
f t - lbs
Nm
f t - lbs
Nm
13
14
23
26
37
41
57
64
80
90
110
130
200
220
320
350
480
530
590
670
840
930
1460
1640
17.6
19
31.2
35.2
50.1
55.5
77.3
86.7
108.4
122
149
176
271
298
433
474
650
718
800
908
1138
1260
1979
2223
17
19
31
35
49
55
75
85
110
120
150
170
270
300
430
470
640
710
790
890
1120
1240
1950
2190
23
25.7
42
47.4
66.4
74.5
101.6
115
149
162
203
230
366
406
583
637
867
962
1071
1206
1518
1681
2643
2969
18
20
33
37
50
60
80
90
120
130
160
180
280
310
450
500
680
750
970
1080
1360
1510
2370
2670
24
27.1
44.7
50.1
67.8
81.3
108.4
122
162
176
217
244
379
420
610
678
922
1016
1315
1464
1844
2047
3213
3620
25
27
44
49
70
80
110
120
150
170
210
240
380
420
610
670
910
990
1290
1440
1820
2010
3160
3560
33.9
36.6
59.6
66.4
94.7
108.4
149
162
203
230
284
325
515
569
827
908
1233
1342
1749
1952
2467
2725
4284
4826
21
24
38
43
61
68
93
105
130
140
180
200
320
350
510
560
770
840
1090
1220
1530
1700
2670
3000
28.4
32.5
51.5
58.3
82.7
92.1
126
142
176
189
244
271
433
474
691
759
1044
1139
1477
1654
2074
2304
3620
4067
METRIC FASTENER TORQUE CHART

This chart is to be used as a guide only unless noted elsewhere in this manual
Class 4.6
Size
(m m )
5
6
7
LUBED
DRY
LUBED
Class 10.9
8.8
DRY
LUBED
Class 12.9
10.9
DRY
LUBED
12.9
DRY
in- lbs
Nm
in-lbs
Nm
in- lbs
Nm
in- lbs
Nm
in- lbs
Nm
in- lbs
Nm
in- lbs
Nm
in- lbs
Nm
16
19
45
1.8
3.05
5.12
21
36
60
2.4
4.07
6.83
41
69
116
4.63
7.87
13.2
54
93
155
6.18
10.5
17.6
58
100
167
6.63
11.3
18.9
78
132
223
8.84
15
25.2
68
116
1.95
7.75
13.2
22.1
91
155
260
10.3
17.6
29.4
LUBED
8
10
12
14
16
18
20
22
24
Class 8.8
4.6
DRY
LUBED
DRY
LUBED
DRY
LUBED
DRY
f t - lbs
Nm
f t -lbs
Nm
f t - lbs
Nm
f t - lbs
Nm
f t - lbs
Nm
ft - lbs
Nm
f t - lbs
Nm
f t - lbs
Nm
5.4
10.8
18.9
30.1
46.9
64.5
91
124
157
7.41
14.7
25.6
40.8
63.6
87.5
124
169
214
7.2
14.4
25.1
40
62.5
86.2
121
166
210
9.88
19.6
34.1
54.3
84.8
117
165
225
285
14
27.9
48.6
77.4
125
171
243
331
420
19.1
37.8
66
105
170
233
330
450
570
18.8
37.2
64.9
103
166
229
325
442
562
25.5
50.5
88
140
226
311
441
600
762
20.1
39.9
69.7
110
173
238
337
458
583
27.3
54.1
94.5
150
235
323
458
622
791
26.9
53.2
92.2
147
230
317
450
612
778
36.5
72.2
125
200
313
430
610
830
1055
23.6
46.7
81
129
202
278
394
536
682
32
63.3
110
175
274
377
535
727
925
31.4
62.3
108
172
269
371
525
715
909
42.6
84.4
147
234
365
503
713
970
1233
Part No. 36540
2-5
2-6
Part No. 36540
Section 3 Scheduled Maintenance Inspections
Scheduled Maintenance Inspections

Warm
About This Section
Tools are
required
New parts
required
The Schedule
Observe and Obey:

Maintenance inspections shall be completed by
a person trained and qualified on the
maintenance of this machine.
Scheduled maintenance inspections shall be
completed daily, hourly, quarterly, annually and
every 2 years as specified on the Maintenance
Inspection Report.
Failure to properly complete each
inspection when required could
cause death, serious injury or
substantial machine damage.
Cold
engine
required
engine
required
Dealer
service
suggested
There are five types of maintenance inspections

that must be performed according to a schedule
daily, hourly, quarterly, annual and two year. To
account for repeated procedures, the Maintenance
Tables and the Maintenance Inspection Report
have been divided into four subsectionsA, B, C,
D. Use the following chart to determine which
group(s) of procedures are required to perform a
scheduled inspection.
Inspection
Table or Checklist
Daily
Hourly and Quarterly
Annual
Two year
A
A+B
A+B+C
A+B+C+D
Immediately tag and remove from service a

damaged or malfunctioning machine.
Repair any machine damage or malfunction
before operating machine.
Machines that have been out of service for a
period longer than 3 months must complete the
hourly and quarterly inspections.
Maintenance Tables
The maintenance tables contained in this section
provide summary information on the specific
physical requirements for each inspection.
Complete step-by-step instructions for each
scheduled maintenance procedure are provided in
section 4, Scheduled Maintenance Procedures.
Maintenance Inspection Report
The maintenance inspection report contains
checklists for each type of scheduled inspection.
Make copies of the Maintenance Inspection Report
to use for each inspection. Maintain completed
forms for a minimum of 4 years or in compliance
with employer, jobsite and govermental regulations
and requirements.
Part No. 36540
3-1
Maintenance Tables
Table A
Tools are
required
A-1
Inspect the Operator's and Safety Manuals
A-2
Inspect the Decals and Placards
A-3
Inspect for Damage and

Loose or Missing Parts
A-4
Check the Hydraulic Oil Level
A-5
Check for Hydraulic Leaks
A-6
Test the Platform and Ground Controls
A-7
Test the Auxiliary Power Operation
A-8
Test the Tilt Sensor
A-9
Test the Limit Switches
A-10
Test the Lift/Drive Select Switch

(if equipped)
A-11
Perform 30 Day/50 Hour Service
New parts
required
Warm
engine
required
Cold
engine
required
Dealer
service
suggested
Table B
B-1
Check the Batteries
B-2
Inspect the Electrical Wiring
B-3
Inspect the Tires and Wheels

(including lug nut torque)
B-4
Confirm the Proper Brake Configuration
B-5
Check the Oil Level in the Drive Hubs
3-2
Part No. 36540
MAINTENANCE TABLES
Table B, continued
Tools are
required
B-6
Test the Key Switch
B-7
Test the Emergency Stop Buttons
B-8
Test the Ground Control Override
B-9
Test the Platform Self-leveling
B-10
Test the Horn
B-11
Test the Foot Switch
B-12
Test the Drive Enable System
B-13
Test the Drive Brakes
B-14
Test the Drive Speed Stowed Position
B-15
Test the Drive Speed Raised or Extended Position
B-16
Test the Alarm Package (if equipped)
B-17
Test the Turntable Rotation Stop
B-18
Check the Electrical Contactors
B-19
Perform Hydraulic Oil Analysis

See D-1 Test or Replace the Hydraulic Oil
New parts
required
Warm
engine
required
Cold
engine
required
Dealer
service
suggested
Every 250 hours, perform the following

maintenance procedure:
B-20
Replace the Hydraulic Tank Return Filter
Part No. 36540
3-3
MAINTENANCE TABLES
Table C
Tools are
required
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 Bearing

and Worm Drive Gear
C-5
Replace the Drive Hub Oil
C-6
Bleed the Platform Rotator
New parts
required
Warm
engine
required
Cold
engine
required
Dealer
service
suggested
Table D
D-1
Test or Replace the Hydraulic Oil
D-2
Grease the Steer Axle Wheel Bearings
3-4
Part No. 36540
Maintenance Inspection Report

Model
Checklist A
Serial number
Date
Hour meter
Machine owner
Refer to Table A
Y N R
Tools are
required
New parts
required
B-9 Platform
Warm levelingCold
engine
B-10 Horn
required
engine
required
A-1 Operator's and

Safety manuals
B-11 Foot switch
A-2 Decals and placards
B-13 Drive brakes
A-3 Damage and loose or

missing parts
B-14 Drive speed-stowed
B-12 Drive enable system
B-15 Drive speed-raised
A-4 Hydraulic oil level
Inspected by (print)
A-5 Hydraulic leaks
B-16 Alarm package

(if equipped)
Inspector signature
A-6 Platform and

ground controls
B-17 Turntable stop
Inspector title
B-18 Electrical contactors
A-7 Auxiliary power
B-19 Hydraulic oil analysis
A-8 Tilt sensor

Inspector company
Instructions
Make copies of this page to use for
each inspection.
Select the appropriate checklist(s) for
the type of inspection to be
performed.
Perform quarterly or every 250 hours:
A-9 Limit switches
B-20 Hydraulic return filter
A-10 Lift/Drive select switch

(if equipped)
Checklist C
A-11 30 Day/50 Hour Service
Y N R
Refer to Table C
Checklist B
Y N R
C-1 Boom wear pads
Refer to Table B
C-2 Turntable bearing bolts
Daily Inspection: A
B-1 Batteries
C-3 Free-wheel configuration
Hourly/Quarterly
Inspection: A+B
B-2 Electrical wiring
C-4 Grease rotation bearing
B-3 Tires and wheels
C-5 Drive hub oil
Annual Inspection: A+B+C
B-4 Brake configuration
C-6 Platform rotator
2 Year Inspection: A+B+C+D
B-5 Drive hub oil level
Place a check in the appropriate box

after each inspection procedure is
completed.
Use the maintenance tables in this
section and the step-by-step
procedures in section 4 to learn how
to perform these inspections.
Dealer
service
suggested
B-6 Key switch

B-7 Emergency stop
B-8 Ground control override
Checklist D
Y N R
Refer to Table D
D-1 Hydraulic oil
D-2 Wheel bearings
If any inspection receives an N, tag

and remove the machine from service,
repair and re-inspect it. After repair,
place a check in the R box.
Legend
Y = yes, acceptable
N = no, remove from service
R = repaired
Comments
Part No. 36540
3-5
Tools are
required
New parts
required
Warm
engine
required
Cold
engine
required
Dealer
service
suggested
3-6
Part No. 36540
Section 4 Scheduled Maintenance Procedures
Scheduled Maintenance Procedures

About This Section
This section contains detailed procedures for each
scheduled maintenance inspection.
Each procedure includes a description, safety
warnings and step-by-step instructions.
Observe and Obey:
Symbols Legend
Maintenance inspections shall be completed by

a person trained and qualified on the
maintenance of this machine.
Scheduled maintenance inspections shall be
completed daily, hourly, quarterly, annually and
every 2 years as specified on the Maintenance
Inspection Report.

serious injury.
Failure to properly complete each

inspection when required may
cause death, serious injury or
substantial machine damage.

serious injury.

before operating machine.

Unless otherwise specified, perform each

procedure with the machine in the following
configuration:
Machine parked on a flat level surface

damage.
Boom in the stowed position

Turntable rotated with the boom between the
non-steering wheels
Key switch in the OFF position with the key
removed
Greenused to indicate operation

or maintenance information.
Wheels chocked
Indicates that a specific result is expected after

performing a series of steps.
Part No. 36540
4-1
Table A Procedures
A-1
Inspect the Operators and
Safety Manuals
A-2
Inspect the
Decals and Placards
Maintaining the operators and safety manuals in

good condition is essential to safe machine
operation. Manuals are included with each
machine and should be stored in the container
provided in the platform. An illegible or missing
manual will not provide safety and operational
information necessary for a safe operating
condition.
Maintaining all of the safety and instructional

decals and placards in good condition is
mandatory for safe machine operation. Decals
alert operators and personnel to the many possible
hazards associated with using this machine. They
also provide users with operation and maintenance
information. An illegible decal will fail to alert
personnel of a procedure or hazard and could
result in unsafe operating conditions.
1 Check to be sure the storage container is

present and in good condition.
2 Check to make sure that the operators,
responsibilities and safety manuals are present
and complete in the storage container in the
platform.
3 Examine the pages of each manual to be sure
that they are legible and in good condition.
1 Refer to the Decals section in the Genie

Z-34/22 & Genie Z-34/22N Operator's Manual
and use the decal list and illustrations to
determine that all decals and placards are in
place.
2 Inspect all decals for legibility and damage.
Replace any damaged or illegible decal
immediately.
4 Always return the manuals to the storage

container after use.
Contact your authorized Genie
distributor or Genie Industries if
replacement manuals are needed.
4-2
Contact your authorized Genie

distributor or Genie Industries if
replacement decals are needed.
Part No. 36540
TABLE A
A-3
Inspect for Damage and Loose or
Missing Parts
PROCEDURES
A-4
Check the Hydraulic Oil Level
Daily machine condition inspections are essential

to safe machine operation and good machine
performance. Failure to locate and repair damage,
and discover loose or missing parts may result in
an unsafe operating condition.
Maintaining the hydraulic oil at the proper level is

essential to machine operation. Improper hydraulic
oil levels can damage hydraulic components. Daily
checks allow the inspector to identify changes in oil
level that might indicate the presence of hydraulic
system problems.
1 Inspect the entire machine for damage and

improperly installed or missing parts including:

Electrical components, wiring and

electrical cables
Hydraulic power units, reservoir, hoses,
fittings, cylinders and manifolds
Drive and turntable motors and drive hubs.
Boom wear pads
1 Be sure that the boom is in the stowed position.

2 Remove the breather cap with dipstick from the
hydraulic tank.
3 Visually inspect the dipstick.
Result: The hydraulic oil level should be at the
FULL mark on the dipstick.
Tires and wheels

Z-34/22 from serial number 572 to 808 and
Z-34/22N from serial number 572 to 1115:
Limit switches, alarms and horn

Nuts, bolts and other fasteners
Platform entry mid-rail/gate
Beacon and alarms (if equipped)
Check entire machine for:
Cracks in welds or structural components
1 Be sure that the boom is in the stowed position,

then visually inspect the sight glass on the
hydraulic tank.
Result: The hydraulic oil level should be within
the top and bottom of the sight glass.
Dents or damage to machine

Battery packs and connections
Compartment covers and latches
Part No. 36540
4-3
TABLE
PROCEDURES

A-5
Check for Hydraulic Leaks
1 Be sure that the boom is in the stowed position.

2 Visually inspect the hydraulic tank.
Result: The hydraulic oil level should be within
the FULL and ADD marks on the hydraulic tank.
Hydraulic Oil Specifications
Hydraulic oil type
Dexron equivalent

Hydraulic system
(including tank)
Hydraulic system
(including tank)
4-4
Detecting hydraulic fluid leaks is essential to

operational safety and good machine performance.
Undiscovered leaks can develop into hazardous
situations, impair machine functions and damage
machine components.
1 Inspect for hydraulic oil puddles, dripping or
residue on or around the following areas:
Hydraulic tankfilter, fittings, hoses
and turntable surface
5 gallons
18.9 liters
7 gallons
26.5 liters
Compartmentshydraulic power unit,

auxiliary power unit, pumps, suction filter,
fittings, hoses, and turntable surface
All hydraulic cylinders
All hydraulic manifolds
4 gallons
15.1 liters
6 gallons
22.7 liters
Primary, secondary and jib booms

The underside of the turntable
The underside of the drive chassis
Ground area under the machine
Part No. 36540
TABLE A
PROCEDURES
4 Turn the key switch to platform controls and pull

out the Emergency Stop button to the ON
position at both the ground and platform
controls.
A-6
Test the Platform and
Ground Controls
Testing the machine functions and the Emergency
Stop buttons for malfunctions is essential for safe
machine operation. An unsafe working condition
exists if any function fails to operate properly or
either Emergency Stop button fails to stop all the
machine functions. Each function should operate
smoothly and be free of hesitation, jerking and
unusual noise.
Z-34/22N before serial number 304 and
Z-34/22 before serial number 153:
1 Turn the key switch to ground controls and pull
controls.
Result: Beacon (if equipped) should flash.

5 Move the lift/drive select toggle switch to the lift
position (if equipped).
6 Press down the foot switch and operate each
machine function through a full cycle.
Result: All machine functions should operate
smoothly.
7 Push in the Emergency Stop button to the OFF
position.
Result: No function should operate. The
machine should stop.

2 Attempt to activate each boom and platform
function toggle switch.
through a full cycle. The descent alarm (if
equipped) should sound while the boom is
lowering.
position.
As a safety feature, selecting

and operating the ground
controls will override the
platform controls, including
the Emergency Stop button.
Machines equipped with Platform
Level Control Disable Function:
The platform level toggle switch
will not operate when the primary
boom is raised past the drive
speed limit switch.

Part No. 36540
4-5
TABLE
PROCEDURES
Z-34/22N after serial number 303 and

Z-34/22 and after serial number 152:
controls.
2 Do not hold the function enable switch to either
side. Attempt to activate each boom and
platform function toggle switch.
Result: All boom and platform functions should
not operate.
3 Hold the function enable switch to either side
and activate each boom and platform function
toggle switch.
5 Turn the key switch to platform control and pull

position at both the ground and the platform
controls.
6 Press down the foot switch and operate each
machine function through a full cycle.
smoothly.
position.

through a full cycle. The descent alarm (if
equipped) should sound while the boom is
lowering.

and operating the ground
controls will override the
platform controls, including
the Emergency Stop button.
Machines equipped with Platform

Level Control Disable Function:
The platform level toggle switch
will not operate when the boom is
raised past the drive speed limit
switch.
position.
4-6
Part No. 36540
TABLE A
A-7
Test the Auxiliary Power
Operation
Detection of auxiliary power system malfunctions is
essential for safe machine operation. An unsafe
working condition exists if the auxiliary powered
functions do not operate in the event of a main
power loss. Auxiliary power is designed for short
term emergency use only. Excessive use will result
in battery drain and component damage.
PROCEDURES
6 Lift the red auxiliary power switch cover.

7 Simultaneously hold
the auxiliary power
switch ON while
activating each
function through a
partial cycle.
Result: Each function
should operate smoothly.
1 Turn the key switch to ground control and pull

position.
2 Lift the red auxiliary power switch cover.
3 Simultaneously hold the
auxiliary power switch in
the ON direction while
activating each function
through a partial cycle.
Result: Each function
should operate smoothly.
4 Turn the key switch to platform control.
5 At the platform controls, pull out the Emergency
Stop button to the ON position, then press down
the foot switch.
Part No. 36540
4-7
TABLE
PROCEDURES
A-8
Test the Tilt Sensor
A-9
Test the Limit Switches
The tilt sensor sounds an alarm in the platform

when the incline of the machine exceeds
the rating on the serial plate.
Detecting limit switch malfunctions is essential to

safe machine operation. The drive limit switch is
used to restrict drive speed when the boom is
raised or extended. The drive enable limit switch
activates a signal light to inform the operator that
the platform is over the steering wheels, and stops
drive movement unless the drive enable override
switch is used. Improperly functioning limit
switches will allow the boom to raise and/or drive
into an unsafe position.
Select a level test area. The tilt

alarm should not be sounding prior
to test.
controls.
2 Open the ground control side turntable cover
and press down on one side of the tilt sensor.
Hold for 5 seconds.
Result: The alarm located in the platform should
sound.
Tip-over hazard. The alarm should
be heard at the ground controls. If
you can't hear the alarm at the
ground controls, replace the alarm
in the platform.
Drive Speed Limit Switches

1 With the boom in the stowed position, visually
inspect the drive speed limit switches for the
following:
Broken or missing rollers or arms
Missing fasteners
Loose wiring
a
b
d
4-8
primary boom drive speed

limit switch (LS2)
Z-34/22N after serial number 540)
boom extend drive speed

limit switch (LS1)
secondary boom drive speed

limit switch (LS4)
Z-34/22N after serial number 539)
primary/secondary boom drive speed

limit switch (LS2)
Part No. 36540
TABLE A
2 Extend the primary boom approximately 12

inches (30 cm).
3 Manually activate the boom extend drive speed
limit switch.
Result: The drive speed limit switch arm should
move freely and spring return to center. A
distinct click should be felt and heard.
4 Fully retract the primary boom.
5 Z-34/22 and Z-34/22N machines
manufactured before May, 1999:
Remove the rear turntable cover mounting
fasteners, then remove the cover. Manually
activate the secondary boom drive speed limit
switch.
Z-34/22 and Z-34/22N machines
manufactured after April, 1999:
Manually activate the secondary boom drive
speed limit switch.
6 Manually activate the primary boom drive limit
switch.
PROCEDURES
8 Press down the foot switch and slowly move the

drive control handle off center.
Result: The machine should move at normal
drive speeds.
9 Raise the primary boom approximately 5 feet
(1.5 m).
10 Slowly move the drive control handle off center.
Result: The machine should move at a reduced
drive speed.
11 Lower the primary boom to the stowed position.
12 Raise the secondary boom approximately
5 feet (1.5 m).
drive speed.
14 Lower the secondary boom to the stowed
position.
15 Extend the primary boom 12 inches (30 cm).
drive speed.
Raised Drive speed (maximum)
Platform raised
40 ft/40 sec
12.2 m/40 sec

position at the platform controls.
Part No. 36540
4-9
TABLE
PROCEDURES
6 Manually activate the drive enable limit switch.
Drive Enable Limit Switch

1 With the boom in the stowed position, visually
inspect the drive enable limit switch for the
following:
Result: The drive enable limit switch roller

should move freely and spring return to center.
A distinct click should be felt and heard.
Broken or missing roller or arm

a
Missing fasteners
Loose wiring

controls.
c
d
3 At the platform controls, rotate the turntable to

the left until the primary boom is past the left
non-steer wheel.
Result: The drive enable indicator light should
be ON.
a
b
c
d
swing chassis
limit switch cam
drive enable limit switch (LS3)
drive chassis
4 Move the drive control handle off center.

Result: The drive function should not operate.
5 Move and hold the drive enable toggle switch to
either side and slowly move the drive control
handle off center.
Result: The drive function should operate.
4 - 10
Part No. 36540
TABLE A
A-10
Test the Lift/Drive Select Switch
(if equipped)
1 Move the lift/drive select switch to the lift
position.
2 Press down the foot switch and move the drive
control handle off center.
Result: No drive functions should operate.
3 Activate each boom function toggle switch.
Result: All boom functions should operate.
4 Move the lift/drive select switch to the drive
position.
PROCEDURES
A-11
Perform 30 Day/50 hour Service
The 30 day maintenance procedure is a onetime
sequence of procedures to be performed after the
first 30 days or 50 hours of usage. After this
interval, refer to the maintenance tables for
continued scheduled maintenance.
1 Perform the following maintenance procedures:
B-3 Inspect Tires and Wheels
B-20 Replace the Hydraulic Tank
Return Filter
C-2 Check the Turnable Rotation
Bearing Bolts
5 Press down the foot switch and activate each

boom function toggle switch.
Result: No boom functions should operate.
Result: The drive functions should operate.
Part No. 36540
4 - 11
Table B Procedures
5 Remove the battery vent caps and check the
specific gravity of each battery cell with a
hydrometer.
Bodily injury hazard. Batteries

contain acid. Avoid spilling or
contacting battery acid. Neutralize
battery acid spills with baking soda
and water.
Electrocution/burn hazard. Contact
with hot or live circuits could result
in death or serious injury. Remove
all rings, watches and other
jewelry.
Result: If any battery cell displays a specific

gravity of less than 1.026, the battery must be
replaced.
6 Check the battery acid level of the battery. If
needed, replenish with distilled water to the
bottom of the battery fill tube. Do not overfill.
7 Install the battery vent caps.
8 Check each battery pack and verify that the
batteries are wired correctly.
9 Connect the battery packs to the machine.
Perform this test after fully

charging the batteries.
1 Put on protective clothing and eye wear.
Proper battery condition is essential to good

machine performance and operational safety.
Improper fluid levels or damaged cables and
connections can result in engine component
damage and hazardous conditions.
B-1
Check the Batteries
2 Disconnect the battery packs from the machine.
3 Be sure the battery cable connections are free

of corrosion.
4 Be sure the battery hold down and cable
connections are tight.
4 - 12
Part No. 36540
TABLE B
B-2
Inspect the Electrical Wiring
Maintaining electrical wiring in good condition is
essential to safe operation and good machine
performance. Failure to find and replace burnt,
chafed, corroded or pinched wires could result in
unsafe operating conditions and may cause
component damage.
PROCEDURES
5 Lower the boom to the stowed position and turn

the machine off.
6 Inspect the following areas for burnt, chafed,
corroded, pinched and loose wires:
Cable track on the primary boom
Primary boom to platform cable harness
Inside of the platform control box

with hot or live circuits could
result in death or serious injury.
Remove all rings, watches and
other jewelry.
1 Inspect the following areas for burnt, chafed,
corroded and loose wires:
Electrical power panel
Electrical relay panel
Ground control panel
Turntable manifold wiring
position.
3 Raise the secondary boom until the lower
mid-pivot is approximately 10 feet (3 m) off
the ground.
4 Inspect the turntable center area for burnt,
chafed and pinched cables.
Part No. 36540
4 - 13
TABLE
PROCEDURES
B-3
Inspect the Tires and Wheels
B-4
Confirm the Proper
Brake Configuration
Maintaining the tires and wheels in good

condition is essential to safe operation and good
performance. Tire and/or wheel failure could result
in a machine tip-over. Component damage may
also result if problems are not discovered and
repaired in a timely fashion.
Proper brake configuration is essential to safe

operation and good machine performance.
Hydraulically-released, spring-applied individual
wheel brakes can appear to operate normally when
they are actually not fully operational.
1 Check the tire surface and sidewalls for cuts,

cracks, and unusual wear.
1 Check each drive hub disconnect cap to be

sure it is in the engaged position.
2 Check each wheel for damage, bends and

cracked welds.
brake disengage position
3 Check each lug nut for proper torque.

brake engage position
Tires and wheels

Lug nut torque, dry
Lug nut torque, lubricated
4 - 14
125 ft-lbs
95 ft-lbs
169.5 Nm
129 Nm
Part No. 36540
TABLE B
PROCEDURES
B-5
Check the Oil Level
in the Drive Hubs
4 Apply pipe thread sealant to the plugs and install

the plugs into the hub.
Failure to maintain proper drive hub oil levels may

cause the machine to perform poorly and
continued use may cause component damage.
Drive Hub Oil
5 Repeat this procedure for each drive hub.
1 Drive the machine to rotate the hub until one of

the plugs is located on top and the other is at
90 degrees.
Capacity
49:1 and 35:1 models
17 fluid ounces
0.5 liters

47:1 models
25.6 fluid ounces
0.76 liters
Type: SAE 90 multipurpose hypoid gear oil - API service

classification GL5
2 Remove the plug located at 90 degrees and

check the oil level.
Result: The oil level should be even with the
bottom of the plug hole.
3 If necessary, remove the top plug and add oil
until the oil level is even with the bottom of the
side plug hole.
Part No. 36540
4 - 15
TABLE
PROCEDURES
B-6
Test the Key Switch
B-7
Test the Emergency Stop Buttons
Proper key switch action and response is essential

to safe machine operation. The machine can be
operated from the ground or platform controls and
the activation of one or the other is accomplished
with the key switch. Failure of the key switch to
activate the appropriate control panel could cause
a hazardous operating situation.
Properly functioning Emergency Stop buttons

are essential for safe machine operation. An
improperly operating Emergency Stop button
will fail to shut off power and stop all machine
functions resulting in a hazardous situation.
and operating the ground controls
will override the platform controls,
including the Emergency Stop
button.
1 Pull out the Emergency Stop button to the ON

controls.
3 Check the machine functions from the ground
controls.
Result: The machine functions should not
operate.
4 Turn the key switch to ground control.
5 Check the machine functions from the platform
controls.
operate.
6 Turn the key switch to the OFF position.

position.
2 Push down the Emergency Stop button to the
OFF position.
Result: No functions should operate. The
controls.
4 Push down the platform Emergency Stop button
to the OFF position.
Result: No machine functions should operate.
The ground Emergency Stop
button will stop all machine
operation, even if the key switch
is switched to platform control.
4 - 16
Part No. 36540
TABLE B
PROCEDURES
B-8
Test the Ground Control Override
B-9
Test the Platform Self-leveling
A properly functioning ground control override is

essential to safe machine operation. The ground
control override function is intended to allow
ground personnel to operate the machine from the
ground controls whether the Emergency Stop
button on the platform controls is in the ON or OFF
position. This function is particularly useful if the
operator at the platform controls cannot return the
boom to the stowed position.
Automatic platform self-leveling throughout

the full cycle of boom raising and lowering is
essential for safe machine operation. The
platform is maintained at level by the platform
leveling slave cylinder which is controlled by the
master cylinder located at the base of the primary
boom. A platform self-leveling failure creates an
unsafe working condition.
1 Push down the platform Emergency Stop button

to the OFF position.
out the ground controls Emergency Stop button
to the ON position.
3 Operate each boom function through a
partial cycle at the ground controls.
Result: All boom functions should operate.
Part No. 36540

position.
2 Lower the boom to the stowed position.
3 Adjust the platform to a level position using the
platform leveling toggle switch.
4 Raise and lower the primary boom through
a full cycle.
Result: The platform should remain level at
all times to within 5 degrees.
4 - 17
TABLE
PROCEDURES
B-10
Test the Horn
B-11
Test the Foot Switch
A properly functioning horn is essential to safe

machine operation. The horn is activated at the
platform controls and sounds at the ground as a
warning to ground personnel. An improperly
functioning horn will prevent the operator from
alerting ground personnel of hazards or unsafe
conditions.
A properly functioning foot switch is essential to

safe machine operation. Machine functions should
activate and operate smoothly as long as the foot
switch is pressed down, and promptly stop when
the foot switch is released. An improperly
functioning foot switch can cause an unsafe
working condition.
1 Turn the key switch to platform control and

pull out the Emergency Stop button to the
ON position at both the ground and
platform controls.

controls.
2 Push down the horn button at the platform

controls.
2 Without pressing down the foot switch, attempt

to operate the machine functions.
Result: The horn should sound.

If necessary, the horn can be
adjusted to obtain the loudest
volume by turning the adjustment
screw near the wire terminals on
the horn.
4 - 18

operate.
3 Press down the foot switch and operate the
machine functions.
Result: The machine functions should operate.
Part No. 36540
TABLE B
PROCEDURES
B-12
Test the Drive Enable System
Proper drive enable system operation is

essential to safe machine operation. When the
primary boom is past the non-steering wheels,
drive movement is stopped and the indicator light
turns on. The drive enable toggle switch must be
used to reactivate drive function and should inform
the operator that the machine may move in the
opposite direction that the drive and steer controls
are moved. An improperly functioning drive enable
system may allow the machine to be moved into
an unsafe position.
5 Move and hold the

drive enable toggle
switch to either side
and slowly move the
drive control handle
off center.

controls.
2 At the platform controls, rotate the turntable to
the right until the primary boom is past the right
non-steer wheel.
Result: The drive function should not operate.
Result: The drive function should operate.

Collision hazard. Always use the
color-coded direction arrows on
the platform control panel and the
drive chassis to identify which
direction the machine will travel.
6 Rotate the turntable to the left until the primary
boom is past the left-steer wheel.
come on.
7 Repeat steps 3 through 5.

come on and remain on while the boom is past
the non-steer wheel.
3 Move the lift/drive select switch to the drive
position.
Part No. 36540
4 - 19
TABLE
PROCEDURES
B-13
Test the Drive Brakes
Proper brake action is essential to safe machine
operation. The drive brake function should operate
smoothly, free of hesitation, jerking and unusual
noise. Hydrostatic brakes and hydraulicallyreleased individual wheel brakes can appear to
operate normally when not fully operational.
6 Bring the machine to maximum drive speed

before reaching the test line. Release the drive
joystick when your reference point on the
machine crosses the test line.
7 Measure the distance between the test line and
your machine reference point.
Braking: paved surface
Stopping distance
Collision hazard. Be sure that the

machine is not in free-wheel or
partial free-wheel configuration.
Refer to B-4 in this section,
Confirm the Proper Brake
Configuration.
3 to 4 ft
0.9 to 1.2 m
The brakes must be able to hold

the machine on any slope it is able
to climb.
Select a test area that is firm, level

and free of obstructions.
1 Mark a test line on the ground for reference.
2 Lower the boom into the stowed position.
controls.
4 Move the lift/drive switch to the DRIVE position (if
equipped).
5 Choose a point on the machine; i.e., contact
patch of a tire, as a visual reference for use
when crossing the test line.
4 - 20
Part No. 36540
TABLE B
PROCEDURES
B-14
Test the Drive Speed Stowed Position

before reaching the start line. Begin timing
when your reference point on the machine
crosses the start line.
Proper drive function movement is essential to

safe machine operation. The drive function should
respond quickly and smoothly to operator control.
Drive performance should also be free of
hesitation, jerking and unusual noise over the
entire proportionally controlled speed range.
7 Continue at full speed and note the time when

the machine reference point passes over the
finish line.

1 Create start and finish lines by marking two
lines on the ground 40 feet (12.2 m) apart.
2 Lower the boom into the stowed position.
controls.
4 Move the lift/drive switch to the DRIVE position (if
equipped).
when crossing the start and finish lines.
Part No. 36540

Drive speed, stowed
4 mph
6.4 km/h
35:1 torque hubs
40 ft/6.8 sec 12.2 m/6.8 sec
Drive speed, stowed
49:1 torque hubs
3.1 mph
5 km/h
40 ft/9.1 sec 12.2 m/9.1 sec

Drive speed, stowed
3.7 mph
6 km/h
47:1 torque hubs
40 ft/7.5 sec 12.2 m/7.5 sec
Drive speed, stowed
3.4 mph
35:1 torque hubs
40 ft/8 sec
Drive speed, stowed
49:1 torque hubs
Drive speed, stowed
47:1 torque hubs
5.5 km/h
12.2 m/8 sec
2.8 mph
4.5 km/h
40 ft/10 sec 12.2 m/10 sec
3.1 mph
40 ft/9 sec
5 km/h
12.2 m/9 sec
4 - 21
TABLE
PROCEDURES
B-15
Test the Drive Speed Raised or Extended Position

before reaching the start line. Begin timing
when your reference point on the machine
crosses the start line.
Proper drive function movement is essential to

safe machine operation. The drive function should
respond quickly and smoothly to operator control.
Drive performance should also be free of
hesitation, jerking and unusual noise over the
entire proportionally controlled speed range.

the machine reference point passes over the
finish line.

Drive speeds (maximum):

raised or extended position
Drive speed,
raised or extended
0.6 mph
1 km/h
40 ft/40 sec 12.2 m/40 sec

controls.
3 Raise the primary boom more than 5 feet
(1.5 m).
4 Move the lift/drive switch to the DRIVE position
(if equipped).
when crossing the start and finish lines.
4 - 22
Part No. 36540
TABLE B
B-16
Test the Alarm Package
(if equipped)
The alarm package includes:
Travel alarm
Descent alarm
Flashing beacon
Alarms and a beacon are installed to alert operators
and ground personnel of machine proximity and
motion. The alarm package is installed on the
ground controls side turntable cover.
out the Emergency Stop buttons to the ON
position.
Result: The flashing beacon should be ON and
flashing.
2 Z-34/22 before serial number 153 and
Move the primary boom toggle switch to the
down position, hold for a moment and then
release it.
Hold the function enable toggle switch to either
side. Move the primary boom toggle switch to
the down position, hold for a moment and then
release it.
Part No. 36540
PROCEDURES

Move the secondary boom toggle switch to the
DOWN position, hold for a moment and then
release it.
side. Move the secondary boom toggle switch
to the DOWN position, hold for a moment and
then release it.
Move the jib boom toggle switch to the DOWN
position, hold for a moment and then release it.
side. Move the jib boom toggle switch to the
DOWN position, hold for a moment and then
release it.
Result: The descent alarm should sound when
each control toggle switch is held down.
4 - 23
TABLE
PROCEDURES
6 At the platform controls pull out the Emergency

Stop button to the ON position.
Result: The flashing beacon should be on
and flashing.
6 Move the lift/drive switch to the LIFT position
(if equipped).
7 Press down the foot switch. Move the primary
boom toggle switch to the DOWN position, hold
for a moment and then release it. Move the
secondary boom toggle switch to the DOWN
Move the jib boom toggle switch to the DOWN
Result: The descent alarm should sound when
each control toggle switch is held down.
8 Move the lift/drive switch to the DRIVE position
(if equipped).
9 Press down the foot switch. Move the drive
control handle off center, hold for a moment
and then release it. Move the drive control
handle off center in the opposite direction, hold
for a moment and then release it.
Result: The travel alarm should sound when the
drive control handle is moved off center in
either direction.
4 - 24
B-17
Test the Turntable Rotation Stop
The turntable is capable of rotating the boom 355
degrees and is stopped midpoint between the
steering wheels by the rotation stop. Detecting a
rotation stop malfunction is essential to safe
operation and good machine performance. If the
turntable rotates past the rotation stop, component
damage may result.
position at both ground and platform controls.
2 Move the lift/drive switch to the LIFT position
(if equipped).
3 Rotate the turntable to the left as far as it will
go.
Result: Movement should stop when the primary
boom reaches midpoint between the steer tires.
4 Rotate the turntable to the right full circle as far
as it will go.
Result: Movement should stop when the
primary boom reaches midpoint between the
steer tires.
Part No. 36540
TABLE B
PROCEDURES
B-18
Check the Electrical Contactors
B-19
Perform Hydraulic Oil Analysis
Maintaining the electrical contactors in good

condition is essential to safe machine operation.
Failure to locate a worn or damaged contactor
could result in an unsafe working condition and
component damage.
See D-1, Test or Replace the Hydraulic Oil.
1 Remove the non-steer drive chassis cover and

locate the electrical contactors mounted on the
component mounting panel.
2 Visually inspect the contact points of each
contactor for the following items:
Excessive burns
Excessive arcs
Excessive pitting
with hot or live circuits could cause
death or serious injury. Remove all
rings, watches and other jewelry.
Replace the contactors if any
damage is found.
Part No. 36540
4 - 25
TABLE
PROCEDURES
B-20
Replace the Hydraulic Tank
Return Filter
Genie requires that this procedure
be performed quarterly or every
250 hours, whichever comes first.
Perform this procedure more often
if dusty conditions exist.
Replacement of the hydraulic return filter is
essential for good machine performance and
service life. A dirty or clogged filter may cause the
machine to perform poorly and continued use may
cause component damage. Extremely dirty
conditions may require that the filter be replaced
more often.
Bodily injury hazard. Beware of hot
oil. Contact with hot oil may cause
severe burns.
The hydraulic return filter is located
on the bulkhead next to the
hydraulic power unit.
1 Clean the area around the oil filter housing, then
remove the filter with an oil filter wrench.

Turn the key switch to ground controls and pull
position. Move the primary boom up toggle
switch in the UP direction.
Turn the key switch to ground controls and pull
position. Hold the function enable toggle switch
to either side and move the primary boom up
toggle switch in the UP direction.
5 Inspect the filter and related components to
be sure that there are no leaks. Clean up any
oil that may have spilled during the replacement
procedure. Properly discard the oil.
1 Clean the area around the oil filter housing
located on top of the tank.
2 Remove the oil filter housing cover fasteners,
then remove the cover.
3 Remove the oil filter element from the housing.
4 Clean the oil filter housing with a mild solvent.
2 Apply a thin layer of fresh oil to the gasket on

the new oil filter. Install the new filter.
3 Tighten it securely by hand.
4 - 26
Part No. 36540
TABLE B
PROCEDURES
5 Install the new oil filter element.

6 Install the oil filter housing cover and tighten the
fasteners.
position. Hold the function enable toggle switch
to either side and move the primary boom up
toggle switch in the UP direction.
8 Inspect the filter and related components to
be sure that there are no leaks. Clean up any
oil that may have spilled during the replacement
procedure. Properly discard the oil.
Oil filters - Genie part numbers
Z34/22
before serial number 431
from serial number 431 to 809
after serial number 3110
45087
44788
58995
74346
74634
Z34/22N
44788
58995
74346
74634
Part No. 36540
4 - 27
Table C Procedures
C-1
Check the Primary Boom
Wear Pads
C-2
Check the Turntable Rotation
Bearing Bolts
Maintaining the primary boom wear pads in good

condition is essential to safe machine operation.
Wear pads are placed on boom tube surfaces to
provide a low friction, replaceable wear pad
between moving parts. Improperly shimmed wear
pads or continued use of worn out wear pads may
result in component damage and unsafe operating
conditions.
Maintaining proper torque on the turntable bearing

bolts is essential to safe machine operation.
Improper bolt torque could result in an unsafe
operating condition and component damage.
1 Raise the secondary boom and place a safety
chock on the secondary boom lift cylinder.
Carefully lower the boom onto the lift cylinder
safety chock.

position.
2 Extend the primary boom approximately
10 inches (25 cm).
3 Measure each wear pad. Replace the wear pad
if it is less than 0.41 inches (1 cm) thick. If the
wear pad is more than 0.41 inches (1 cm) thick,
see 4-2, How to Shim the Primary Boom, in the
Repair Section.
Crushing hazard. Keep hands

away from the cylinder and all
moving parts when lowering the
secondary boom.
The lift cylinder safety chock is
available from Genie Industries
4 Extend and retract the primary boom through

the entire range of motion to check for tight
spots that could cause binding or scraping.
Always maintain squareness
between the primary boom outer
and inner tubes.
4 - 28
Part No. 36540
TABLE C
2 Check to ensure that each turntable bearing bolt

is torqued in specified order to
190 ft-lbs (258 Nm).
PROCEDURES
5 Check to ensure that each bearing mounting bolt

under the drive chassis is torqued in specified
order to 190 ft-lbs (258 Nm).
Bolt torque sequence




3 Raise boom and remove the safety chock.

Lower the boom to the stowed position.
4 Swing out the battery packs to expose the
turntable bearing bolt access hole.
Part No. 36540
4 - 29
TABLE
C PROCEDURES
5 Manually rotate each non-steering wheel.
C-3
Check the Free-wheel
Configuration
Result: Each non-steering wheel should rotate

with minimum effort.
Proper use of the free-wheel configuration is

essential to safe machine operation. The
free-wheel configuration is used primarily for
towing. A machine configured to free-wheel without
operator knowledge may cause death or serious
injury and property damage.
6 Engage the drive hubs by turning over

the drive hub disconnect caps. Carefully
remove the jack stands, lower the machine and
remove the jack.
Collision hazard. Select a work

site that is firm and level.
Collision hazard. Failure to

engage the drive hubs could
cause death or serious injury and
property damage.
Component damage hazard. If the

machine must be towed, do not
exceed 2 mph (3.2 km/h).
1 Chock the steer wheels to prevent the machine
from rolling.
2 Center a lifting jack of ample capacity
(15000 lbs/6804 kg) under the drive chassis
between the non-steering wheels.
3 Lift the wheels off the ground and then place
jack stands under the drive chassis for support.
4 Disengage the drive hubs by turning over the
drive hub disconnect caps on each
non-steering wheel hub.
brake disengage position
brake engage position
4 - 30
Part No. 36540
TABLE C
C-4
Grease the Turntable Rotation
Bearing and Worm Drive Gear
Yearly application of lubrication to the turntable
bearing and worm drive gear is essential to good
machine performance and service life. Continued
use of an improperly greased gear will result in
component damage.
1 Locate the grease fitting mounted on the
bulkhead next to the hydraulic power unit.
2 Pump grease into the turntable rotation bearing.
Rotate the turntable in increments of 4 to 5
inches (10 to 13 cm) at a time and repeat this
step until the entire bearing has been greased.
PROCEDURES
C-5
Replace the Drive Hub Oil
Replacing the drive hub oil is essential for good
machine performance and service life. Failure to
replace the drive hub oil at yearly intervals may
1 Select the drive hub to be serviced. Drive the
machine until one of the two plugs is at the
lowest point.
2 Remove both plugs and drain the oil.
3 Drive the machine until one plug is at the top
and the other is at 90 degrees.
3 Locate the 3 grease fittings on the worm drive

housing.
b
a
b
grease fittings
grease overflow
4 Fill the hub with oil from the top hole until the oil
level is even with the bottom of the side hole.
4 Pump grease into the gear until you see it

coming out of the side of the gear housing.
Lubricant Type
Part No. 36540
Multipurpose grease
4 - 31
TABLE
C PROCEDURES
5 Apply pipe thread sealant to the plugs, then

install the plugs.
6 Repeat this procedure for each drive hub.
Drive Hub Oil
Capacity
49:1 and 35:1 models
17 fluid ounces
0.5 liters

47:1 models
25.6 fluid ounces
0.76 liters
C-6
Bleed the Platform Rotator
See Repair procedure 2-3, How to Bleed the
Platform Rotator.
Type: SAE 90 multipurpose hypoid gear oil - API service

classification GL5
4 - 32
Part No. 36540
Table D Procedures
D-1
Test or Replace the Hydraulic Oil
Replacement or testing of the hydraulic oil is
essential for good machine performance and
service life. Dirty oil and suction strainers may
Extremely dirty conditions may require oil changes
to be performed more often.
The machine uses Dexron
equivalent hydraulic oil. Before
replacing the hydraulic oil, the oil
may be tested by an oil distributor
for specific levels of contamination
to verify that changing the oil is
necessary. If the hydraulic oil
is not replaced at the two year
inspection, test the oil quarterly.
Replace the oil when it fails the
test.
2 Completely drain the tank into a suitable

container. See capacity specifications.
3 Remove the suction strainer and the magnet
and then clean the tank with mild solvent.
4 Install the suction strainer.
5 Place the magnet inside the tank and install the
tank on the power unit.
6 Fill the tank with hydraulic oil until the level is
within the top 2 inches (5 cm) of the hydraulic
oil decal. Do not overfill.
7 Clean up any oil that may have spilled.
1 Close the hydraulic shut-off valve located at the
hydraulic tank.
Component damage hazard. The
machine must not be operated
with the hydraulic tank shut-off
valve in the CLOSED position or
component damage will occur. If
the tank valve is closed, remove
the key from the key switch and
tag the machine to inform
personnel of the condition.
Perform this procedure with the

boom in the stowed position.
When removing a hose assembly
or fitting, the O-ring on the fitting
and/or hose end must be replaced
and then torqued to specification
during installation.
Refer to Section Two, Hydraulic
Hose and Fitting Torque
Specifications.
2 Place a suitable container under the hydraulic

tank. See capacity specifications.

1 Remove the tank mounting fasteners.
Remove the tank from the power unit.
Part No. 36540
4 - 33
TABLE
D PROCEDURES
3 Disconnect and plug the hydraulic hose from the

hydraulic tank shut-off valve.
Bodily injury hazard. Spraying
hydraulic oil can penetrate and
burn skin. Loosen hydraulic
connections very slowly to allow
the oil pressure to dissipate
gradually. Do not allow oil to squirt
or spray.
4 Open the valve on the hydraulic tank and drain
the oil into a suitable container.
Bodily injury hazard. Beware of
hot oil. Contact with hot oil may
cause severe burns.
5 Tag, disconnect and plug the hydraulic hoses
from the hydraulic tank filter. Cap the fittings on
the filter.
or spray.
severe burns.
8 Remove the tank lid retaining fasteners and

remove the lid and filter assembly from the
tank.
9 Remove the suction strainer from the tank and
clean with a mild solvent
10 Rinse out the inside of the tank with a mild
solvent.
11 Install the lid and filter assembly onto the
hydraulic tank.
12 Install the suction strainer using a thread
sealant on the threads.
13 Install the hydraulic tank on the machine. Install
the hydraulic tank mounting fasteners and
torque to 5 ft-lbs (6.8 Nm).
hydraulic tank may become
damaged if the tank mounting
fasteners are over tightened.
14 Install the hydraulic hoses.
15 Fill the tank with hydraulic oil until the fluid is
within the FULL and ADD marks on the hydraulic
tank. Do not overfill.
16 Clean up any oil that may have spilled. Properly
discard the oil.
17 Open the hydraulic tank shut-off valve.
6 Remove the hydraulic tank mounting fasteners.

7 Remove the hydraulic tank from the machine.
4 - 34
Component damage hazard. Be

sure to open the hydraulic tank
shut-off valve after installing the
hydraulic tank.
Part No. 36540
TABLE D
18 Operate all machine functions through a full

cycle and check for leaks.
19 Check oil level.
Torque specification
1
/4 -20 fasteners
5 ft-lbs
6.8 Nm

5 gallons
18.9 liters
Hydraulic system
(including tank)
26.5 liters
7 gallons
PROCEDURES
D-2
Grease the Steer Axle Wheel
Bearings
Maintaining the steer axle wheel bearings is
essential for safe machine operation and service
life. Operating the machine with loose or worn
wheel bearings may cause an unsafe operating
condition and continued use may result in
component damage. Extremely wet or dirty
conditions or regular steam cleaning and pressure
washing of the machine may require that this
procedure be performed more often.
1 Loosen the wheel lug nuts. Do not remove
them.

4 gallons
15.1 liters
Hydraulic system
(including tank)
2 Block the non-steering wheels, then center a

lifting jack under the steer axle.
22.7 liters
3 Raise the machine approximately 6 inches

(15 cm) and place blocks under the drive
chassis for support.
6 gallons
4 Remove the lug nuts, then remove the tire and

wheel assembly.
5 Check for wheel bearing wear by attempting to
move the wheel hub side to side, then up and
down.
Result: There should be no side to side or up
and down movement.
Skip to step 9 if there is no movement.
6 Remove the dust cap from the hub, then
remove the cotter pin from the castle nut.
Part No. 36540
4 - 35
TABLE
D PROCEDURES
7 Tighten the castle nut to 35 ft-lbs (47 Nm).
15 Slide the hub onto the yoke spindle.
8 Check for wheel bearing wear by attempting to

move the wheel hub side to side, then up and
down.
Result: If there is no side to side or up and
down movement, proceed to step 9 to replace
the wheel bearings with new ones.
When replacing a wheel bearing,
both the inner and outer bearings,
including the pressed-in races,
must be replaced.
Result: If there is no side to side or up and
down movement, grease the wheel bearings.
Component damage hazard. Do not

apply excessive force or damage
to the lip of the seal may occur.
16 Place the outer bearing into the hub.
17 Install the washer and castle nut.
18 Tighten the castle nut to 35 ft-lbs (47 Nm) to
seat the bearings.
19 Loosen the castle nut, then tighten to
8 ft-lbs (11 Nm).
20 Install a new cotter pin. Bend the cotter pin to
lock it in place.
Always replace the cotter pin with
a new one when removing the
castle nut or when checking the
torque of the castle nut.
9 Remove the castle nut.

castle nut.
10 Pull the hub off of the spindle. The washer and
outer bearing should fall loose from the hub.
11 Place the hub on a flat surface and gently pry
the bearing seal out of the hub. Remove the
inner bearing.
21 Install the dust cap.

22 Install the tire and wheel assembly. Torque the
wheel lug nuts to 125 ft-lbs (169.5 Nm).
12 Pack both bearings with clean, fresh grease.

13 Place the large inner bearing into the rear of the
hub.
14 Install a new bearing grease seal into the hub
by pressing it evenly into the hub until it is flush.
Always replace the bearing grease
seal when removing the hub.
4 - 36
Part No. 36540
Section 5 Troubleshooting Flow Charts
Troubleshooting Flow Charts

Before Troubleshooting:
Read, understand and obey the safety rules
and operating instructions printed in the Genie
Z-34/22 & Z-34/22N Operators Manual.
Be sure that all necessary tools and test
equipment are available and ready for use.
Observe and Obey:

Troubleshooting and repair procedures shall be
completed by a person trained and qualified on
the repair of this machine.
Read each appropriate flow chart thoroughly.

Attempting shortcuts may produce hazardous
conditions.
Be aware of the following hazards and follow
generally accepted safe workshop practices.

before operating the machine.
Unless otherwise specified, perform each
repair procedure with the machine in the
following configuration:
Machine parked on a flat level surface
Boom in stowed position
Turntable rotated with the boom between
the non-steering wheels
Key switch in the OFF position with the
key removed
Wheels chocked
Crushing hazard. When testing

or replacing any hydraulic
component, always support
the structure and secure it
from movement.
with electrically charged circuits
could result in death or serious
injury. Remove all rings, watches
and other jewelry.
gradually. Do not allow oil to
squirt or spray.
Perform all troubleshooting on a
firm level surface.
Two persons will be required to
safely perform some
troubleshooting procedures.
Part No. 36540
5-1
TROUBLESHOOTING FLOW CHARTS
General Repair Process
About This Section

When a malfunction is discovered, the flow charts
in this section will help a service professional
pinpoint the cause of the problem. To use this
section, basic hand tools and certain pieces of test
equipment are requiredvoltmeter, ohmmeter,
pressure gauges.
The location of terminals mentioned in this section
can be found on the appropriate electrical or
hydraulic schematics provided in Section 6,
Schematics.
Identify
symptoms
Malfunction
discovered
Troubleshoot
problem
still exists
Return to
service
problem
solved
Inspect
and test
Perform
repair
Since various degrees of a particular function

loss may occur, selecting the appropriate flow
chart may be troublesome. When a function will not
operate with the same speed or power as a
machine in good working condition, refer to the
flow chart which most closely describes the
problem.
On Z-34/22 models after serial number 1733 and
Z-34/22N models after serial number 2227, an LED
will flash a fault code to aid in troubleshooting. This
LED is mounted on the ground controls panel,
located behind the side cover on the ground
controls side.
5-2
Part No. 36540
Fault Code Chart

(Z-34/22 after serial number 1733 and Z-34/22N after serial number 2226)
Fault Code
Fault Indicator
Light is OFF or
is ON but not
blinking
Programmer
Diagnostic Display
Condition
Solution
The key switch or

Emergency Stop
button(s) was cycled on
and off faster than 5
seconds OR controller
sensed an internal error
during start up.
Push in the ground

control Emergency Stop
button to the OFF
position and wait for 5
seconds. Pull out the
ground control
Emergency Stop button
to the ON position. If
problem persists,
replace the motor
controller.
The motor controller

failed self test.
Replace the motor

controller.
The motor controller

has an internal short
between M- and Bterminals.
Test the motor

controller. See Repair
Section.
FIELD OPEN
Machine will not drive.

Controller fault indicator
light on at the platform
controls.
Motor wiring is loose

OR motor is defective
OR motor controller has
an internal short.
Check for loose or open

connections at the drive
motors and motor
controller OR replace
the defective drive
motor OR test the motor
controller. See Repair
Section.
ARM SENSOR

controls.
Defective motor
controller.
Replace the motor

controller.
FLD SENSOR

controls.
Defective motor
controller.
Replace the motor

controller.
COMMUNICATION
ERROR
01

light may or may not be
on at the platform
controls.
Normal operation.
12
HW FAILSAFE 1-2-3

controls.
13
M- SHORTED

controls.
Part No. 36540
Possible Causes
5-3
FAULT CODE CHART

(Z-34/22 AFTER SERIAL NUMBER 1733 AND Z-34/22N AFTER SERIAL NUMBER 2226)
Fault Code
21
31
32
5-4
Programmer
Diagnostic Display
Condition
Possible Causes
Solution
THROTTLE FAULT 1

controls.
Open in wht/red wire

#32 at pin 14 or red/wht
wire #29 at pin 16 on
the motor controller
going from drive joystick
to pins 14 and 16 at the
motor controller OR pin
14 is internally shorted
to power or ground OR
the potentiometer on
the drive joystick is
defective.
See Chart 29A
THROTTLE FAULT 2

controls.
Pin 14 (wht/red #32) is

shorted to power or
ground OR the
potentiometer on the
drive joystick is
defective.
See Chart 29A
CONT DRVR OC

controls.
Main contactor (PR1)

coil defective OR brake
release relay CR5
defective.
Replace main contactor

PR1 or brake release
relay CR5 OR replace
the motor controller.

controls.
Main contactor (PR1)

contacts stuck closed
OR grn wire at pin 17 on
motor controller shorted
to ground OR open in
motor armature wiring
OR motor controller has
an internal short to
ground.
See Chart 29B
MAIN CONT WELDED
Part No. 36540
FAULT CODE CHART

Fault Code
33
34
Programmer
Diagnostic Display
Possible Causes
Solution
PRECHARGE FAULT

controls.
External short between

B+ terminal on motor
controller and ground
OR motor controller is
defective.
Repair short between

B+ terminal on motor
controller and ground
OR replace motor
controller.
Note: Short can be on
any part of circuit
connected to the B+
terminal on the motor
controller.
MISSING CONTACTOR

controls.
Motor controller does

not detect the main
contactor PR1 or brake
release relay CR5.
See Chart 29C

controls.
Main contactor PR1 or

brake release relay CR5
did not close OR open
in org/red wire to PR1
and/or CR5 OR main
contactor and/or brake
release relay is
defective.
See Chart 29C
Battery supply voltage

to motor controller less
than 32V.
Completely charge
batteries OR check
battery cable condition
OR check for corrosion
or loose connections at
battery terminals and
motor controller.
MAIN CONT DNC
41
Part No. 36540
LOW BATTERY
VOLTAGE
Condition

controls.
5-5
FAULT CODE CHART

Fault Code
42
43
5-6
Programmer
Diagnostic Display
OVERVOLTAGE
THERMAL CUTBACK
Condition
Possible Causes
Solution

controls.
Battery supply voltage

to motor controller more
than 55V OR machine
is being operated with
the battery charger
plugged in.
Be sure the battery

charger is disconnected
OR check for loose
battery cables or poor
connections.

controls.
Machine being operated

outside of temperature
range of -13F to 185F
(-25C to 85C) OR
machine being driven
under excessive load
OR motor controller is
not being cooled
sufficently.
Operate machine within

specified temperature
limits OR check for
debris around motor
controller preventing
proper cooling of the
controller OR check for
mechanical restrictions
causing excessive load
on the machine.
Part No. 36540
Chart 1
All Functions
Will Not
Operate
Be sure key switch
is in the appropriate
position.
Disconnect battery
packs and check voltage
on each pack.
24V or more
Be sure the
Emergency Stop
buttons are pulled
out to the ON
position.
Connect battery packs

and check voltage on
the input side of 100A
fuse F3.
Be sure the circuit

breaker and fuses
are not tripped or
blown.
Check voltage on the

output side of 100A fuse
F3.
Be sure the battery

packs are properly
connected and fully
charged.
If the Error Indicator
light is on at the
platform controls,
please refer to the
specific chart that
relates to the error
code that is
displayed on the
ECM.
less than Check battery condition

24V
and replace bad
batteries OR check for
short circuits OR check
battery cables OR
consult Genie Industries
Service Department.
0V
Repair open in 24V

supply cables (positive
and negative) from the
battery packs.
24V
0V
Replace 100A fuse F3
24V
Check voltage at the
input side of 10A circuit
breaker CB1.
0V
Repair open in power

wire from 100A fuse F3
to PR4 to CB1.
0V
Reset or replace circuit

breaker CB1 OR consult
Genie Industries Service
Department.
0V
Repair open in red wire

from CB1 to the
Emergency Stop button.
24V
output side of circuit
breaker CB1.
24V
input side of Emergency
Stop button P1.
24V
Continued on the next

page.
Part No. 36540
5-7
CHART 1
Continued from the

previous page.

output side of the
0V
Check to see if
contact is being
activated.
yes
Replace Emergency
Stop button contact.
yes
Replace key switch

contact for ground
controls.
no
Replace Emergency
Stop button OR refer to
Ground Controls
Inoperative, Chart 6 OR
Service Department.
24V

input side of the key
switch.
0V

from Emergency Stop
button to key switch.
24V
Turn key switch to
ground controls and
check voltage on output
side of ground controls
contact of the keyswitch.
0V
Check to see if key

switch internal cam is
activating ground
controls contact.
no
Replace key switch OR
refer to Ground Controls
Inoperative, Chart 6 OR
Service Department.
24V

page.
5-8
Part No. 36540
CHART 1
Continued from the

previous page.
Turn key switch to

platform controls and
check voltage on output
side of the platform
controls contact of the
key switch.
0V
yes
Replace key switch

contact for platform
controls.
no
Replace key switch OR
refer to Platform
Controls Inoperative,
Chart 7 OR consult
Department.
24V

input side of 500A fuse
F1.
Check to see if the key

activating the platform
controls contact.
less than
Repair open in 48V
48V
supply cables (positive
and negative) from
battery packs.
48V or more
output side of 500A fuse
F1.
0V
Replace 500A fuse F1.
48V
Troubleshoot lift and
drive systems
separately OR consult
Department.
Part No. 36540
5-9
Chart 2
Lift Pump
Motor Will
Not Operate
Be sure key switch
position.
Be sure the
Emergency Stop
buttons are pulled
out to the ON
position.
Be sure the battery
packs are properly
connected and fully
charged.
Turn key switch to

ground controls and pull
both Emergency Stop
buttons out to the on
position.
Z-34/22 before serial
number 153 and
Z-34/22N before serial
number 304: Move the
primary boom extend/
retract toggle switch
TS13 in the RETRACT
direction and check
voltage at the positive
terminal on the lift pump
motor.
Z-34/22 from serial
number 153 to 1733
and Z-34/22N from
serial number 304 to
2226: Hold the function
enable switch TS19 to
either side and move the
TS13 in the RETRACT
direction and check
terminal on the lift pump
motor.
Z-34/22 after serial
number 1733 and
Z-34/22N after serial
number 2226: Hold the
function enable switch
TS55 to either side and
move the primary boom
extend/retract toggle
switch TS63 in the
RETRACT direction and
check voltage at the
positive terminal on the
lift pump motor.
48V
Check for continuity in

the ground cable circuit
from lift pump motor to
ground.
continuity Repair or replace the lift

pump motor.
no continuity
Replace the ground
cable on the lift pump
motor OR repair open in
the ground cable from
the battery packs.
0V

page.
5 - 10
Part No. 36540
CHART 2
Continued from the

previous page.

number 153 and
retract toggle switch in
the RETRACT direction
and check voltage at the
positive cable on the
output side of PR3.
Z-34/22 from serial
number 153 to 1733
and Z-34/22N from
enable switch to either
side and move the
output side of PR3.
number 1733 and
Z-34/22N after 2226:
Hold the function enable
switch to either side and
switch in the RETRACT
direction and check
cable on the output side
of PR2.
48V

number 153 and Z-34/
22N before serial
number 304: Repair or
replace the positive
cable from the lift pump
motor to PR3.
number 152 and
Z-34/22N after 303:
Repair or replace the
positive cable from the
lift pump motor to PR2.
0V
number 1734 and
number 2227: Check
cable on the input side
of PR3.
number 1733 and
Z-34/22N after 2226:
input side of PR2.
48V

page.
Part No. 36540
0V

number 1734 and
number 2227: Replace
the 100A fuse F2 OR
repair open in the
positive cable from the
battery packs to the
100A fuse F2 to PR3
OR consult Genie
Industries Service
Department.
number 1733 and
Z-34/22N after 2226:
Replace the 100A fuse
F2 OR repair open in
the positive cable from
the battery packs to the
100A fuse F2 to PR2
OR consult Genie
Industries Service
Department.
5 - 11
CHART 2
Continued from the

previous page.

number 153 and
the grn/wht wire at PR3.
Z-34/22 from serial
number 153 to 1733
and Z-34/22N from
side and move the
the grn/wht wire at PR3.
number 1733 and
Z-34/22N after 2226:
direction and check
voltage on the grn/wht
wire at PR2.
24V

number 1734 and
number 2227: Check
for continuity in the brn
ground wire circuit from
PR3 to ground.
number 1733 and
Z-34/22N after 2226:
the brn ground wire
circuit from PR2 to
ground.

number 1734 and
continuity PR3.
number 1733 and
PR2.
no
continuity
22N before serial
number 2227: Repair
open in the brn ground
wire circuit from PR3 to
ground.
number 1733 and
number 2226: Repair
wire circuit from PR2 to
ground.
0V

page.
5 - 12
Part No. 36540
CHART 2
Continued from the

previous page.

22N before serial
and check voltage at
terminal #2 on CR2.
Z-34/22 from serial
number 153 to 1733
and Z-34/22N from
side and move the
terminal #5 on CR8.
22N after 2226: Hold
the function enable
direction and check
voltage at terminal #87
on CR20.
24V

22N before serial
number 304: Repair
open in wire circuit from
terminal #2 on CR2 to
PR3.
Z-34/22 from serial
number 153 to 1733
and Z-34/22N from
2226: Repair open in
wire circuit from terminal
#5 on CR8 to PR3.
22N after serial
number 2226: Repair
PR2.
0V

page.
Part No. 36540
5 - 13
CHART 2
Continued from the

previous page.

22N before serial
terminal #6 on CR2.
Z-34/22 from serial
number 153 to 1733
and Z-34/22N from
side and move the
terminal #9 on CR8.
number 1733 and
function enable switch to
terminal #30 on CR20.
0V

22N before serial
number 304: Repair
open in grn/wht wire
circuit from TB19 to
terminal #6 on CR2 OR
repair open in function
switch wire circuit with
diode to TB19 OR repair
the key switch ground
controls contact to the
function switch wire
circuit OR replace
retract toggle switch OR
contact Genie Industries
Service Department.
Z-34/22 from serial
number 153 to 1733
and Z-34/22N from
red#20 wire circuit from
PR4 to terminal #9 on
CR8.
number 1733 and
number 2226: Repair
open in red wire circuit
from the key switch
ground controls contact
to the function enable
switch to terminal #30
on CR3.
24V

page.
5 - 14
Part No. 36540
CHART 2
Continued from the

previous page.

number 153 and
number 304: Replace
CR2.
Z-34/22 from serial
number 153 to 1733
and Z-34/22N from
side and move the
number 1733 and
24V
Z-34/22 from serial

number 153 to 1733
and Z-34/22N from
ground OR replace CR8
OR replace the relay
socket.
number 1733 and
number 2226: Repair
open in ground wire
circuit with diode from
ground OR replace
diode OR replace CR20
OR replace the relay
socket.
0V
Z-34/22 from serial
number 153 to 1733
and Z-34/22N from
side and move the
terminal #2 on CR2.
number 1733 and
terminal #87A on CR3.
24V
Z-34/22 from serial

number 153 to 1733
and Z-34/22N from
the grn/wht wire circuit
from terminal #2 on
CR2.
number 1733 and
number 2226: Repair
open in the grn/wht wire
circuit from terminal
#87A on CR3 to terminal
#85 on CR20.
0V
page.
Part No. 36540
5 - 15
CHART 2
Continued from the

previous page.
Z-34/22 from serial

number 153 to 1733
and Z-34/22N from
side and move the
terminal #6 on CR2.
number 1733 and
24V
Z-34/22 from serial
number 153 to 1733
and Z-34/22N from
2226: Replace CR2.
number 1733 and
CR3.
5 - 16
0V
Z-34/22 from serial

number 153 to 1733
and Z-34/22N from
grn/wht wire circuit from
TB19 to terminal #6 on
CR2 OR repair open in
the wire circuit from the
key switch ground
control contact to the
the function switch wire
circuit with diode to
TB19 OR replace diode
OR replace primary
boom extend/retract
toggle switch OR
Service Department.
number 1733 and
number 2226: Repair
open in grn/wht wire
repair open in the wire
circuit from the key
switch ground control
contact to the function
enable switch to the
function switch wire
circuit with diode to
TB19 OR replace diode
OR replace primary
boom extend/retract
toggle switch OR
Service Department.
Part No. 36540
Chart 3
Auxiliary
Pump Motor
Will Not
Operate.
Be sure all other
functions operate
normally.
Be sure key switch
position.
Be sure the
Emergency Stop
buttons are pulled
out to the ON
position.
Be sure the battery
packs are properly
connected and fully
charged.
Turn key switch to

both Emergency Stop
motor
buttons out to the ON
operates
position. Lift the red
auxiliary pump switch
cover and hold the
auxiliary toggle switch
number 1734 and
number 2227: TS17
number 1733 and
number 2226: TS51
in the ON direction.
Move any boom function
toggle switch and listen
for the sound of the
auxiliary pump motor
operating.
Install a 0 to 5000 psi

(0 to 345 bar) pressure
gauge into the pressure
port of the auxiliary
pump and hold the
auxiliary power toggle
switch and move any
boom function toggle
switch. Note the
pressure.
Immediately stop. The

pump is good. There is
2800 psi possibly not enough
battery capacity to
operate both the
auxiliary pump and
function valves.
less than
2800 psi
Check for a positive
connection between the
electric motor and the
pump by removing the
pump from the motor,
but leave all the hoses
connected. Visually
check the coupling
connection.
good

pump OR consult the
Department.
bad
motor does
not operate
Hold the auxiliary pump

toggle switch and move
any boom function
toggle switch. Check
voltage at the red cable
on the auxiliary power
unit.
Replace the auxiliary

power unit.
24V
no
Check continuity in the continuity Replace the ground
cable from the auxiliary
the negative terminal on
pump to ground.
auxiliary power unit to
ground.
continuity
Replace the auxiliary
pump motor.
0V

page.
Part No. 36540
5 - 17
CHART 3
Continued from the

previous page.

any boom function
voltage at the grn/wht
wire on PR3.
24V
no
continuity Repair open in the brn
PR3 to ground.
continuity
Replace the 500A fuse
F1 OR replace the PR3
contacts OR replace
PR3.
0V

center terminal on the
auxiliary pump toggle
switch.
Check continuity of the

brn ground wire circuit
from PR3 to ground.
0V
Repair open in the red

power supply wire circuit
from key switch to the
switch.
24V
toggle switch and check
voltage at TB27.
0V

wire circuit from the
switch to TB27 OR
replace toggle switch.
0V

#27 wire from toggle
switch to control relay.
24V

the voltage red #27 wire
on control relay
number 1734 and
number 2227: CR2
number 1733 and
number 2226: CR3.
24V

page.
5 - 18
Part No. 36540
CHART 3
Continued from the

previous page.
no
Check continuity of the continuity Repair open in the brn
brn ground wire from the
control relay to ground.
control relay to ground.
continuity
any boom function
voltage at the control
relay output terminal.
0V
Replace control relay.
24V
wire from control relay to
number 1734 and
number 2227: PR4
number 1733 and
number 2226: PR3
Part No. 36540
5 - 19
Chart 4
All Functions
Inoperative,
Power Unit
Starts and Runs
Be sure the circuit
breaker and fuse are
not tripped or blown.
Be sure the battery
packs are properly
connected and fully
charged.
Check the hydraulic fluid

level.
low
Fill with Dexron

equivalent hydraulic
fluid.
no good
Replace the pump

coupling.
OK
Check for a positive
connection between the
electric motor and the
pump by removing the
pump from the motor,
but leave all hoses
connected. Visually
check coupling
connection.
good
Test the hydraulic pump.
See Repair section.
no good
Replace the pump.
good
Consult Genie Industries
Service Department.
5 - 20
Part No. 36540
Chart 5
All Lift and
Steer
Functions
Inoperative,
Drive
Function
Operational
Be sure the battery
packs are properly
connected and fully
charged.
Install a 0 to 5000 psi (0 3200 PSI

to 345 bar) pressure
or more
gauge to the test port on
the function manifold.
Turn key switch to
Emergency Stop buttons
out to the ON position,
22N before serial
boom extend/retract
toggle switch TS13 in
and check the hydraulic
pressure.
number 152 and
Z-34/22N after 303:
toggle switch TS19 to
boom extend/retract
and check the hydraulic
pressure.
Troubleshoot each
function individually OR
consult the Genie
Industries Service
Department.
less than 3200 PSI

page.
Part No. 36540
5 - 21
CHART 5
Continued from the

previous page.
Adjust the relief valve on

the function manifold
(item AB or BB or BC)
all the way in
(clockwise), counting the
number of turns. Move
the boom extend/retract
direction. Check the
pressure.
3200
PSI or
more
less than 3200 PSI

22N before serial
number 304: Move any
switch and manually
activate the boom
proportional valve (item
AU or BU or CH). Does
the function operate?
number 152 and
Z-34/22N after 303:
toggle switch to either
side and move any
switch and manually
activate the boom
proportional valve (item
AU or BU or CH). Does
the function operate?
no

22N before serial
number 304: Move
TS13 in the RETRACT
direction and adjust the
relief valve pressure to
3200 PSI OR consult
Department.
number 152 and
Z-34/22N after 303:
side and move TS13 in
and adjust the relief
valve pressure to 3200
PSI OR consult Genie
Industries Service
Department.
Check function pump

(See Repair section).
bad
Replace the pump.
good
Replace the boom
proportional valve OR
replace the differential
sensing valve (item AA
or BA or CQ) OR
function or steer/brake
manifolds could have an
internal defect. Consult
Department.
yes
page.
5 - 22
Part No. 36540
CHART 5
Continued from the

previous page.
no
continuity Repair open in the
ground wire circuit.
22N before serial
number 304: Check for
continuity in the ground
proportional valve coil to
TB48 to the wht wire at
the boom function speed
controller.
number 152 and
Z-34/22N after 303:
the ground wire circuit
from the proportional
valve coil to ground.
continuity
number 152 and
Z-34/22N after 303:
Move any boom function
voltage on the wht/red
#6 wire on the
proportional valve coil.
number 152 and
Z-34/22N after 303:
side and move any
switch and check
#6 wire on the
24V
Replace defective coil.
0V

page.
Part No. 36540
5 - 23
CHART 5
Continued from the

previous page.

22N before serial
number 304: Move any
switch and check
#6 wire at TB6.
number 152 and
Z-34/22N after 303:
side and move any
switch and check
#6 wire at TB6.
24V
Repair open in the

wht/red #6 wire circuit
from TB6 to the boom
function proportional
valve.
0V
Repair open in wht/red-3
wire circuit with diode
from TB6 to the blk/red
wire at the boom
function speed controller
OR replace diode OR
troubleshoot ground and
platform control
functions separately
(refer to charts 6 and 7)
OR consult Genie
Industries Service
Department.
5 - 24
Part No. 36540
Chart 6
Ground
Controls
Inoperative,
Platform
Controls
Operate
Normally
Be sure key switch
position.
Be sure the
Emergency Stop
buttons are pulled
out to the ON
position.
Be sure the battery
packs are properly
connected and fully
charged.
Check voltage at the red

wire on the input side of
the ground controls
contact of the key switch
(this wire should
originate at the
Emergency Stop
button).
0V

to the input side of the
of the key switch.
24V
Turn key switch to
both Emergency Stop
position. Check voltage
at the output side of
of the key switch.
0V

activating the ground
controls contact.
yes
Replace the key switch

contact for ground
controls.
no
Replace the key switch.
24V
number 153 and
Z34/22N before serial
secondary boom toggle
switch (TS11) in the UP
direction and check
voltage at TB6.
number 152 and
Z34/22N after serial
function enable toggle
hold the secondary
boom toggle switch
number 1734 and
number 2227: (TS11)
number 1733 and
number 2226: (TS60)
in the UP direction and
check voltage at TB6.
0V
Check the voltage on

the red wire at center
terminal of each ground
control toggle switch.
0V

circuit supplying 24V to
the center terminal of
each ground control
toggle switch.
24V
Repair open in wht/red
from TS60 to TB6 OR
replace the diode.
24V

page.
Part No. 36540
5 - 25
CHART 6
Continued from the

previous page.
Move the function

enable toggle switch to
either side and hold the
switch in the UP
direction. Check voltage
at TB19.
0V
Repair open in grn/wht

from TS60 to TB19 OR
replace the diode.
24V
Service Department.
5 - 26
Part No. 36540
Chart 7
Platform
Controls
Inoperative,
Ground
Controls
Operate
Normally
(Z-34/22 before
serial number 1734
and
Z-34/22N before
serial number
2227)
Be sure key switch
position.
Be sure the
Emergency Stop
buttons are pulled
out to the ON
position.
Be sure the battery
packs are properly
connected and fully
charged.
Turn key switch to

pull both Emergency
Stop buttons out to the
ON position. Check
voltage at the red wire
on the input side of the
platform controls contact
of key switch (this wire
should originate at the
Emergency Stop
button).
0V

to the input side of the
of the key switch.
20V or more
output side of platform
controls contact of the
key switch.
0V

controls contact.
yes

controls.
yes
Replace the platform

contact.
no
Replace the key switch.
20V or more
Check voltage at TB22.
0V
Repair open in blk #22

wire circuit from key
switch to TB22.
20V or more

input side of the platform
contact.
0V
20V or more

contact.
0V
Repair open in blk-2

wire circuit from TB22 to
platform Emergency
Stop button OR repair
open in ground wire
circuit from platform
controls to ground.
Check to see if the

is activating the contact.
no
20V or more


page.
Part No. 36540
5 - 27
CHART 7
Continued from the

previous page.
Check the voltage at the

input side of the foot
switch.
0V
Repair open in the wire

circuit from the platform
P2 to foot switch.
0V
Replace foot switch

contacts OR replace the
foot switch.
0V
Repair open in the

blu/wht-3 wire circuit
from foot switch to TB12
0V
Repair open in the

blk #12 wire circuit from
TB12 to LS3.
20V or more
Press down foot switch
Before serial number
747: the wht wire at the
foot switch
After serial number
746: the blu/wht wire at
the foot switch.
20V or more
TB12.
20V or more
blk #12 wire on LS3.
20V or more
red #16 wire on LS3.
0V
Replace LS3.
20V or more
TB16.
0V
Repair open in red #16

wire from LS3 to TB16.
20V or more

page.
5 - 28
Part No. 36540
CHART 7
Continued from the

previous page.

terminal "+" on the drive
controller.
0V
20V or more
Turn the boom function

speed controller to 9,
press down foot switch
and move any boom
function toggle switch
and check the voltage at
the red wire on the
boom function speed
controller.
0V

number 153 and
number 304: Repair
open in the org/red-3
controller.
number 152 and
number 303: Repair
open in the org/red-3
CR5 OR repair or
replace CR5 OR repair
wire circuit from CR5 to
ground.
Repair open in the

power supply circuit
from each individual
boom toggle switch to
controller.
20V or more
and move any boom
the blk/red wire on the
boom function speed
controller.
0V
Adjust boom function

speed controller OR
replace boom function
speed controller OR
Service Department.
20V or more
and move any boom
TB6.
0V
Repair open in wire

controller to TB6 OR
replace diode.
20V or more

page.
Part No. 36540
5 - 29
CHART 7
Continued from the

previous page.
With the boom function

speed controller turned
to 9, press down foot
switch and move any
switch and check
voltage at the wht/red
wire on the proportional
valve coil item AU or BU
or CH.
0V

wire circuit from
TB6.
20V or more
Disconnect the wire to
the proportional valve
coil. Test the resistance
of the valve coil. See
Repair Section.
0 or
infinite
ohms
Replace proportional
valve coil.
19 to 20 ohms
number 153 and
number 304: Repair
open in the blu/wht wire
circuit from the
TB48 to the boom
OR replace proportional
valve (item AU or BU or
CH) OR troubleshoot lift
and drive functions
individually OR consult
Department.
number 152 and
number 303: Repair
open in brn ground wire
circuit from proportional
valve to ground OR
replace proportional
CH) OR troubleshoot lift
and drive functions
Department.
5 - 30
Part No. 36540
Chart 8
Platform
Controls
Inoperative,
Ground
Controls
Operate
Normally
(Z-34/22 after
serial number 1733
and
Z-34/22N after
serial number
2226)
Turn key switch to

pull both Emergency
ON position. Check
on the input side of the
of the key switch (this
wire should originate at
Emergency Stop
button P1).
0V

circuit from Emergency
Stop button to the key
switch.
24V
output side of the
on the key switch.
0V

controls contact.
yes

controls.
yes

contact.
no
Be sure key switch

position.
Be sure the
Emergency Stop
buttons are pulled
out to the ON
position.
Be sure the battery
packs are properly
connected and fully
charged.
Replace the keyswitch.
24V
0V
Repair open in blk#22

wire circuit from key
switch to TB22.
24V
input side of the platform
contact.
0V

the platform Emergency
Stop button OR repair
circuit from TB52 to the
platform.
24V

contact.
0V
Check to see if the

is activating the contact.
no
24V


page.
Part No. 36540
5 - 31
CHART 8
Continued from the

previous page.
Turn key switch to

pull both Emergency
ON position. Press down
the foot switch and
check voltage at
terminal 6 on the drive
controller.
0V
Test the foot switch. See

Repair Section.
good
bad
Repair open in wht-FS

wire circuit from foot
switch to the center
terminal of TS1 to
controller.
Replace the foot switch.
24V
Press down the foot
switch and check
voltage at the center
terminal of each function
toggle switch.
0V
Press down the foot

switch and check
voltage at the terminal 7
on the drive controller.
24V

circuit from terminal 6 to
controller to each
function toggle switch.
0V
Replace the drive
controller or consult
Department.
24V
Press down the foot

switch and move any
switch and check
on the boom function
speed controller.
0V

supply circuit to boom
from each individual
switch OR consult Genie
Industries Service
Department.
24V
With the boom function
speed controller set to 9,
press down the foot
switch and move any
switch and check
voltage at the blk/red
wire on boom function
speed controller.
less
than
20V
Adjust boom function

speed controller (see
Repair Section) OR
replace boom function
speed controller OR
Service Department.
20V or more

page.
5 - 32
Part No. 36540
CHART 8
Continued from the

previous page.
Press down the foot

switch and move any
switch and check
voltage at TB6.
0V
Replace the diode on

the blk/red wire on boom
OR repair open in wht/
red-3 wire circuit from
boom function speed
controller to TB6.
20V or more
Press down the foot

switch and move any
switch and check
voltage at the wht/red
wire on the proportional
CH).
0V

wire from TB6 to the
proportional valve.
20V or more
Repair open in brn
ground wire circuit to the
proportional valve
OR troubleshoot lift and
drive functions
Department.
Part No. 36540
5 - 33
Chart 9
Primary
Boom Up
Function
Inoperative
Be sure key switch
position.
Be sure the
Emergency Stop
buttons are pulled
out to the ON
position.
Be sure the battery
packs are properly
connected and fully
charged.
Turn key switch to

both Emergency Stop
position.
number 153 and
primary boom toggle
switch TS12 in the UP
direction and check
#6 wire at the boom
valve coil (item AU or
BU or CH).
Z-34/22 from serial
number 153 to 1733
and Z-34/22N from
primary boom toggle
direction and check
#6 wire at the boom
BU or CH).
number 1733 and
the UP direction and
check voltage on the
wht/red #6 wire at the
boom function
proportional valve coil
(item AU or BU or CH)..
0V

number 153 and
primary boom toggle
switch in the UP direction
TB6.
number 152 and
toggle switch in the up
direction and check
voltage at TB6.
24V
Repair open in the

wht/red #6 wire circuit
from TB6 to the boom
valve coil OR repair
boom function
ground.
0V
Turn key switch to
pull both Emergency
ON position. With the
boom function speed
controller turned to 9,
press down the foot
switch and move the
primary boom toggle
switch
number 1734 and
number 2227: TS3
number 1733 and
number 2226: TS11
in the UP direction.
0V
Repair open in the blk/

red wire to the wht/red
wire to TB6.
15V
24V
Continued on page 36.
5 - 34

page.
Part No. 36540
CHART 9
Continued from the

previous page.
Press down the foot

switch and move the
primary boom toggle
switch in the UP
direction. Check for
speed controller.
0V

circuit through the boom
function toggle switches
to the red wire on the
boom function speed
controller.
24V
Press down the foot
switch and move the
primary boom toggle
switch in the UP
at the blk/red wire on the
boom function speed
controller.
0V
Repair open in the

controller to ground OR
replace the boom
function speed
controller.
24V
Repair open in the
blk/red to wht/red wire
from the boom function
speed controller to TB6.
Part No. 36540
5 - 35
CHART 9
Continued from page 34.

number 153 and
primary boom toggle
the red #1 wire on the
primary boom up
directional valve coil
(item AD or BD or CU).
number 153 and
toggle switch in the UP
direction and check
voltage on the red #1
wire on the primary
boom up directional
valve coil (item AD or
BD or CU).
24V
0V

number 153 and
primary boom toggle
TB1.
number 152 and
direction and check
voltage at TB1.
24V

#1 wire circuit from TB1
to the primary boom up
directional valve coil OR
repair open in the brn
manifold.
0V
Turn key switch to
pull both Emergency
boom function speed
press down the foot
switch and move the
primary boom toggle
switch
number 1734 and
number 2227: TS3
number 1733 and
number 2226: TS11
0V
Repair open in the red-3

wire circuit from primary
boom toggle switch to
TB1.
24V
Troubleshoot the
primary boom toggle
switch at ground
controls OR replace the
diode on toggle switch
OR repair open in the
red #1 wire circuit from
toggle switch to TB1 OR
page.
5 - 36
Part No. 36540
CHART 9
Continued from the

previous page.
Disconnect the red #1

wire to the primary
boom up directional
valve coil (item AD or
BD or CU) and test the
resistance of the valve
coil. See the Repair
Section.
0 or
infinite
ohms
Replace the primary

boom up directional
valve coil.
23 to 25
ohms
Exchange the primary
and secondary boom
directional valves
(items AD and AE or
(items BD and BE or
items CU and CT).
Activate the primary
boom UP function.
function
does not
operate
function operates
Install a 0 to 5000 PSI

gauge at the quick
disconnect coupling on
number 153 and
primary boom toggle
switch in the up direction
and check the pressure.
number 152 and
toggle switch in the up
direction and check the
pressure.
3200
PSI
Check for mechanical

restrictions keeping the
primary boom up
function from operating
OR repair the cylinder or
cylinder counterbalance
valve OR consult Genie
Industries Service
Department.
less than 3200 PSI

Replace the defective
directional valve.
Part No. 36540
Adjust the system relief

valve (item AB or BB or
CR) (see Repair
Section) OR repair or
replace the cylinder or
the cylinder
counterbalance valve
OR the function
manifold could have an
Department.
5 - 37
Chart 10
Primary
Boom Down
Function
Inoperative
Be sure key switch
position.
Be sure the
Emergency Stop
buttons are pulled
out to the ON
position.
Be sure the battery
packs are properly
connected and fully
charged.
Turn key switch to

both Emergency Stop
position.
number 153 and
primary boom toggle
switch TS12 in the
DOWN direction and
boom function
(item AU or BU or CH).
Z-34/22 from serial
number 153 to 1733
and Z-34/22N from
primary boom toggle
switch TS12 in the down
direction and check
#6 wire at the boom
BU or CH).
number 1733 and
the DOWN direction and
boom function
(item CH).
24V
5 - 38
0V

side and move the
primary boom toggle
switch in the DOWN
voltage at TB6.
24V

to boom function
OR repair open in brn
the boom function
ground.
0V
Turn key switch to

pull both Emergency
boom function speed
press down the foot
switch and move the
primary boom toggle
switch
number 1734 and
number 2227: TS3
number 1733 and
number 2226: TS11
in the DOWN direction.
24V
Repair open in blk/red

wire to wht/red wire to
TB6.
0V
Press down the foot
switch and move the
primary boom toggle
switch in the DOWN
at the red wire on the
boom function speed
controller.
0V
Repair open in wire

circuit through boom
boom function speed
controller.
24V

page.
Part No. 36540
CHART 10
Continued from the

previous page.
Press down the foot

switch and move the
primary boom toggle
switch in the DOWN
wire on the boom
function speed
controller.
0V
Repair open in ground

boom function speed
replace the boom
function speed
controller.
24V
Repair open in blk/red to
wht/red wire circuit from
controller to TB6.
Part No. 36540
5 - 39
CHART 10
Turn key switch to

both Emergency Stop
position.
number 153 and
primary boom toggle
switch in the DOWN
direction and check
voltage on the red/blk #2
wire at the primary
boom down directional
valve coil (item I).
Z-34/22 from serial
number 153 to 1733
and Z-34/22N from
2226:Hold the function
primary boom toggle
switch in the down
direction and check
voltage on the red/blk #2
wire at the primary
valve coil (item I).
number 1733 and
toggle switch in the
down direction and
red/blk #2 wire at the
primary boom down
(item AC).
0V

number 153 and
primary boom toggle
switch in the DOWN
direction and check
voltage at TB2.
number 152 and
down direction and
24V
Repair open in red/blk

to primary boom down
repair open in brn
ground wire circuit to
manifold.
0V
Turn key switch to
pull both Emergency
boom function speed
press down the foot
switch and move the
primary boom toggle
switch in the DOWN
at TB2.
0V
Repair open in red/blk

#2 wire circuit to TB2.
24V
Troubleshoot the
primary boom toggle
switch OR replace diode
on toggle switch OR
repair open in red/blk #2
wire circuit from toggle
switch to TB2 OR
24V

page.
5 - 40
Part No. 36540
CHART 10
Continued from the

previous page.
Disconnect the red/blk

wire to the primary
valve coil. Test the
coil. See Repair Section.
0 or
infinite
ohms
Replace the primary

valve coil.
23 to 25
ohms
function
operates
and secondary boom
directional valves
number 1734 and
number 2227: items D
and E
number 1733 and
number 2226: items AC
and AB. Activate the
primary boom DOWN
function.
Replace defective
directional valve.
function inoperative
number 1734 and
valve (see Repair
Section)
primary boom toggle
number 1734 and
switch in the DOWN
number 2227: item B
less than Z-34/22 after serial
pressure.
3200 PSI number 1733 and
number 1733 and
number 2226: item YY
OR repair or replace
cylinder or cylinder
counterbalance valve
OR function manifold
could have an internal
defect. Consult Genie
down direction and
Industries Service
check the pressure.
Department.
3200 PSI
primary boom down
OR repair cylinder or
Industries Service
Department.
Part No. 36540
5 - 41
Chart 11
Secondary
Boom Up
Function
Inoperative
Be sure key switch
position.
Be sure the
Emergency Stop
buttons are pulled
out to the ON
position.
Be sure the battery
packs are properly
connected and fully
charged.
Turn key switch to

both Emergency Stop
position.
number 153 and
direction and check
#6 wire at the boom
BU or CH).
Z-34/22 from serial
number 153 to 1733
and Z-34/22N from
direction and check
#6 wire at the boom
BU or CH).
number 1733 and
move the secondary
boom toggle switch
TS60 in the UP direction
the wht/red #6 wire at
the boom function
24V
5 - 42
0V

number 153 and
switch in the DOWN
direction and check
voltage at TB6.
number 152 and
move the secondary
boom toggle switch in
24V

boom function
the boom function
ground.
0V
Turn key switch to
pull both Emergency
boom function speed
press down the foot
switch and move the
switch
number 1734 and
number 2227: TS2
number 1733 and
number 2226: TS10
Check voltage at blk/red
at boom function speed
controller.
24V

wht/red wire circuit to
TB6.
0V

page.
Part No. 36540
CHART 11
Continued from the

previous page.
Press down the foot

switch and move the
switch in the UP
boom function speed
controller.
0V

wire circuit through
switches to the red wire
speed controller.
24V
Press down the foot
switch and move the
switch in the UP
boom function speed
controller.
0V
Repair open in grn wire

from the boom function
speed controller to
ground OR replace the
boom function speed
controller.
24V
boom function speed
controller to TB6.
Part No. 36540
5 - 43
CHART 11

number 153 and
the blu #10 wire on the
secondary boom up
(item E).
Z-34/22 from serial
number 153 to 1733
and Z-34/22N from
switch in the up direction
secondary boom up
(item E).
number 1733 and
move the secondary
the up direction and
check voltage on the blu
#10 wire on the
secondary boom up
(item AB).
0V

number 153 and
TB10.
number 152 and
number 303: hold the
move the secondary
24V
Repair open in blu #10

secondary boom up
repair open in the
manifold.
0V
Turn key switch to
pull both Emergency
boom function speed
press down the foot
switch and move the
TB10.
0V
Repair open in blu-3

wire circuit to TB10.
24V
Troubleshoot the
on toggle switch OR
repair open in blu #10
switch to TB10 OR
24V

page.
5 - 44
Part No. 36540
CHART 11
Continued from the

previous page.
Disconnect the blu #10

wire to the secondary
boom up directional
0 or
infinite
ohms
Replace the secondary

boom up directional
valve coil.
23 to 25
ohms
Exchange the
secondary and primary
boom directional valves
number 1734 and
number 2227:
(items D and E)
number 1733 and
number 2226:
(items AB and AC)
Activate the secondary
boom UP function.
function
operates
Replace defective
directional valve.
Install a 0 to 5000 PSI (0
valve (see Repair
gauge at the quick
Section)
number 1734 and
number 2227: item B
number 153 and
less than Z-34/22 after serial
number 304: Move the 3200 PSI number 1733 and
number 2226: item YY
cylinder(s) or cylinder(s)
counterbalance valve(s)
number 152 and
Industries Service
Department.
move the secondary
check the pressure.
3200 PSI
secondary boom up
OR repair cylinder(s) or
cylinder(s)
OR consult Genie
Industries Service
Department.
Part No. 36540
5 - 45
Chart 12
Secondary
Boom Down
Function
Inoperative
Be sure key switch
position.
Be sure the
Emergency Stop
buttons are pulled
out to the ON
position.
Be sure the battery
packs are properly
connected and fully
charged.
Turn key switch to

both Emergency Stop
position.
number 153 and
switch TS11 in the
DOWN direction and
boom function
Z-34/22 from serial
number 153 to 1733
and Z-34/22N from
switch TS11 in the
DOWN direction and
boom function
number 1733 and
move the secondary
boom toggle switch
TS60 in the DOWN
direction and check
#6 wire at the boom
BU or CH).
0V

number 153 and
switch in the DOWN
direction and check
voltage at TB6.
number 152 and
move the secondary
24V

boom function
boom function
0V
Turn key switch to
pull both Emergency
boom function speed
press down the foot
switch and move the
switch
number 1734 and
number 2227: TS2
number 1733 and
number 2226: TS10
Check voltage at blk/red
at the boom function
speed controller.
24V

wht/red wire circuit to
TB6.
0V
24V
5 - 46

page.
Part No. 36540
CHART 12
Continued from the

previous page.
Press down the foot

switch and move the
switch in the DOWN
speed controller.
0V

speed controller.
24V
Press down the foot
switch and move the
switch in the DOWN
boom function speed
controller.
0V

boom function speed
replace the boom
function speed
controller.
24V
wire from the boom
to TB6.
Part No. 36540
5 - 47
CHART 12

number 153 and
secondary boom up
(item AE or BE or CT).
22N after serial
move the secondary
#10 wire on the
secondary boom up
(item AE or BE or CT).
0V

number 153 and
switch in the DOWN
direction and check
voltage at TB11.
number 152 and
number 303: hold the
move the secondary
24V

secondary boom down
repair open in the
manifold.
0V
Turn key switch to
pull both Emergency
boom function speed
press down the foot
switch and move the
switch in the DOWN
direction and check
voltage at TB10.
0V

24V
24V
Troubleshoot the
on toggle switch OR
repair open in blu #11
switch to TB11 OR

page.
5 - 48
Part No. 36540
CHART 12
Continued from the

previous page.

wire to the secondary
0 or
infinite
ohms
Replace the secondary

valve coil.
23 to 25
ohms
Exchange the
secondary and primary
valves (items AJ and AI
or BJ and BI or CU and
CT). Activate the
secondary boom UP
function.
function
operates
Replace defective
directional valve.
valve (see Repair
gauge at the quick
Section) (item AB or BB
or CR) OR repair or
less than replace cylinder(s) or
3200 PSI cylinder(s)
number 153 and
Industries Service
switch in the DOWN
Department.
pressure.
number 153 and
move the secondary
check the pressure.
3200 PSI
secondary boom down
OR repair cylinder(s) or
cylinder(s)
OR consult Genie
Industries Service
Department.
Part No. 36540
5 - 49
Chart 13
Primary
Boom
Extend
Function
Inoperative
Be sure key switch
position.
Be sure the
Emergency Stop
buttons are pulled
out to the ON
position.
Be sure the battery
packs are properly
connected and fully
charged.
Turn key switch to

both Emergency Stop
position.
number 153 and
TS13 in the EXTEND
direction and check
#6 wire at the boom
BU or CH).
Z-34/22 from serial
number 153 to 1733
and Z-34/22N from
TS13 in the EXTEND
direction and check
#6 wire at the boom
BU or CH).
number 1733 and
switch TS63 in the
EXTEND direction and
boom function
0V

number 153 and
the EXTEND direction and
number 152 and
switch in the EXTEND
direction and check
voltage at TB6.
24V

to boom function
boom function
proportional valve coil .
0V
Turn key switch to
pull both Emergency
boom function speed
press down the foot
switch and move the
number 1734 and
number 2227: TS4
number 1733 and
number 2226: TS13
in the EXTEND direction.
Check voltage at TP6.
24V

wire to TB6.
0V
24V
5 - 50

page.
Part No. 36540
CHART 13
Continued from the

previous page.
Press down the foot

switch and move the
the EXTEND direction.
wire on the boom
function speed
controller.
0V
Repair open in wire

circuit through boom
boom function speed
controller.
24V
Press down the foot
switch and move the
the EXTEND direction.
Check voltage at the blk/
red wire on the boom
function speed
controller.
0V

boom function speed
replace the boom
function speed
controller.
24V
wht/red wire from the
boom function speed
controller to TB6.
Part No. 36540
5 - 51
CHART 13
Turn key switch to

both Emergency Stop
position.
number 153 and
check voltage on the blk
#7 wire primary boom
extend directional valve
coil (item AT).
Z-34/22 from serial
number 153 to 1733
and Z-34/22N from
check voltage on the blk
coil (item BT).
number 1733 and
direction and check
voltage on the blk #7
wire primary boom
coil (item CK).
0V

number 153 and
direction and check
voltage at TB7.
number 152 and
voltage at TB7.
24V

primary boom extend
repair open in brn
manifold.
0V
Turn key switch to
pull both Emergency
boom function speed
press down the foot
switch and move the
number 1734 and
number 2227: TS4
number 1733 and
number 2226: TS13
0V

24V
24V
Troubleshoot the
retract toggle switch on
ground controls OR
replace diode on toggle
switch OR repair open in
blk #7 wire circuit from
toggle switch to TB7 OR

page.
5 - 52
Part No. 36540
CHART 13
Continued from the

previous page.
Disconnect the blk wire

to the primary boom
Repair Section.
0 or
infinite
ohms
Replace the primary

boom extend directional
valve coil .
23 to 25
ohms
function
operates
boom extend and retract
directional valves
(items AT and AC or
BT and BC or CK and
CU). Activate the
primary boom EXTEND
function.
Replace defective
directional valve.

page.
Part No. 36540
5 - 53
CHART 13
Continued from the

previous page.

valve (see Repair
gauge at the quick
or CR) OR repair or
less than replace cylinder(s) or
3200 PSI cylinder(s)
number 153 and
Industries Service
retract function toggle
Department.
pressure.
number 152 and
extend/retract function
EXTEND direction and
check the pressure.
3200 PSI
primary boom extend
Industries Service
Department.
5 - 54
Part No. 36540
Chart 14
Primary
Boom
Retract
Function
Inoperative
Be sure key switch
position.
Be sure the
Emergency Stop
buttons are pulled
out to the ON
position.
Be sure the battery
packs are properly
connected and fully
charged.
Turn key switch to

both Emergency Stop
position.
number 153 and
TS13 in the RETRACT
direction and check
#6 wire at the boom
valve coil (item AU).
Z-34/22 from serial
number 153 to 1733
and Z-34/22N from
TS13 in the RETRACT
direction and check
#6 wire at the boom
valve coil
(item AU or BU).
number 1733 and
switch TS63 in the
boom function
(item CH).
0V

number 153 and
TB6.
number 152 and
direction and check
voltage at TB6.
24V

to the boom function
boom function
0V
Turn key switch to
pull both Emergency
boom function speed
press down the foot
switch and move the
number 1734 and
number 2227: TS4
number 1733 and
number 2226: TS13
24V

wire circuit from TP6 to
to TB6.
0V
24V
Part No. 36540

page.
5 - 55
CHART 14
Continued from the

previous page.
Press down the foot

switch and move the
the RETRACT direction.
wire on the boom
function speed
controller.
0V

speed controller.
24V
Press down the foot
switch and move the
Check voltage at the blk/
red wire on the boom
function speed
controller.
0V

boom function speed
replace the boom
function speed
controller.
24V
wire from the boom
to TB6.
5 - 56
Part No. 36540
CHART 14
Turn key switch to

both Emergency Stop
position.
number 153 and
the blk/wht #8 wire
primary boom retract
(item AC).
number 152 and
direction and check
voltage on the blk/wht
retract directional valve
coil (item AC or BC or
CK).
0V

number 153 and
primary boom toggle
direction and check
voltage at TB8.
number 152 and
voltage at TB8.
24V
Repair open in blk/wht

to primary boom retract
repair open in brn
manifold.
0V
Turn key switch to
pull both Emergency
boom function speed
press down the foot
switch and move the
0V
Repair open in blk/wht

#8 wire circuit to TB8.
24V
24V
Troubleshoot the
retract toggle switch on
ground controls OR
replace diode on toggle
switch OR repair open in
blk/wht #8 wire circuit
from toggle switch to
TB8 OR replace toggle
switch.

page.
Part No. 36540
5 - 57
CHART 14
Continued from the

previous page.
Disconnect the blk wire

to the primary boom
Repair Section.
0 or
infinite
ohms
Replace the primary

boom extend directional
valve coil.
23 to 25
ohms
function
operates
boom extend and retract
directional valves
number 1734 and
number 2227: items AH
and AC or BH and BC.
number 1733 and
number 2226: items CK
and CU.
Activate the primary
boom RETRACT function.
Replace defective
directional valve.

page.
5 - 58
Part No. 36540
CHART 14
Continued from the

previous page.

valve (see Repair
gauge at the quick
Section)
number 1734 and
number 2227:
number 153 and
(item AB or BB)
number 304: Move the less than Z-34/22 after serial
3200 PSI number 1733 and
retract function toggle
number 2226: (item
CR) OR repair or
replace cylinder(s) or
pressure.
cylinder(s)
number 152 and
Industries Service
Department.
extend/retract function
check the pressure.
3200 PSI
primary boom extend
Industries Service
Department.
Part No. 36540
5 - 59
Chart 15
Turntable
Rotate Left
Function
Inoperative
Be sure key switch
position.
Be sure the
Emergency Stop
buttons are pulled
up to the ON
position.
Be sure the battery
packs are properly
connected and fully
charged.
Turn key switch to

both Emergency Stop
position.
number 153 and
turntable rotate toggle
switch TS10 in the LEFT
direction and check
#6 wire at the boom
Z-34/22 from serial
number 153 to 1733
and Z-34/22N from
direction and check
#6 wire at the boom
valve coil
(item AU or BU).
number 1733 and
move the turntable
rotate toggle switch
TS62 in the LEFT
direction and check
#6 wire at the boom
valve coil (item CH).
24V
5 - 60
0V

number 153 and
switch in the LEFT
voltage at TB6.
number 152 and
move the turntable
rotate toggle switch in
the LEFT direction and
check the voltage at
TB6.
24V

boom function
0V
Turn key switch to
pull both Emergency
boom function speed
press down the foot
switch and move the
switch
number 1734 and
number 2227: TS1
number 1733 and
number 2226: TS12
in the LEFT direction.
24V

to TB6.
0V

page.
Part No. 36540
CHART 15
Continued from the

previous page.
Press down the foot

switch and move the
switch in the LEFT
speed controller.
0V

speed controller.
24V
Press down the foot
switch and move the
turntable rotate function
toggle switch in the LEFT
wire on the boom
function speed
controller.
0V

boom function speed
replace the boom
function speed
controller.
24V
wire from the boom
to TB6.
Part No. 36540
5 - 61
CHART 15
Turn key switch to

both Emergency Stop
position.
number 153 and
switch in the LEFT
direction and check
voltage on the wht #4
wire on the turntable
rotate directional valve
coil (item AF).
Z-34/22 from serial
number 153 to 1733
and Z-34/22N from
switch in the LEFT
direction and check
coil (item AF or BF).
number 1733 and
move the turntable
wht #4 wire on the
turntable rotate
(item CD).
0V

number 153 and
switch in the LEFT
direction and check
voltage at TB4.
number 152 and
move the turntable
24V
Repair open in wht/blk

to turntable rotate left
repair open in brn
manifold.
0V
Turn key switch to
pull both Emergency
boom function speed
press down the foot
switch and move the
switch
number 1734 and
number 2227: TS4
number 1733 and
number 2226: TS13
0V
Repair open in wht-3

24V
24V
Troubleshoot the
on toggle switch OR
repair open in wht-3 wire
circuit from toggle switch
to TB4 OR replace
toggle switch.

page.
5 - 62
Part No. 36540
CHART 15
Continued from the

previous page.

the turntable rotate left
directional valve coil.
Test the resistance of
the valve coil. See
Repair Section.
0 or
infinite
ohms
Replace the turntable

rotate left directional
valve coil.
23 to 25
ohms
Exchange the turntable
rotate and secondary
number 674 and
number 935:
item AF and AK.
Z-34/22 from serial
number 674 to 1733
and Z-34/22N from
2226:
item BF and BK.
number 1733 and
number 2226:
item CX and CJ.
Activate the turntable
rotate LEFT function.
function
operates
Replace defective
directional valve.

page.
Part No. 36540
5 - 63
CHART 15
Continued from the

previous page.

gauge at the quick
number 153 and
switch in the LEFT
pressure.
number 152 and
move the turntable
check the pressure.
3200
PSI

turntable rotate left
OR repair or replace the
turntable rotation motor
OR consult Genie
Industries Service
Department.
less than 3200 PSI

valve (see Repair
or CR) OR repair or
replace the turntable
rotation motor OR
function manifold could
have an internal defect.
Service Department.
5 - 64
Part No. 36540
Chart 16
Turntable
Rotate Right
Function
Inoperative
Be sure key switch
position.
Be sure the
Emergency Stop
buttons are pulled
up to the ON
position.
Be sure the battery
packs are properly
connected and fully
charged.
Turn key switch to

both Emergency Stop
position.
number 153 and
switch TS10 in the RIGHT
direction and check
#6 wire at the boom
Z-34/22 from serial
number 153 to 1733
and Z-34/22N from
direction and check
#6 wire at the boom
valve coil
(item AU or BU).
number 1733 and
move the turntable
rotate toggle switch
TS62 in the RIGHT
direction and check
#6 wire at the boom
24V
Part No. 36540
0V

number 153 and
switch in the RIGHT
voltage at TB6.
number 152 and
move the turntable
the RIGHT direction and
TB6.
24V

boom function
0V
Turn key switch to
pull both Emergency
boom function speed
press down the foot
switch and move the
switch
number 1734 and
number 2227: TS1
number 1733 and
number 2226: TS12
in the RIGHT direction.
24V

to TB6.
0V

page.
5 - 65
CHART 16
Continued from the

previous page.
Press down the foot

switch and move the
switch in the RIGHT
speed controller.
0V
Repair open in red/wht

speed controller.
24V
Press down the foot
switch and move the
turntable rotate function
RIGHT direction. Check
the voltage at the blk/red
wire on the boom
function speed
controller.
0V

boom function speed
replace the boom
function speed
controller.
24V
wire from the boom
to TB6.
5 - 66
Part No. 36540
CHART 16
Turn key switch to

both Emergency Stop
position.
number 153 and
switch in the RIGHT
direction and check
coil (item AK).
Z-34/22 from serial
number 153 to 1733
and Z-34/22N from
switch in the RIGHT
direction and check
coil (item AK or BK).
number 1733 and
move the turntable
wht #5 wire on the
turntable rotate
(item CX).
0V

number 153 and
switch in the RIGHT
direction and check
voltage at TB5.
number 152 and
move the turntable
24V
Repair open in wht/blk

to turntable rotate right
repair open in brn
manifold.
0V
Turn key switch to
pull both Emergency
boom function speed
press down the foot
switch and move the
switch
number 1734 and
number 2227: TS1
number 1733 and
number 2226: TS12
0V
Repair open in wht/blk-3

24V
24V
Troubleshoot the
on toggle switch OR
repair open in wht #5
switch to TB5 OR

page.
Part No. 36540
5 - 67
CHART 16
Continued from the

previous page.

the turntable rotate right
the valve coil. See
Repair Section.
0 or
infinite
ohms
Replace the turntable

rotate right directional
valve coil.
23 to 25
ohms
Exchange the turntable
rotate and secondary
(items AE and AK or
items BE and BK or
items CX and CJ).
Activate the turntable
rotate RIGHT function.
function
operates
Replace defective
directional valve.
gauge at the quick
number 153 and
switch in the RIGHT
pressure.
number 153 and
move the turntable
check the pressure.
3200
PSI

turntable rotate left
OR repair or replace the
turntable rotation motor
OR consult Genie
Industries Service
Department.
less than 3200 PSI

valve (see Repair
or CR) OR repair or
replace the turntable
rotation motor OR
Service Department.
5 - 68
Part No. 36540
Chart 17
All Platform
Level
Functions
Inoperative
Be sure key switch
position.
Be sure the
Emergency Stop
buttons are pulled
out to the ON
position.
Be sure the battery
packs are properly
connected and fully
charged.

number 153 and
number 304: Remove
both hydraulic hoses
from the function
manifold (ports C1 and
C2). Plug the hoses and
cap the manifold fittings.
Move the primary boom
the UP direction. Does
the platform level?
Z-34/22 from serial
number 153 to 1733
and Z-34/22N from
2226: Remove both
hydraulic hoses from the
function manifold (ports
C1 and C2). Plug the
hoses and cap the
manifold fittings. Hold
the function enable
the platform level?
number 1733 and
number 2226: Remove
both hydraulic hoses
from the function
manifold (ports L1 and
L2). Plug the hoses and
cap the manifold fittings.
the platform level?
yes
Replace the
counterbalance valves
in the function manifold
(items AN and AO or
items BN and BO or
items CB and CC).
no

page.
Part No. 36540
5 - 69
CHART 17
Continued from the

previous page.
less than
2000 PSI Repair or replace the
number 153 and
master cylinder.
gauge into the barrelnumber 304: Plumb a 0
end hydraulic hose
(hose connected to
to 5000 psi (0 to 345
bar) pressure gauge into less than port C2 OR L2) from the
master cylinder rod-end 2000 PSI master cylinder and
raise the primary boom
hydraulic hose (hose
one inch (2.5 cm) at a
connected to port C1)
time. Continually
using a tee fitting. Move
monitor the pressure
the primary boom toggle
gauge while raising the
primary boom. Do not
allow the pressure to
exceed 2500 PSI.
number 152 and
number 303: Plumb a 0
2000 PSI or more
to 5000 psi (0 to 345
bar) pressure gauge into
master cylinder rod-end
hydraulic hose
slave cylinder.
number 1734 and
number 2227: (hose
connected to port C1)
number 1733 and
number 2226: (hose
connected to port L1)
using a tee fitting. Hold
the function enable
pressure.
2000 PSI
platform level function
from operating OR
replace the slave
valves.
5 - 70
Part No. 36540
Chart 18
Platform
Level Up
Function
Inoperative
Be sure key switch
position.
Be sure the
Emergency Stop
buttons are pulled
out to the ON
position.
Be sure the battery
packs are properly
connected and fully
charged.
Turn key switch to

both Emergency Stop
position.
number 153 and
platform level toggle
#6 wire at the boom
valve coil
(item AU).
Z-34/22 from serial
number 153 to 1733
and Z-34/22N from
#6 wire at the boom
valve coil
(item AU or BU).
number 1733 and
move the platform level
check the voltage on the
boom function
(item CH).
0V

number 153 and
TB6.
number 152 and
voltage at TB6.
24V

boom function
0V
Turn key switch to
pull both Emergency
boom function speed
press down the foot
switch and move the
switch
number 1734 and
number 2227: TS5
number 1733 and
number 2226: TS9
0V

to TB6.
24V
24V
Part No. 36540

page.
5 - 71
CHART 18
Continued from the

previous page.
Press down the foot

switch and move the
switch in the UP
speed controller.
0V

speed controller.
24V
Press down the foot
switch and move the
switch in the UP
wire on the boom
function speed
controller.
0V

boom function speed
replace the boom
function speed
controller.
24V
wire from the boom
to TB6.
5 - 72
Part No. 36540
CHART 18
Turn key switch to

both Emergency Stop
position.
number 153 and
number 304: Move
the org #14 wire on the
platform level up
(item AG).
number 152 and
move platform level
direction and check
voltage on the org #14
wire on the platform
level up directional valve
coil (item AG or BG or
CA).
0V

number 153 and
TB14.
number 152 and
direction and check
voltage at TB14.
24V
Repair open in org #14

platform level up
repair open in brn
manifold.
0V
Turn key switch to
pull both Emergency
boom function speed
press down the foot
switch and move the
switch
number 1734 and
number 2227: TS5
number 1733 and
number 2226: TS9
24V
0V

supply wiring to
switch
number 1734 and
number 2227: (TS14)
number 1733 and
number 2226: (TS59)
on ground controls OR
number 1734 and
number 2227: (TS5)
number 1733 and
number 2226: (TS9) on
the platform controls.
24V
Repair open in org-3
wire to TB14.

page.
Part No. 36540
5 - 73
CHART 18
Continued from the

previous page.
Disconnect the org wire

from the platform level
up directional valve coil.
the valve coil. See
Repair Section.
0 or
infinite
ohms
Replace platform level

23 to 25
ohms
Exchange the platform
level and secondary
(items AG, AL, and AE,
AJ or BG, BL and BE,
BJ or CA and CT).
Activate the platform
level UP function.
function
operates
Replace defective
directional valve.
level counterbalance
valves (items AN and
AO or items BN and BO
or items CC and CB).
level UP function.
function
operates
Replace defective
counterbalance valve.

page.
5 - 74
Part No. 36540
CHART 18
Continued from the

previous page.
Install a 0 to 3000 psi (0

gauge at the quick
disconnect coupling on 2800 psi
the boom function
manifold.
number 1734 and
platform level up toggle
switch and check the
pressure.
number 1733 and
up toggle switch and
check the pressure.

restrictions keeping
platform level up
function from moving
OR replace slave
valves OR consult
Department.
less than 2800 psi

Test master cylinder OR
repair or replace slave
cylinder or slave
valves OR boom
Service Department.
Part No. 36540
5 - 75
Chart 19
Platform
Level Down
Function
Inoperative
Be sure key switch
position.
Be sure the
Emergency Stop
buttons are pulled
out to the ON
position.
Be sure the battery
packs are properly
connected and fully
charged.
Turn key switch to

both Emergency Stop
position.
number 153 and
switch TS14 in the
DOWN direction and
boom function
(item AU).
Z-34/22 from serial
number 153 to 1733
and Z-34/22N from
switch TS14 in the
DOWN direction and
boom function
(item AU or BU).
number 1733 and
boom function
(item CH).
0V

number 153 and
switch in the DOWN
voltage at TB6.
number 152 and
DOWN direction and
TB6.
24V

boom function
0V
Turn key switch to
pull both Emergency
boom function speed
press down the foot
switch and move the
switch
number 1734 and
number 2227: TS5
number 1733 and
number 2226: TS9
0V

to TB6.
24V
24V
5 - 76

page.
Part No. 36540
CHART 19
Continued from the

previous page.
Press down the foot

switch and move the
switch in the DOWN
speed controller.
0V

speed controller.
24V
Press down the foot
switch and move the
switch in the DOWN
wire on the boom
function speed
controller.
0V

boom function speed
replace the boom
function speed
controller.
24V
wire from the boom
to TB6.
Part No. 36540
5 - 77
CHART 19
Turn key switch to

both Emergency Stop
position.
number 153 and
number 304: Move
switch in the DOWN
direction and check
voltage on the org #15
coil (item AL).
number 152 and
move platform level
DOWN direction and
check voltage on the org
#15 wire on the platform
coil (item AL or BL or
CB).
0V

number 153 and
switch in the DOWN
direction and check
voltage at TB15.
number 152 and
DOWN direction and
24V
Repair open in org/blk

#15 wire circuit from
TB15 to platform level
down directional valve
coil OR repair open in
brn ground wire circuit to
the manifold.
0V
Turn key switch to
pull both Emergency
boom function speed
press down the foot
switch, and move the
switch
number 1734 and
number 2227: TS5
number 1733 and
number 2226: TS9
24V

#15 wire to TB15.
24V
0V
supply wiring to
switch at ground
controls OR platform
controls.

page.
5 - 78
Part No. 36540
CHART 19
Continued from the

previous page.
Disconnect the org/blk

wire from the platform
level down directional
0 or
infinite
ohms
Replace platform level

coil.
23 to 25
ohms
level and turntable
rotate directional valves
(items AL and AJ or
items BL and BJ or
items CA and CT).
level DOWN function.
function
operates
Replace defective
directional valve.
level counterbalance
valves (items AN and
AO or items BN and BO
or items CB adn CC).
level DOWN function.
function
operates
Replace defective
counterbalance valve.
(345 bar) pressure
gauge at the quick
level down function and
check the pressure.
3200
PSI

platform level down
the slave cylinder or
slave cylinder
OR consult Genie
Industries Service
Department.
less than 3200 PSI
Test the master cylinder

(refer to Chart #16) OR
repair or replace the
slave cylinder
Industries Service
Department.
Part No. 36540
5 - 79
Chart 20
Platform
Rotate Left
Function
Inoperative
Be sure key switch
position.
Be sure the
Emergency Stop
buttons are pulled
up to the ON
position.
Be sure the battery
packs are properly
connected and fully
charged.
Turn key switch to

both Emergency Stop
position.
number 153 and
platform rotate toggle
#6 wire at the boom
Z-34/22 from serial
number 153 to 1733
and Z-34/22N from
#6 wire at the boom
valve coil
(item AU or BU).
number 1733 and
move the platform rotate
boom function
(item CH).
0V

number 153 and
switch in the LEFT
voltage at TB6.
number 152 and
move the platfrom rotate
voltage at TB6.
24V

to boom function
boom function
0V
Turn key switch to
pull both Emergency
boom function speed
press down the foot
switch and move the
switch
number 1734 and
number 2227: TS6
number 1733 and
number 2226: TS7
0V

to TB6.
24V
24V
5 - 80

page.
Part No. 36540
CHART 20
Continued from the

previous page.
Press down the foot

switch and move the
switch in the LEFT
speed controller.
0V

speed controller.
24V
Press down the foot
switch and move the
switch in the LEFT
boom function speed
controller.
0V

boom function speed
replace the boom
function speed
controller.
24V
wire from the boom
to TB6.
Part No. 36540
5 - 81
CHART 20
Turn key switch to

both Emergency Stop
position.
number 153 and
number 304: Move
switch in the LEFT
direction and check
voltage on the grn wire
on the platform rotate
left directional valve coil
(item D).
number 152 and
direction and check
voltage on the grn wire
(item D).
0V

number 153 and
switch in the LEFT
direction and check
voltage at TB17.
number 152 and
direction and check
voltage at TB17.
24V
Repair open in org wire

platform rotate left
manifold.
0V
Turn key switch to
pull both Emergency
boom function speed
press down the foot
switch and move the
switch in the LEFT
at platform rotate left
24V
Repair open in the

ground wire circuit on
the platform rotate left
directional coil.
0V
24V

supply wiring to
switch on ground
controls or on the
platform controls.

page.
5 - 82
Part No. 36540
CHART 20
Continued from the

previous page.
Disconnect the org wire

from the platform rotate
left directional valve coil.
the valve coil. See
Repair Section.
0 or
infinite
ohms
Replace platform rotate

.
23 to 25
ohms
rotate left and jib boom
up directional valves
(items D and A).
rotate LEFT function.
function
operates
Replace defective
directional valve.
gauge at the quick
the boom function
manifold and activate
the platform rotate LEFT
function.
Repair hydraulic rotation

less than motor OR platform
2800 psi rotate/jib function
Department.
2800 psi
Check for mechanial
platform rotate LEFT
OR the
number 1734 and
number 2227:
0.030" orifice (item W)
number 1733 and
number 2226:
0.025" orifice (item W)
could be plugged OR
repair hydraulic rotation
motor OR consult Genie
Industried Service
Department.
Part No. 36540
5 - 83
Chart 21
Platform
Rotate Right
Function
Inoperative
Be sure key switch
position.
Be sure the
Emergency Stop
buttons are pulled
out to the ON
position.
Be sure the battery
packs are properly
connected and fully
charged.
Turn key switch to

both Emergency Stop
position.
number 153 and
#6 wire at the boom
Z-34/22 from serial
number 153 to 1733
and Z-34/22N from
#6 wire at the boom
valve coil
(item AU or BU).
number 1733 and
boom function
(item CH).
24V
5 - 84
0V

number 153 and
switch in the RIGHT
voltage at TB6.
number 152 and
move the platfrom rotate
RIGHT direction and
TB6.
24V

to boom function
boom function
0V
Turn key switch to
pull both Emergency
boom function speed
press down the foot
switch and move the
switch
number 1734 and
number 2227: TS6
number 1733 and
number 2226: TS7
0V

to TB6.
24V

page.
Part No. 36540
CHART 21
Continued from the

previous page.
Press down the foot

switch and move the
switch in the RIGHT
boom function speed
controller.
0V

speed controller.
24V
Press down the foot
switch and move the
switch in the RIGHT
boom function speed
controller.
0V

boom function speed
replace the boom
function speed
controller.
24V
wire from the boom
to TB6.
Part No. 36540
5 - 85
CHART 21
Turn key switch to

both Emergency Stop
position.
number 153 and
number 304: Move
switch in the RIGHT
direction and check
voltage on the yel wire
right directional valve
coil (item B).
Z-34/22 from serial
number 153 to 1733
and Z-34/22N from
either side and move
switch in the RIGHT
direction and check
voltage on the yel wire
coil (item B).
number 1733 and
move platform rotate
RIGHT direction and
rotate right directional
valve coil (item B).
0V

number 153 and
switch in the RIGHT
direction and check
voltage at TB18.
number 152 and
RIGHT direction and
24V
Repair open in wire

platform rotate right
manifold.
0V
Turn key switch to
pull both Emergency
boom function speed
press down the foot
switch and move the
switch in the RIGHT
at the platform rotate
coil.
24V
Repair open in the

ground wire circuit on
the platform rotate right
directional coil.
0V
supply wiring to
switch on ground
controls OR on the
platform controls.
24V

page.
5 - 86
Part No. 36540
CHART 21
Continued from the

previous page.
Disconnect the wires

from the platform rotate
Repair Section.
0 or
infinite
ohms
Replace platform rotate

coil.
23 to 25
ohms
function
rotate right and jib boom operates
up directional valves
(item B and A). Activate
the platform rotate RIGHT
function.
Replace defective
directional valve.
gauge at the quick
the boom function
manifold and activate
the platform rotate right
function.
Repair hydraulic rotation

less than motor OR platform
3200 psi rotate/jib function
Department.
3200 psi
Check for mechanial
platform rotate right
OR the
number 1734 and
number 2227:
0.030" orifice (item C)
number 1733 and
number 2226:
0.025 orifice (item C)
could be plugged OR
repair hydraulic rotation
motor OR consult Genie
Industried Service
Department.
Part No. 36540
5 - 87
Chart 22
Jib Boom Up
Function
Inoperative
Be sure key switch
position.
Be sure the
Emergency Stop
buttons are pulled
out to the ON
position.
Be sure the battery
packs are properly
connected and fully
charged.
Turn key switch to

both Emergency Stop
position.
number 153 and
jib toggle switch TS16 in
boom function
(item AU).
Z-34/22 from serial
number 153 to 1733
and Z-34/22N from
boom function
(item AU or BU).
number 1733 and
move the jib toggle
#6 wire at the boom
20V or more
0V

number 153 and
jib toggle switch in the
UP direction and check
voltage at TB6.
number 152 and
move the jib toggle
TB6.
20V or
more

to boom function
boom function
0V
Turn key switch to
pull both Emergency
ON position. With boom
turned to 9, press down
the foot switch and
move the jib toggle
switch
number 1734 and
number 2227: TS7
number 1733 and
number 2226: TS8
0V
Troubleshoot jib function

toggle switches on
ground and platform
controls OR repair open
in wht/red #6 wire circuit
from ground controls
toggle switch to TB6 and
from platform controls
toggle switch to red wire
on boom function speed
controller OR consult
Department.
20V or more
toggle switch on ground
TB6 OR consult Genie
Industries Service
Department.
If voltage to TB6 from

toggle switch at ground
control and toggle
switch at platform
control has been
restored and jib up
function is still
inoperative, continue
trouble shooting from
beginning of chart.

page.
5 - 88
Part No. 36540
CHART 22
Continued from the

previous page.
Turn key switch to

both Emergency Stop
position.
number 153 and
number 304: Move jib
direction and check
voltage on the blk wire
on the jib up directional
valve coil (item A).
number 152 and
move jib toggle switch in
check voltage on the yel
wire on the jib up
(item A).
0V

number 153 and
UP direction and check
voltage at TB43.
number 152 and
move the jib toggle
TB43.
20V or
more
Repair open in the grn-1

to blk-jib wire circuit
from TB43 to the jib up
repair open in the
valve coil.
0V
Turn key switch to
pull both Emergency
boom function speed
press down the foot
switch and move the jib
on the blk-jib wire at jib
0V
Troubleshoot jib toggle

switches on ground and
platform controls OR
replace diodes on toggle
switches OR repair open
in grn-1 to blk-jib wire
circuit from toggle
switches to jib up
Service Department.
20V or more
20V or more

controls OR replace
OR repair open in grn-1
to blk-jib wire circuit
boom function
OR consult Genie
Industries Service
Department.
If voltage to boom
function directional valve
coil from ground toggle
switch and platform
toggle switch has been
restored and jib up
function is still
beginning of chart.

page.
Part No. 36540
5 - 89
CHART 22
Continued from the

previous page.

from the jib up
the valve coil. See
Repair Section.
0 or
infinite
ohms
Replace jib up
23 to 25
ohms
Exchange the jib up and function
operates
jib down directional
valves (item A and E).
Activate the jib up
function.
Replace defective
directional valve.
gauge at the quick
the boom function
manifold.
number 153 and
UP direction.
number 152 and
move the jib toggle
switch in the UP
direction.
2800
PSI

restrictions keeping jib
up function from moving
OR repair or replace jib
cylinder OR replace jib
valves OR consult
Department.
less than 2800 PSI

Repair or replace jib
valves OR platform
rotate/jib function
Department.
5 - 90
Part No. 36540
Chart 23
Jib Boom
Down
Function
Inoperative
Be sure key switch
position.
Be sure the
Emergency Stop
buttons are pulled
out to the ON
position.
Be sure the battery
packs are properly
connected and fully
charged.
Turn key switch to

both Emergency Stop
position.
number 153 and
boom function
(item AU).
number 152 and
move the jib toggle
switch TS16 in the
DOWN direction and
boom function
(item AU or BU).
number 1733 and
move the jib toggle
switch TS58 in the
DOWN direction and
boom function
(item CH).
20V or more
0V

number 153 and
DOWN direction and
TB6.
number 152 and
move the jib toggle
switch in the DOWN
voltage at TB6.
20V or
more

to boom function
boom function
0V
Turn key switch to
pull both Emergency
boom function speed
press down the foot
switch and move the jib
toggle switch
number 1734 and
number 2227: TS7
number 1733 and
number 2226: TS8
0V

toggle switches on
ground and platform
from ground controls
toggle switch to TB6 and
from platform controls
toggle switch to red wire
on boom rotary speed
Department.
20V or more
Industries Service
Department.
If voltage to TB6 from

toggle switch at ground
control and toggle
switch at platform
control has been
restored and jib down
function is still
beginning of chart.

page.
Part No. 36540
5 - 91
CHART 23
Continued from the

previous page.
Turn key switch to

both Emergency Stop
position.
number 153 and
number 304: Move
platform jib toggle switch
in the DOWN direction
the wht wire on the jib
coil (item E).
number 152 and
move jib toggle switch in
wht wire on the jib down
(item E).
0V

number 153 and
DOWN direction and
number 152 and
move the jib toggle
switch in the DOWN
direction and check
voltage at TB44.
20V or
more
Repair open in grn/blk-1

to wht-jib wire circuit
from TB44 to jib down
repair open in ground
wire circuit to valve coil.
0V
Turn key switch to
pull both Emergency
boom function speed
press down the foot
switch. Hold the jib
function toggle switch in
check voltage on wht-jib
wire on jib down
0V

toggle switches on
ground and platform
controls OR replace
diodes on toggle
switches OR repair open
in grn/blk-1 to wht-jib
switches to jib down
Service Department.
20V or more
20V or more

controls OR replace
OR repair open in grn-1
to sht-jib wire circuit
from toggle switch to jib
coil OR consult Genie
Industries Service
Department.
If voltage to jib down

from ground toggle
switch and platform
toggle switch has been
restored and jib up
function is still
beginning of chart.

page.
5 - 92
Part No. 36540
CHART 23
Continued from the

previous page.

from the jib down
the valve coil. See
Repair Section.
0 or
infinite
ohms
Replace jib down

23 to 25
ohms
Exchange the jib up and function
operates
jib down directional
valves (item A and E).
Activate the jib down
function.
Replace defective
directional valve.
gauge at the quick
the boom function
manifold.
number 153 and
DOWN direction.
number 152 and
move the jib toggle
switch in the DOWN
direction.
3200
PSI

restrictions keeping jib
down function from
moving OR repair or
replace jib cylinder OR
replace jib cylinder
OR consult Genie
Industries Service
Department.
less than 3200 PSI

Repair or replace jib
valves OR platform
rotate/jib function
Department.
Part No. 36540
5 - 93
Chart 24
Steer Left
Function
Inoperative
(Z-34/22 before
serial number 1734
and
Z-34/22N before
serial number 2227)
Be sure key switch is
in the appropriate
position.
Be sure the
Emergency Stop
buttons are pulled out
to the ON position.
Be sure the battery
packs are properly
connected and fully
charged.
Be sure all other
functions operate
normally.
Turn key switch to

pull both Emergency
the foot switch and
press the steer rocker
switch in the LEFT
direction and check
voltage on TB36.
0V
0V

steer microswitch OR
Service Department.
20V or more
wire circuit from drive
controller to TB36.
20V or more
Press down the foot

switch and press the
steer rocker switch in
check voltage on TB19.
Press down the foot

drive contoller terminal
with the blu-1 wire
attached.
0V

TB36 to TB19.
20V or more
Press down the foot
check voltage on blu
#36 wire at the steer left
(item I) on the
steer/brake manifold.
0V
20V or
more

from the steer left
the valve coil. See
Repair Section.
0 or
infinite
ohms
Replace steer left

20 to 25 ohms
gauge at the quick
the boom function
manifold. Press down
the foot switch and
switch in the LEFT
pressure.
2800 psi

steer left function from
moving OR the 0.085"
orifice (item O) is
plugged OR repair or
replace steer cylinder
OR consult Genie
Industries Service
Department.
less than 2800 psi

Repair or replace steer
cylinder OR the
steer/brake function
internal defect OR
Service Department.
the steer left directional
valve coil.
5 - 94
Part No. 36540
Chart 25
Steer Left
Function
Inoperative
(Z-34/22 after
serial number 1733
and
Z-34/22N after
serial number 2226)
in the appropriate
position.
Be sure the
Emergency Stop
buttons are pulled
out to the ON position.
Be sure the battery
packs are properly
connected and fully
charged.
Be sure all other
functions operate
normally.
Turn key switch to

pull both Emergency
the foot switch and
switch on the drive
controller in the LEFT
at TB36.
0V
0V

steer microswitch on the
the drive controller OR
Service Department.
20V or more
controller terminal "9" to
TB36.
20V or more
Press down the foot

the LEFT direction.
Press down the foot

the LEFT direction.
Check voltage at
terminal "9" on the drive
controller.
0V

#19 wire circuit with
diode from TB36 to
TB19 OR replace the
diode.
20V or more
Press down the foot
the LEFT direction.
blu #36 wire at the steer
(item CJ).
0V

the steer left directional
valve coil OR repair
circuit to the function
manifold.
20V or more
wire to the steer left
the valve coil. See
Repair Section.
0 or
infinite
ohms
Replace steer left

23 to 25
ohms

page.
Part No. 36540
5 - 95
CHART 25
Continued from the

previous page.
function
Exchange the steer
operates
directional valve (item
CJ) with the turntable
(item CX). Test the steer
left function.
Replace defective
directional valve.
gauge at the quick
Press down the foot
check the pressure.
3200
PSI

steer right function from
operating OR the 0.045"
orifice (item CN) may be
replace the steer
cylinder OR consult
Department.
less than 3200 psi

steer cylinder OR the
function manifold may
Service Department.
5 - 96
Part No. 36540
Chart 26
Steer Right
Function
Inoperative
(Z-34/22 before
serial number 1734
and
Z-34/22N before
serial number 2227)
in the appropriate
position.
Be sure the
Emergency Stop
buttons are pulled up
to the ON position.
Be sure the battery
packs are properly
connected and fully
charged.
Be sure all other
functions operate
normally.
Turn key switch to

pull both Emergency
the foot switch and
switch in the RIGHT
direction and check
voltage on TB37.
0V
0V

steer microswitch OR
Service Department.
20V or more
Repair open in blu/blk-1
drive controller to TB36.
20V or more
Press down the foot

Press down the foot

drive controller terminal
where the blu/blk-1 wire
is attached.
0V
Repair open in wire

TB37 to TB19.
20V or more
Press down the foot
check voltage on blu/blk
#37 wire at the steer
coil (item I) on the steer/
brake manifold.
0V
20V or
more

from the steer right
the valve coil. See
Repair Section.
0 or
infinite
ohms
Replace steer right

20 to 25 ohms
gauge at the quick
the boom function
manifold. Press down
the foot switch and
switch in the RIGHT
pressure.
3200
PSI

moving OR the 0.085"
orifice (item O) is
replace steer cylinder
OR consult Genie
Industries Service
Department.
less than 3200 PSI

Repair or replace steer
cylinder OR the steer/
brake function manifold
defect OR consult Genie
Industries Service
Department.
Repair open in blu/blk
TB37 to the steer right
Part No. 36540
5 - 97
Chart 27
Steer Right
Function
Inoperative
(Z-34/22 after
serial number 1733
and
Z-34/22N after
serial number 2226)
in the appropriate
position.
Be sure the
Emergency Stop
to the ON position.
Be sure the battery
packs are properly
connected and fully
charged.
Be sure all other
functions operate
normally.
Turn key switch to

pull both Emergency
the foot switch and
switch on the drive
controller in the RIGHT
at TB37.
0V
20V or
more
Repair open in blu/blk -1

controller terminal "10"
to TB37.
0V
steer microswitch on the
Service Department.
20V or more
Press down the foot

the RIGHT direction.
Check voltage on TB19.
Press down the foot

Check voltage at
terminal "10" on the
drive controller.
0V

#19 wire circuit with
diode from TB37 to
TB19 OR replace the
diode.
20V or more
Press down the foot
blu/blk #37 wire at the
steer right directional
valve coil (item CJ).
0V
Repair open in blu/blk

TB37 to the steer right
repair open in brn
function manifold.
20V or more
Disconnect the blu/blk
#37 wire to the steer
Repair Section.
0 or
infinite
ohms
Replace steer right

23 to 25
ohms

page.
5 - 98
Part No. 36540
CHART 27
Continued from the

previous page.
function
Exchange the steer
operates
directional valve
(item CJ) with turntable
(item CX). Test the steer
left function.
Replace defective
directional valve.
(345 bar) pressure
gauge at the quick
Press down the foot
check the pressure.
3200
PSI

operating OR the 0.450"
orifice (item CN) may be
replace the steer
cylinder OR consult
Department.
less than 3200 psi

steer cylinder OR the
function manifold may
Service Department.
Part No. 36540
5 - 99
Chart 28
All Drive
Functions
Inoperative,
All Other
Functions
Operate
Normally
function
Turn key switch to
operates
pull both Emergency
the foot switch and hold
the drive enable toggle
switch TS9 to either side
and move the drive
controller in the
FORWARD direction.
(Z-34/22 before
serial number 1734
and
Z-34/22N before
serial number 2227)
Be sure the unit is in
the fully stowed
position with the
boom located
between the drive
tires.
Press down the foot

switch and check
voltage at TB16.
20V or
more
0V
Press down the foot
switch and check
voltage at TB12.
Be sure the battery

packs are properly
connected and fully
charged.
0V
20V or
more

number 153 and
number 304: Repair
open in org/red wire
circuit from TB16 to "+"
terminal on the drive
controller.
number 152 and
number 303: Repair
open in org/red wire
circuit from TB16 to CR5
OR repair open in
CR5 to ground OR
repair open in blu/wht
wire circuit from center
pole at TS9 to CR5 OR
repair open in wire
circuit from CR5 to
CR5.
Repair open in wire

circuit from TB12 to LS3
OR repair open in wire
circuit from TB16 to LS3
OR replace LS3.
Repair open in blu/wht-3

Industries Service
Department.
Check voltage from Bterminal on the motor

controller to input side of
500A fuse F1.
less than Repair open in power

48V
cable from battery packs
to F1 OR ground cable
to B- terminal on the
motor controller.
48V or more

page.
5 - 100
Part No. 36540
CHART 28
Continued from the

previous page.
Check voltage on output

side of 500A fuse F1.
0V
Replace 500A F1.
48V or more
positive cable at input
side of PR1.
0V
Repair open in positive

cable from output
terminal of 500A fuse F1
to input side of PR1.
48V
Press down the foot
switch and move the
drive controller in the
FORWARD direction and
positive cable on output
side of PR1.
0V
Repair open in wire

circuit from terminal #1
on the motor controller
to PR1 OR repair open
in the ground wire circuit
from PR1 to ground OR
replace PR1 contacts
OR replace PR1 OR
Service Department.
48V
Block the steer wheels

and raise the machine
so the drive tires are off
the ground. Place blocks
under the drive chassis
for support. Disconnect
wht wire on forward/
reverse contactor PR2.
With key switch turned
to platform controls and
both Emergency Stop
buttons pulled out to the
ON position, press down
the foot switch and
move the drive controller
to full FORWARD
direction and try to
rotate the drive tires by
hand. Note: this will
require 2 people.
tires
don't
move
Go to Chart 28A, Brake

Function Inoperative.
tires move

page.
Part No. 36540
5 - 101
CHART 28
Continued from the

previous page.
less
Connect wht wire to
than
forward/reverse
48V
contactor PR2. Press
down the foot switch and
to full FORWARD direction
positive cable on output
side of PR1.
Press down the foot

switch and move the
drive controller to full
check voltage at org/blk
wire on PR1.
20V or
more

wire circuit to PR1 OR
replace PR1.
0V
Press down the foot
switch and move the
drive contoller to full
check voltage at org/blk
wire at TB41.
20V or
more

PR1.
0V
Press down the foot
switch and move the
check voltage at
terminal "X" on the drive
controller.
20V or
more

"X" on the drive
controller to TB41.
0V
48V or more
Press down the foot

switch and move the
check voltage at
controller.
20V or more

drive controller.
0V

number 153 and
number 304: Repair
open in power circuit
from drive enable toggle
switch TS9 to TB12 to
LS3 to TB16 to "+"
terminal on the drive
controller.
number 152 and
number 303: Repair
open in power circuit
from drive enable toggle
switch TS9 to TB12 to
LS3 to TB16 to CR5 to
replace CR5 OR consult
Department.

page.
5 - 102
Part No. 36540
CHART 28
Continued from the

previous page.
Press down the foot

switch and move the
check voltage at
terminal B+ on the motor
controller.
0V

cable from PR1 to
terminal B+ on the motor
controller.
48V or more
Press down the foot
switch and move the
check voltage at A1
terminal on the left drive
motor.
0V

cable from PR1 to
terminal A1 on the left
drive motor.
48V or more
Press down the foot
switch and move the
check voltage on
terminal #1 on the motor
controller.
0V

controller.
20V or more

page.
Part No. 36540
5 - 103
CHART 28
Continued from the

previous page.
Check voltage at
controller. Voltage
should ramp up from 0V
to 5V.
bad
Press down the foot

switch and slowly move
the drive controller from
neutral to full stroke in
the FORWARD direction
TB3. Voltage should
ramp up from 0V to 5V.
good

controller.
bad
good

number 153 and
number 304: Press
slowly move the drive
controller from neutral to
full stroke in the
check voltage at
terminal "A" on the drive
controller. Voltage
to 5V.
number 152 and
number 303: Press
full stroke in the
check voltage at
terminal "D" on the drive
controller. Voltage
to 5V.
good

number 153 and
number 304: Repair
open in red/wht wire
circuit from terminal "A"
at the drive controller to
TB3 to #3 terminal on
number 152 and
number 303: Repair
circuit from terminal "D"
at the drive controller to
TB3 to #3 terminal on
bad
Adjust the drive
controller OR refer to
Chart 33 OR repair or
replace the drive
Department.

page.
5 - 104
Part No. 36540
CHART 28
Continued from the

previous page.
Disconnect wht wire on

the forward/reverse
contactor PR2. Connect
a volt meter to terminals
B+ and M- on the motor
controller. Press down
the foot switch and
full stroke in the
FORWARD direction.
Voltage should ramp up
from 0V to 48V.
bad
Replace the motor

controller.
good
Connect wht wire on
forward/reverse
contactor PR2. Connect
a volt meter to terminals
B+ and M- on the motor
controller. Press down
the foot switch and
full stroke in the
FORWARD direction.
Voltage should ramp up
from 0V to 48V.
bad
Disconnect the battery

packs from the machine
and disconnect the
positive cable from
terminal A2 on the motor
controller. Using an
ohmmeter, check
resistance in both
directions across
terminals A2 and B+ on
Resistance should be
high in one direction and
low in the other.
bad
Replace motor
controller.
good
good

bad motor OR consult
Department.
Repair open in cable

circuit from the motor
controller to PR2 to the
drive motors OR repair
open in the ground wire
circuit from PR2 coils to
ground OR repair or
replace PR2 OR repair
or replace the bad motor
OR consult Genie
Industries Service
Department.
Part No. 36540
5 - 105
Chart 28A
Brake
Function
Inoperative
(Z-34/22 before
serial number 1734
and
Z-34/22N before
serial number 2227)
Turn key switch to

pull both Emergency
ON position, press down
the foot switch and
in the FORWARD direction
until the first micro
switch activates. Check
voltage at TB19.
Be sure the drive

hubs are not
disengaged
0V
Press down the foot

switch and move the
FORWARD direction until
the first micro switch
activates and check
voltage at TB47.

from pressure switch
(item K) to TB19 OR
replace pressure switch
OR repair open in wire
circuit from TB47 to the
brake release valve N.C.
(item K) to pressure
switch.
0V
Press down the foot

switch and move the
activates and check
voltage at TB41.
Be sure the remote

brake release is
removed.
20V or
more
20V or
more

from TB41 to TB47 OR
replace diode.
0V
Press down the foot
switch and move the
activates and check
voltage at terminal "X"
20V or more
20V or
more

"X" on the drive
controller to TB41.
0V
Press down the foot
switch and move the
joystick in the FORWARD
direction until the first
micro switch activates
controller.
0V

circuit from drive enable
TB12 to LS3 to TB16 to
terminal "+" on drive
LS3 OR consult Genie
Industries Service
Department.
20V or more
Repair or replace drive
controller. Consult
Department.

page.
5 - 106
Part No. 36540
CHART 28A
Continued from the

previous page.
Press down the foot

switch and move the
the 1/2 stroke micro
switch activates and
check voltage at red/wht
and ground wires on 1/2
stroke brake release
valve (item H).
0V
Press down the foot

switch and move the
20V or
more

the brake release valve.
0V
Press down the foot
switch and move the
check voltage at red/wht
wire on 1/2 stroke micro
switch on drive
controller.
20V or
more

wire with diode from 1/2
stroke micro switch on
20V or more
0V
Repare or replace drive
Department.
Disconnect red/wht #29

and ground wires from
1/2 stroke brake release
0 or
infinite
ohms
Replace brake release

valve coil.
22 to 24 ohms

page.
Part No. 36540
5 - 107
CHART 28A
Continued from the

previous page.
Press down the foot

switch and move the
switch activates. Check
voltage at red wire on
brake release valve N.C.
(item L).
0V
Repair open in red #47

pressure switch to brake
release valve N.C. OR
repair open in ground
wire circuit from brake
release valve N.C. coil
to ground.
20V or more
from the brake release
valve N.C. coil. Test the
0 or
infinite
ohms

valve N.C. coil.
22 to 24 ohms
Connect an ammeter in
series with wht/red wire
and brake proportional
valve coil (item N).
Press down the foot
switch and move the
switch activates. Does
the amperage increase
proportionally from 0.10
amps to 0.90 amps at
1/2 stroke of drive
controller?
no

from the brake
the proportional valve
coil (item N). See Repair
Section.
18 to 20
ohms
0 or infinite ohms
Replace brake
Adjust drive controller

(See Repair Section)
OR repair open in wht/
red-1 wire circuit from
number 153 and
number 304: terminal
"A" on drive controller to
TB32
Z-34/22 from serial
number 153 to 1733
and Z-34/22N from
2226: terminal "B" on
drive controller to TB32
proportional brake
release valve coil OR
repair or replace drive
Department.
yes

page.
5 - 108
Part No. 36540
CHART 28A
Continued from the

previous page.
Press down the foot

switch and move the
FORWARD direction to full
stroke and check
voltage at TB19.
20V

gauge at the quick
Press down the foot
switch and move the
check pressure.
1200 psi
Replace pressure switch

(item K) OR consult
Department.
less than 1200 psi

0V

gauge at the quick
Press down the foot
switch and move the
check pressure.

valve half stroke (item
G) OR replace brake
proportional valve OR
Service Department.
less than Replace pressure switch

1200 psi OR consult Genie
Industries Service
Department.
1200 psi
restriction keeping drive
OR consult Genie
Industries Service
Department.
Part No. 36540
5 - 109
Chart 29
All Drive
Functions
Inoperative, all
Other Functions
Operate
Normally
(Z-34/22 after
serial number 1733 and
Z-34/22N after
serial number 2226)
Troubleshooting drive
function faults may also
be accomplished by using
the hand-held pendant
motor controller
programmer (Genie part
number 56303).

so the drive tires are off
the ground. Turn key
switch to platform
controls and pull both
out to the ON position.
Press down the foot
switch and move the
drive controller in either
direction. Have
someone try to rotate
the drive tires by hand.
Note: this will require 2
people.
Press down the foot

switch and move the
drive contoller in the
FORWARD direction.
Check voltage at
terminal #5 on the drive
controller.
Press down the foot

switch and check
voltage on terminal #4
0V
Replace the drive

controller.
20V or more
0V
Repair open in the wht-1

#4 on the drive
controller to TB30 to pin
10 on the motor
controller harness
connector.
20V or more
0V
Press down the foot

switch and move the
REVERSE direction.
Check voltage on
controller.
0V
Replace the drive

controller.
20V or more
Press down the foot
switch and move the
REVERSE direction.
Check voltage at pin 11
harness connector.
Be sure the machine is

not in the free wheel
configuration.
5 - 110
20V or
more
Press down the foot

switch and move the
FORWARD direction.
harness connector.
Be sure the batteries are

properly connected and
fully charged.
Be sure the unit is in the

fully stowed position with
the boom located
between the non-steer
end tires.
Go to Chart 30, Brake

Release Function
Inoperative.
tires move
Be sure to check the

motor controller status
indicator light on the
ground control box or on
the motor controller. If the
indicator light is flashing a
fault code, refer to the
fault code chart at the
beginning of this section.
Be sure the circuit
breakers and fuses are
tires
don't
move

page.
0V
Repair open in the wht/

blk-1 wire from terminal
#3 on the drive
controller to TB31 to pin
11 on the motor
controller harness
connector.
20V or more
See Chart 29A, Motor
Controller Fault Code
21: Throttle Fault.
Part No. 36540
CHART 29
Continued from the

previous page.
Press down the foot

switch and move the
at TB16.
20V or
more
Repair open in org/red

controller.
0V
Press down the foot
switch and move the
at terminal #13 on LS3.
20V or
more
Repair open in red-5

#13 on LS3 to TB16.
0V
Press down the foot
switch and move the
at terminal #14 on LS3.
20V or
more
Replace LS3.
0V
Press down the foot
switch and move the
at TB12.
20V or
more

terminal #14 on LS3.
0V
Press down the foot
switch and move the
at the center terminal at
TS15.
Press down the foot

switch and move the
at terminal #2 at the
motor controller.
20V or
more
20V or
more

center terminal at TS15
to TB12.
Repair open in blu/wht

terminal #2 at the motor
controller to TB12.
0V
Replace the motor
controller OR contact
Department.
Part No. 36540
5 - 111
Chart 29A
Motor
Controller Fault
Code 21:
Throttle Fault
(Z-34/22 after serial
number 1733 and
number 2226)
be accomplished by
using the hand-held
pendant motor controller
number 56303).
the motor controller. If
status indicator light is
flashing a fault code,
refer to the fault code
chart at the beginning of
this section.
Be sure the circuit
Be sure the battery
packs are properly
connected and fully
charged.
Turn key switch to the

OFF position and
disconnect motor
controller harness
connector from the
motor controller.
Connect the leads from
an ohmmeter to pins 14
and 16 on the connector
(pins 14 and 16 are the
wht/red and red/wht
wires). Check the
resistance.
less
than
4000
ohms

circuit from the
potentiometer to
terminals1 and 2 on the
drive controller OR
replace the drive
controller.
greater
than
7500
ohms
Repair open in the

ground wire circuit in the
red/wht or wht/red wires
from pins 14 and 16 to
terminals #1 and #2 on
replace the drive
controller.
no
Replace the drive

controller.
4000 to
7500 ohms

so drive tires are off the
ground.
With the leads from an
ohmmeter connected to
pins 14 and 16 on the
connector, move the
drive controller slowly to
full stroke in both the
FORWARD and REVERSE
directions while
watching the ohm meter.
Does the resistance
ramp smoothly down to
10 ohms or less in both
directions?
Note: This will require 2
people.
yes
Begin troubleshooting
from the beginning of
the chart OR consult
Department.

configuration.
fully stowed position
with the boom located
end tires.
5 - 112
Part No. 36540
Chart 29B
Motor Controller
Fault Code 32:
Main Contactor
Welded
number 1733 and
number 2226)
be accomplished by
using the hand-held
number 56303).
Disconnect the battery

packs from the machine.
Visually inspect the
contacts on PR1. Are
the contacts stuck
closed?
Test the resistance

between terminals Mand B+ on the motor
controller.
Note: An ohmmeter
capable of reading 1
ohm or less is needed
for this test.
1 ohm or
less
Remove the grn wire

from PR1. Check
continuity from the grn
wire that was just
removed from PR1 to
the B- terminal on the
motor controller.
Part No. 36540
Test the resistance

more than between terminals A1
1 ohm
and A2 on each drive
motor. Is the resistance
1 ohm or less on each
drive motor?
no
Replace the drive motor

that has a resistance of
more than 1 ohm.
yes
Repair open in motor
armature cables from
terminals M- and B+ on
the motor controller to
each drive motor.
less than Remove the motor

controller harness
500
kilohms connector from the
motor controller. Check
continuity from the grn
wire that was just
removed from PR1 to
the B- terminal on the
motor controller.
less than
Repair open in the
500
kilohms ground wire circuit from
pin 17 on the motor
controller harness
connector to PR1.
more
than 500
kilohms
more
than 500
kilohms

configuration.
the boom located
end tires.
Replace drive contactor

PR1 contacts OR
replace the drive
contactor PR1.
no
Be sure the circuit

Be sure the battery packs
are properly connected
and fully charged.
yes
Check continuity from

pin 17 (grn wire) on the
motor controller to the
B- terminal on the motor
controller.
less than
500
kilohms Replace the motor
controller.
more
than 500
kilohms
Please begin
troubleshooting from
beginning of chart.
Please begin
beginning of chart.
5 - 113
Chart 29C
Motor Controller
Fault Code 34:
Missing Main
Contactor OR
Main Contactor
Did Not Close
number 1733 and
number 2226)

ground. Turn key switch
to platform controls and
pull both Emergency
the foot switch and
check the voltage at pin
1 on the motor controller
harness connector.

from TB42 to pin 1 on
harness connector OR
replace the diode.
0V

platform Emergency
Stop button P2.
0V

wire from TB3 to
0V
Repair open in brn

ground OR repair open
in wire from terminal #87
on CR2 to terminal #30
on CR1 OR repair open
in org/red #CR2 from
the 10A fuse F5 to
replace CR2.
0V
Repair open in brn

ground wire from
in red/wht wire from TB3
to terminal #85 on CR1
OR replace CR1.
24V
Check the voltage at
48V
48V
Check the voltage at

48V
Be sure the battery packs

are properly connected
and fully charged.

wire from terminal #87
on CR1 to TB42.

configuration.
5 - 114
48V
0V
Check voltage at
Be sure the circuit


the boom located
end tires.
Press down the foot

switch and check the
voltage at TB42.
24V
be accomplished by using
the hand-held pendant
motor controller
number 56303).
0V

page.
Part No. 36540
CHART 29C
Continued from the

previous page.

battery cable on the
input side of PR1.
0V
Repair open in cable

circuit from battery
packs to 500A fuse F4
OR replace the 500A
fuse F4.
0V

wire from TB12 to
terminal "A" on the
joystick controller.
48V
Press down the foot

switch and check
voltage at TB12.
20V or more
Press down the foot
switch and check
voltage at pin 2 on the
motor controller harness
connector.
0V

wire from TB12 to pin 2
harness connector.
20V or more
Turn key switch to the
OFF position. Wait for 5
seconds and turn the
key switch to platform
controls. Do not press
down the foot switch.
Check voltage at the grn
wire on PR1.
0V

org/red wire at PR1.
48V
Replace PR1.
0V
PR1.
48V
Remove the diode from
PR3 and install it onto
PR1 with the band on
the diode aligned with
the org/red-42 wire.
Push in the Emergency
Stop button to the OFF
position and wait for 5
seconds, then pull out
the Emergency Stop
button to the ON
position. Press down the
foot switch and test the
drive function. Does the
machine drive?
yes
Install a new diode onto

PR3 with the band on
the diode aligned with
the red-27 wire.
no
page.
Part No. 36540
5 - 115
CHART 29C
Continued from the

previous page.
Check voltage between

the terminals B+ and Bon the motor controller.
Note the voltage. Press
check voltage between
pin 1 on the motor
controller harness
connector and terminal
B-. Is the voltage within
1V of the first reading?
yes
no
Disconnect the batteries

from the machine.
Remove the PR1
mounting fasteners.
Clean all 4 contact tips
until they are clean and
smooth. Install the
contactor onto the
power panel and
connect the batteries.
Turn key switch to
pull both Emergency
the foot switch and test
the drive function. Does
the machine drive?
yes
Drive function should be

operating normally. If it
does not, begin
beginning of chart.
no
Replace the motor
controller.
Repair open in grn wire

from PR1 to pin 17 OR
replace PR1 OR test the
motor controller. See
Repair Section.
5 - 116
Part No. 36540
Chart 30
Brake Release
Function
Inoperative
number 1733 and
number 2226)
Be sure all other
functions operate
normally.
Troubleshooting brake
release faults may also
be accomplished by
using the hand-held
number 56303).
the motor controller. If
status indicator light is
flashing a fault code,
refer to the fault code
this section.
Be sure the battery
packs are properly
connected and fully
charged.
Be sure the circuit
fully stowed position
with the boom located
end tires.
Turn key switch to

pull both Emergency
the foot switch and
check the status
motor controller to see if
there is a fault. Is there
a fault?
yes
Refer to the fault code

this section to determine
the cause of the fault.
no
ground. With key switch
turned to platform
controls and both
pulled out to the ON
position, press down the
foot switch and move
the drive controller in
either direction and
0V
Press down the foot

switch and move the
voltage at TP41.
0V
See Chart 38, Drive

Enable System
Inoperative.
24V
wire from TB41 to TP41.
24V
Press down the foot
switch and move the
direction and check
on CR5.
0V

#41 wire from TB41 to
24V
Press down the foot
switch and move the
direction and check
on CR5.
0V
Do not press down the

foot switch. Check
voltage at the red/blk
wire on pin 20 of the
connector.
0V

repair open in red/blk
wire from pin 20 to
replace CR5.
48V
24V

page.
Press down the foot

switch and check
voltage at the red/blk
wire on pin 20 of the
connector.
0V
Replace the motor

controller.
24V
Replace CR5.
Part No. 36540
5 - 117
CHART 30
Continued from the

previous page.
Press down the foot

switch and move the
direction and check
voltage at TB48.
0V

#48 wire from terminal
#87 on CR5 to TB48 OR
replace diode.
24V
Insert a jumper wire
between TB48 and
TB19. Press down the
either direction. Does
the power unit turn on?
yes
Remove the pressure

switch plug and place a
jumper between
terminals 1 and 2 on the
plug. Press down the
either direction. Does
the power unit turn on?
yes
Replace the pressure

switch.
no
#48 wire from TB48
through red/wht wire
circuit to pressure
switch, then grn/wht #19
wire with diode to TB19
OR replace the diode.
no
Press down the foot

switch and move the
on the red/wht wires on
the brake release valve
coils (items G and K).
0V

wires from TB48 to the
brake release valve
coils (items G and K).
24V
Remove the brake
release valve coil and
clean the coil contact
rings on both ends of
the coil. Then install the
coil onto the valve
cartridge. Drive the
machine. Do the brakes
release?
yes
Drive and brake release

functions should be
operating normally. If
they do not, begin
beginning of chart.
no
page.
5 - 118
Part No. 36540
CHART 30
Continued from the

previous page.
Check continuity from

the brake release valve
cartridge to the ground
bolt inside the ground
control box.
no
continuity
Repair open in brn

the function manifold to
the ground bolt inside
the ground control box.
continuity
from each of the valve
coils and check the
coils. See Repair
Section.
0 or
infinite
ohms
Replace defective valve

coil.
22 to 25
ohms
Service Department.
Part No. 36540
5 - 119
Chart 31
Drive Forward
Function
Inoperative
(Z-34/22 before
serial number 1734
and
Z-34/22N before
serial number 2227)
in the appropriate
position.
Be sure the
Emergency Stop
to the ON position.
Be sure the battery
packs are properly
connected and fully
charged.
Turn key switch to

pull both Emergency
the footswitch and move
the drive controller in the
check voltage on wht/blk
#31 wire on forward
contactor PR2.
20V or
more
0 or
Remove wht/blk #31 and infinite
ground wires from PR2 ohms
coil and check
resistance of forward
coil.
Repair or replace PR2.
40 ohms
Repair or replace PR2
contacts OR repair open
in ground wire circuit OR
Service Department.
0V
Press down the foot

switch and move the
20V or
more
Repair open in white/blk

TB31 to the forward
contactor.
20V or
more
Repair open in wire

circuit from wht/blk-1
wire on micro switch on
0V
Press down the foot
switch and move the
check voltage on wht/
blk-1 wire on micro
switch on the drive
controller.
0V
Repair or replace micro
switch on the drive
controller OR drive
controller cams are out
of adjustment. Consult
Department.
5 - 120
Part No. 36540
Chart 32
Drive Reverse
Function
Inoperative
(Z-34/22 before
serial number 1734
and
Z-34/22N before
serial number 2227)
in the appropriate
position.
Be sure the
Emergency Stop
to the ON position.
Be sure the battery
packs are properly
connected and fully
charged.
Turn key switch to

pull both Emergency
the foot switch and
in the REVERSE direction
wht #30 wire on forward/
reverse contactor PR2.
20V or
more
Remove wht #30 and

ground wires from PR2
coil and check
resistance of reverse
coil.
0 or
infinite
ohms
Repair or replace PR2.
40 ohms
Repair or replace PR2
contacts OR repair open
in ground wire circuit OR
Service Department.
0V
Press down the foot

switch and move the
REVERSE direction and
20V or
more
Repair open in wht #30

forward/reverse
contactor.
20V or
more
Repair open in wire

circuit from wht-1 wire
on micro switch on the
0V
Press down the foot
switch and move the
REVERSE direction and
check voltage on wht-1
wire on micro switch on
the drive controller.
0V
Repair or replace micro
switch on the drive
controller OR drive
controller cams are out
of adjustment. Consult
Department.
Part No. 36540
5 - 121
Chart 33
Machine Will
Not Drive At
Full Speed
(Z-34/22 before
serial number 1734
and
Z-34/22N before
serial number 2227)
Be sure the unit is in
the fully stowed
position with the
boom located
between the nonsteer end tires.
Turn key switch to

pull both Emergency
ON position. Check
voltage on "R" terminal
0V
20V or
more
20V or
more
Adjust the drive

controller (See Repair
Section) OR repair or
replace drive controller
OR consult Genie
Industries Service
Department.
Repair open in org-1

"R" terminal on the drive
controller.
0V
Be sure the battery

packs are properly
connected and fully
charged.
0V
20V or
more
Repair open in wire

circuit from
number 153 and
number 304: TB23 to
LS1 to TB49 to LS2 to
TB40. Z-34/22 from
1733 and Z-34/22N
from serial number
304 to 2226: TB23 to
LS1 to TB49 to LS2 to
TB52 to LS4 to TB40.
Repair open in the wht-2

from the platform
to TB23 OR replace the
diode.
5 - 122
Part No. 36540
Chart 34
Machine Will
Not Drive At
Full Speed
number 1733 and
Z-34/22N after
serial number 2226)
Be sure all other
functions operate
normally.
Be sure the boom is in
the stowed position
with the primary boom
fully retracted.
Be sure the primary
boom extension limit
switch (LS1) is being
activated when the
primary boom is
retracted.
Be sure the primary
boom and secondary
boom limit switches
(LS2 and LS3) are not
being activated when
the primary and
secondary booms are
in the stowed position.
Be sure the battery
packs are properly
connected and fully
charged.
Turn key switch to

both Emergency Stop
position. Check the
status indicator light on
see if there is a fault. Is
there a fault?
yes

no
0V

wire from key switch to
TB22.
24V

wht-7 wire on the input
side of LS1.
0V

input side of LS1.
24V
0V
24V

blk-6 wire on the input
side of LS2.
0V
Check to make sure LS1

is being activated when
the primary boom is
retracted OR repair
open in blk-7 wire from
the output side of LS1 to
TB49 OR replace LS1
contacts OR replace
LS1.

input side of LS2.
24V
24V
0V

is not being activated
when the primary boom
is in the stowed position
OR repair open in wht-6
wire from the output side
of LS2 to TB50 OR
replace LS2 contacts
OR replace LS2.

page.
Part No. 36540
5 - 123
CHART 34
Continued from the

previous page.

wht-8 wire on the input
side of LS4.
0V

input side of LS4.
24V
0V
24V

harness connector.
0V

is not being activated
when the secondary
boom is in the lowered
position OR repair open
in blk-8 wire circuit from
the output side of LS4 to
TB40 OR replace LS4
contacts OR replace
LS4.
Repair open in org #40

pin 3 on the motor
controller harness
connector.
24V
Test the motor controller

(see Repair Section) OR
Service Department.
5 - 124
Part No. 36540
Chart 35
Machine
Drives At Full
Speed With
Platform
Raised Or
Extended
(Z-34/22 before
serial number 1734
and Z-34/22N before
serial number 2227)
Remove the machine
from service
immediately.
Be sure the wiring to
the limit switches is
intact and shows no
signs of damage or
corrosion.
Be sure the primary
boom drive limit
switch is being
activated by the cam
on the boom when
the primary boom is
raised.
Be sure the
secondary boom
drive limit switch is
being activated by the
secondary boom
compression arm
when the secondary
boom is raised.
Part No. 36540
Turn key switch to

pull both Emergency
primary boom raised
above the limit switch
LS2, check voltage on
TB49.
20V or
more
Repair or replace LS2

OR check for
mechanical restriction
keeping LS2 activated.
20V or
more

OR check for
keeping LS1 activated.
20V or
more

OR check for
keeping LS4 activated .
0V

drive controller OR
Service Department.
0V
Extend the primary
boom past the limit
switch LS1 and check
voltage on
number 153 and
number 304: TB40.
Z-34/22 from serial
number 153 to 1733
and Z-34/22N from
2226: TB52.
0V

drive controller OR
Service Department.
0V
Z-34/22 from serial
number 153 to 1733
and Z-34/22N from
2226: Raise the
secondary boom above
the limit switch LS4 and
0V
drive controller OR
Service Department.
5 - 125
Chart 36
Machine
Drives At Full
Speed With
Platform
Raised Or
Extended
Turn key switch to

both Emergency Stop
position. Check the
status indicator light on
see if there is a fault.
Is there a fault?
yes

no

number 1733 and
Z-34/22N after
serial number 2226)
Remove the machine
from service
immediately.
Be sure the wiring to
the limit switches is
intact and shows no
signs of damage or
corrosion.
With the boom in the

lowered position, check
voltage at pin 3 on the
connector.
0V
Refer to Chart 34.
24V
Raise the primary boom
approximately 10 feet
(3m) and check voltage
at pin 3 on the motor
controller harness
connector.
24V
Check for proper

activation of primary
boom limit switch LS2
OR replace LS2 contact
OR replace LS2.
0V
Be sure the primary

boom drive limit
switch is being
activated by the cam
on the boom when the
primary boom is
raised.
Be sure the
secondary boom drive
limit switch is being
activated by the
secondary boom
compression arm
when the secondary
boom is raised.
Lower the primary boom

to the lowered position
and raise the secondary
boom approximately 10
feet (3m). Check voltage
controller harness
connector.
24V
Check for proper

activation of secondary
boom limit switch LS4
OR replace LS4 contact
OR replace LS4.
0V
Lower the secondary
boom to the lowered
position and extend the
primary boom
approximately 12 inches
(30 cm). Check voltage
controller harness
connector.
0V
Check for proper

activation of primary
boom extend limit switch
LS1 OR replace LS1
contact OR replace LS1.
24V
Replace the motor
Department.
5 - 126
Part No. 36540
Chart 37
Drive Enable
System Is
Malfunctioning
(Z-34/22 before
serial number 1734
and
Z-34/22N before
serial number 2227)
Be sure the machine
is in the stowed
position with the
turntable rotated so
the boom is in
wheels.
Turn key switch to

pull both Emergency
the foot switch and
0V

center pole of TS9.
0V

wire circuit from TB12
through normally closed
contact of LS3 to TB16.
24V
Press down the foot
switch and check
voltage at TB16.
24V
Press down the foot
switch and check
voltage at terminal "+"
on drive controller.
0V
Be sure all other

functions operate
normally.
24V
Rotate the boom past

either non-steer wheel
TB16.
24V

number 153 and
number 304: Repair
open in org/red-3 wire
controller.
Z-34/22 from serial
number 153 to 1733
and Z-34/22N from
org/red wire circuit from
TB16 to CR5 OR repair
open in ground wire
circuit from CR5 to
in blu/wht wire circuit
from center pole at TS9
to CR5 OR repair open
in wire circuit from CR5
to terminal "+" on the
drive controller OR
replace CR5.
Repair or replace LS3.
0V

page.
Part No. 36540
5 - 127
CHART 37
Continued from the

previous page.
Press down the foot

switch and hold the
drive enable toggle
switch TS9 to either side
controller.
0V
Repair open in wire

circuit from drive enable
TS9 OR consult Genie
Industries Service
Department.
24V
OR replace drive
Department.
5 - 128
Part No. 36540
Chart 38
Drive Enable
System Is
Malfunctioning
number 1733 and
Z-34/22N after
serial number 2226)
Be sure the machine
is in the stowed
position with the
turntable rotated so
the boom is in
wheels.
Be sure all other
functions operate
normally.
Turn key switch to

pull both Emergency
the foot switch and
0V

the wht wire on the
center terminal of TS15.
24V
Press down the foot
switch and check
on the drive enable limit
switch LS3.
0V
Repair open in the blk-5

wire from TB12 to
terminal #14 on the
drive enable limit switch.
24V
Rotate the boom past
either non-steer wheel
the red-5 wire at
terminal #13 of the drive
enable limit switch LS3.
24V
Check for proper

activation of drive
enable limit switch LS3
when the boom is
rotated past either nonsteer wheel OR replace
LS3 contact OR replace
LS3.
0V
Press down the foot
switch and check
voltage on org/blk wire
at terminal #5 on drive
controller.
24V
Replace drive controller.
0V
Press down the foot
switch and check
voltage at the wht wire
on the center terminal
on TS15.
0V
Repair open in wht wire

from terminal #6 on the
drive controller to the
center terminal on TS15.
24V
Press down the foot
switch and hold the
drive enable toggle
switch TS15 to either
side and check voltage
at terminal #5 on the
drive controller.
0V
Replace the drive

enable toggle switch OR
repair open in the wht
wire from TS15 to center
terminal on TS1.
24V
Begin troubleshooting
from the beginning of
the chart OR consult
Department.
Part No. 36540
5 - 129
Chart 39
Remote
Brake
Release
Inoperative
(Z34/22 before
serial number 3578
and Z34/22N
before serial
number 4261)
Be sure all other
functions operate
normally.
Be sure the battery
packs are properly
connected and fully
charged.
Pull the Emergency

Stop button at ground
controls out to the ON
position. Check voltage
at the input side of the
remote brake release
jack J1 on the ground
control panel.
0V

circuit from input side of
the key switch to the
input side of the remote
brake release jack.
20V or more
With the remote brake
release switch plugged
into the remote brake
release jack on the
ground control panel,
press down the remote
brake release button
output side of the plug.
0V
Replace remote brake

release button OR
replace the remote
brake release jack.
20V or more
number 1734 and
number 2227: Activate
TB46
number 1733 and
TB48.
0V

number 1734 and
number 2227: Repair
circuit from the output
side of the remote brake
release jackto TB46
number 1733 and
number 2226: Repair
circuit from the output
side of the remote brake
release jack to TB48.
20V or more

number 1734 and
TB47.
0V

number 1734 and
number 2227: Repair
TB46 to TB47 OR
replace the diode.
20V or more
Remote brake release

function should be
operating. Begin
troubleshooting from the
beginning of this chart.
5 - 130
Part No. 36540
Section 6 Schematics
Schematics
About This Section
There are two groups of schematics in this section.
may result in death or serious
and other jewelry.
Observe and Obey:

Troubleshooting and repair procedures shall be
completed by a person trained and qualified on
the repair of this machine.
Hydraulic Schematics
or spray.

Before Troubleshooting:
General Repair Process

and operating instructions printed in the
Genie Z-34/22 & Genie Z-34/22N Operator's
Manual.
Identify
symptoms
Malfunction
discovered
Be sure that all necessary tools and test

equipment are available and ready for use.
problem
still exists
Return to
service
Part No. 36540
Troubleshoot
problem
solved
Inspect
and test
Perform
repair
6-1
Electrical Components
Item
Description
Genie Part
Number
Manufacturer
Manufacturer
Part Number
Qty
Part Number
AP1, AP2 ....... Anderson connector ............ 19436 ............. Anderson ............................. 63325-G1 ....................... 2
BAT1 .............. Battery, 6V DC, 350 AH ....... 44820 ............. Allied Battery Co .................. L-16GH .......................... 8
BCI ................. Battery charge indicator ....... 23868 ............. Curtis Instruments ................ 13508010 ....................... 1
BP1 ................ Rotational Controller ............ 36557 ............. OEM Controls ...................... RS10T4331 .................... 1
CB1 ................ Circuit breaker .................... 375785 ............ ETA ...................................... 45-700-IG1-P10 ............. 1
CR .................. Relay, DPDT, 24V DC ......... 42616 ............. Potter and Brumfield ............ K10P 11D15-24 ............. 3
CR .................. Relay, SPST, 24V DC .......... 56302 ............. Potter and Brumfield ............ VF4-15H11-CO5 ............ 9
CR .................. Relay, DPDT, 24V DC ......... 36354 ............. Omron .................................. N/A ................................. 1
Diode .............. Diode, 6 amp, 200 PIV ......... 45782 ............. Motorola ............................... MOTMR752 ................. 36
DP1 ................ Joystick controller ................ 56274 ............. OEM Controls ...................... MS6M11498 ................... 1
FB .................. Flashing beacon .................. 20189 ............. ECCO Electronic Controls ... 6400X ............................. 1
F1 ................... Fuse, 500 amp ..................... 43179 ............. Buss ..................................... ANN-500 ........................ 1
F2, F3 ............. Fuse, 100 amp ..................... 36355 ............. Buss ..................................... ANN-100 ........................ 2
FS1 ................ Foot switch ........................... 13482 ............. Linemaster Switch Corp. ..... 632-S ............................. 1
H1 .................. Alarm, Warble tone .............. 45383 ............. Floyd Bell Inc. ...................... MW-09-530-Q ................ 1
H2 .................. Horn, 24V DC, 108 dB ......... 56265 ............. FIAMM ................................. 7324021 ......................... 1
H3 .................. Alarm, intermittent ................ 18963 ............. Floyd Bell Inc. ...................... XB-09-630-Q .................. 1
H4 .................. Alarm, chime tone ................ 45462 ............. Floyd Bell Inc. ...................... CH-09-525-Q ................. 1
HM .................. Hour meter ........................... 56100 ............. Curtis Instruments ................ 17305628 ....................... 1
This list continues on the next page.
6-2
Part No. 36540
ELECTRICAL COMPONENTS
Item
Description
Genie Part
Number
Manufacturer
Manufacturer
Part Number
Qty
KS1 ................ Contact - Key switch, N.O. ... 45081 ............. Telemecanique .................... ZB2-BE101 .................... 2
LS1-LS4 ......... Contact - Limit switch .......... 19491 ............. Telemecanique .................... XESP2051 ..................... 1
Level sensor .. Level sensor,
4.5 (ANSI & CSA) ............... 44586 ............. Power Comp. of Midwest ..... LS36 ............................... 1
MC1 ............... Motor controller, Curtis ........ 23314 ............. Curtis Instruments ................ 1205-205 ........................ 1
MC1 ............... Motor controller, Sepex
48V, 500 amp ...................... 56012 ............. Curtis Instruments ................ 1244-5502 ...................... 1
P1, P2 ............ Contact, N.C. ....................... 29732 ............. Telemecanique .................... ZB2-BE102 .................... 4
P3 ................... Contact, N.O. ....................... 45081 ............. Telemecanique .................... ZB2-BE101 .................... 1
PR1 ................ Relay, 180 amp .................... 19550 ............. Curtis Instruments ................ SW180 24DCCW/4 ........ 1
PR2 ................ Relay, 180 amp .................... 56434 ............. Curtis Instruments ................ SW180L 24DCCW/26 ... 1
PR3 ................ Relay, 80 amp ...................... 19549 ............. Curtis Instruments ................ SW80 24DCCW/6 ......... 1
TS1, TS51 ...... Toggle switch, DPST
2 position momentary .......... 13480 ............. Microswitch Control Inc. ...... 2NT1-8 ........................... 2
TS54 .............. Toggle switch, DPST
2 position maintained ........... 27378 ............. Microswitch Control Inc. ...... 2NT1-3 ........................... 1
TS7-TS13 and
TS57-TS63 ..... Toggle switch, DPDT
3 position momentary .......... 16397 ............. Microswitch Control Inc. ...... 2NT1-7 ......................... 14
TS2, TS6,
TS15, TS52,
TS55, TS56 .... Toggle switch, SPDT
3 position momentary .......... 13037 ............. Microswitch Control Inc. ...... 1NT1-7 ........................... 6
TS4 ................ Toggle switch, DPDT
3 position maintained ........... 13038 ............. Microswitch Control Inc. ...... 2NT1-1 ........................... 1
Part No. 36540
6-3

(Z-34/22 before serial number 1734)
(Z-34/22N before serial number 2227)
YE
BLK
RE
WH
LABEL
4
LOAD SENSE PCB
CR5
3
1
3
2
4
LOAD SENSOR
10 11 12
RED/BLK
8
8
BRN
RESET
DISCHARGE
L.V.I.
OPTION
SET TO "A"
SET TO "N"
FUSE
FOOT
SWITCH
110
DESCRIPTION
P2
P3
DP1
BP1
TS1
TS2
TS3
TS4
TS5
TS6
TS7
TS8
EMERGENCY STOP BUTTON

HORN BUTTON
DRIVE CONTROLLER
BOOM SPEED CONTROLLER
TURNTABLE ROTATE SWITCH
SECONDARY BOOM SWITCH
PRIMARY BOOM SWITCH
EXTEND/RETRACT SWITCH
PLATFORM LEVEL SWITCH
PLATFORM ROTATE SWITCH
JIB SWITCH
AUXILIARY SWITCH
TS9
L1
BCI
TS18
L2
DRIVE ENABLE SWITCH

DRIVE ENABLE LIGHT
BATTERY CHARGE INDICATOR
LIFT/DRIVE SELECT (OPTION)
OVERLOAD LIGHT (OPTION)
JIB
BLK - FOOT SWITCH
RED/BLK
BRN
CR6
CABLE
#3
CABLE
#2
BRN
CABLE
#1
WHT
2
3
TILT
ALARM
RED/BLK
RED/WHT
TS9
TS7
TS2
TS1
BP1
TS5
TS3
GRN
L2
RED
BLK/RED
TS4
TS6
TS18
(OPTION)
L1
BLK
DP1
TS8
P3
P2
NO
NC NC
BCI
B
+
X
D
R
+
R
BRN
6-4
Part No. 36540

(Z-34/22 from serial number 1734 to 2060)
(Z-34/22N from serial number 2227 to 2870)
DESCRIPTION
LABEL
BLK
LOAD SENSE
(OPTION)
1 2 3 4 5 6 7 8 9
P3
HORN BUTTON
DP1
DRIVE CONTROLLER
BP1
BOOM FUNCTION SPEED CONTROLLER
TS1
AUXILIARY TOGGLE SWITCH
TS7
PLATFORM ROTATE TOGGLE SWITCH
TS8
JIB UP/DOWN TOGGLE SWITCH
TS9
PLATFORM LEVEL TOGGLE SWITCH
TS10
SECONDARY BOOM TOGGLE SWITCH
TS11
PRIMARY BOOM TOGGLE SWITCH
TS12
TURNTABLE ROTATE TOGGLE SWITCH
TS13
PRIMARY BOOM EXTEND TOGGLE SWITCH
TS15
DRIVE ENABLE TOGGLE SWITCH
L1
DRIVE ENABLE LIGHT
L2
F.S.
JIB
CABLE
#2
CABLE
#1
BRN
RED/WHT
NC
WHT-FS
NO
WHT
BRN
RED/BLK
CABLE
#3
BRN
RE
GR
WH
P2
LOAD CELL
WHT-FS
TS15
TS12
TS10
BP1
BLK/RED
TS8
TS11
TS7
RED
TS13
L2
NC
NC
NO
TS1
P3
Part No. 36540
L1
9 10
TS9
BRN
GRN
P2
DP1
6-5

LABEL
BLK
RE
LOAD SENSE
OPTION
1 2 3 4 5 6 7 8 9
HORN BUTTON
DRIVE CONTROLLER
BP1
TS1
TS7
TS8
TS9
TS10
TS11
TS12
TS13
PRIMARY BOOM EXTEND TOGGLE SWITCH
TS15
L1
DRIVE ENABLE LIGHT
L2
F.S.
JIB
CABLE
#2
CABLE
#1
BRN
RED/WHT
NC
WHT-FS
NO
WHT
BRN
RED/BLK
P3
DP1
CABLE
#3
BRN
WH
GR
DESCRIPTION
P2
LOAD CELL
WHT-FS
TS15
TS12
TS10
BP1
TS11
TS7
BLK/RED
TS8
RED
TS13
+
L2
6-6
NC
NC
NO
TS1
L1
9 10
TS9
BRN
GRN
P3
P2
DP1
Part No. 36540
Power Cable Diagram

+
6V
6V
AMMETER
BLK
WHT
6V
6V
TANK SIDE
BATTERY PACK
GROUND CONTROLS
SIDE BATTERY PACK
AC
BATTERY
CHARGER
6V
6V
PRIMARY
LIFT PUMP
AUXILIARY
LIFT PUMP
BLK
BLK
RED
RED
6V
RED
BLK
AP2
-
BLK (10 Ga)
WHT (10 Ga)
6V
BLK
RED
RED
BLK
BLK
RED
AP1
-
24V
PR3
PRIMARY
LIFT PUMP
CONTACTOR
PR1
F1
DRIVE
400A CONTACTOR
F2
100A
B-
B+
M-
A2
PR4
AUXILIARY
LIFT PUMP
CONTACTOR
F3
100A
48V
Power Cable Diagram

FWD

REV
PR2
LEFT SIDE
DRIVE MOTOR
S2
A1
A2
A2
A1
S1
RIGHT SIDE
DRIVE MOTOR
S2
S1
AMMETER
BLK (10 Ga)
WHT (10 Ga)
RED
TANK SIDE
BATTERY PACK
+
-
GROUND CONTROLS
SIDE BATTERY PACK
AC
BATTERY
CHARGER
PRIMARY
LIFT PUMP
A1
D1
BLK
RED
BLK
RED
BLK
3 DIODES
F1
500A
F2
100A
F3
100A
PR1
DRIVE
CONTACTOR
48V
F1
B+
BLK
F2
LEFT SIDE
DRIVE MOTOR
A2
A1
F1
F1
BLK
BLK
A2
A1
PR3
AUXILIARY
LIFT PUMP
CONTACTOR

F2
M-
RED
(10 Ga)
B-
Power Cable Diagram
BLK
SEPEX
MOTOR
CONTROLLER
RED (10 Ga)
AP1
-
24V
BATTERY
CONTROLLER
PR2
PRIMARY
LIFT PUMP
CONTACTOR
RED
AUXILIARY
LIFT PUMP
A2
RED
BLK
RED
BLK
AP2
-
D1
BLK (10 Ga)
WHT (10 Ga)
BLK
F2
RIGHT SIDE
DRIVE MOTOR
RED (10 Ga)
Part No. 36540
6-7
Power Cable Diagram

(Z-34/22 after serial number 3577)
(Z-34/22N after serial number 4260)
RIGHT SIDE
BATTERY PACK
AMMETER
LEFT SIDE
BATTERY PACK
BLK (10)
WHT (10)
_
AC
BATTERY
CHARGER
+
BLK (2)
RED (2)
_
+
+
A1
PRIMARY
LIFT PUMP
D1
BLK (4)
D1
_
AUXILIARY
LIFT PUMP
A2
RED (2)
BLK (2)
BLK (2)
RED (2)
RED (2)
RED (4)
BLK (10)
WHT (10)
BLK (4)
RED (4)
BLK (2)
AP2
+
AP1
_
24V
BATTERY
CONTROLLER
PR2
PRIMARY
LIFT PUMP
CONTACTOR
F1
500A
F2
100A
F3
100A
3 DIODES
PR1
DRIVE
CONTACTOR
PR3
AUXILIARY
LIFT PUMP
CONTACTOR
BLK (2)
48V
CURTIS
MOTOR
CONTROLLER
NOTES:
1. WIRE GAUGE NOTED IN PARENTHESES AFTER
F1
RED (10)
WIRE COLOR.
2 DO NOT ROUTE POWER CABLES ACROSS
B-
M-
F2
RED (10)
B+
FRONT OF THE MOTOR CONTROLLER. DOING SO

CAN AFFECT INTERNAL CURRENT SENSORS,
CAUSING REDUCED MOTOR PERFORMANCE.
BLK (2)
F2
LEFT SIDE
DRIVE MOTOR
A1
A2
BLK (2)
F1
F1
BLK (2)
A2
A1
F2
RIGHT SIDE
DRIVR MOTOR
RED (10)
6-8
Part No. 36540
Abbreviations Legend
LABEL
DESCRIPTION
A .................. Alarm
AP ............... Anderson Plug
BCI .............. Battery charge indicator (option)
BP ............... Boom function speed controller
CB ............... Circuit breaker
CR ............... Control relay
DE ............... Drive enable
DP1 ............. Drive proportional controller
F .................. Fuse
FB ................ Flashing beacon
FS ................ Foot switch
HM ............... Hour meter
J1 ................ Brake release receptacle
KS ............... Key switch
L .................. Light or LED
LS ................ Limit switch
LVI ............... Low voltage indicator (option)
OL ............... Overload light (option)
P .................. Power switch
PR ............... Power relay
PS ............... Pressure switch
TB ............... Terminal base location
TP ............... Terminal platform location
TS ............... Toggle switch
Part No. 36540
6-9
Electrical Symbols Legend
BRAKE
BOARD
TB17
DRIVE
BOARD
DP1
ORG/BLK-1
BLK
GRN/BLK
LED
+
R
Wire color
with cable
number
TB20
Horn/Alarm
Drive controller
(Joystick)
FB
RED
BP1
GRN
BLK/RED
Flashing
beacon
WHT
Ground
supression
circuit
Solenoid or
relay coil
Terminal
+
Circuit breaker
Boom function
speed controller
HM
_
CR4
AP1
FORWARD REVERSE
Hour
meter
PR2
Quick disconnect
terminal
BLK #21
NC
NO
LS3
Dual pole
power relay
J1
Limit switch
TB21
CR4
T-circuits connect
at terminal
M-
PR4
Brake release
jack
BB+
A2
Power relay
normally open
TS3
Motor controller before:

Z34-1737, Z34N-2227
S2
A2
Connection
no terminal
Toggle switch SPDT
S1
PLATFORM
TS6
GROUND
Key switch
RIGHT
P3
Toggle switch
DPDT
PUMP
KS1
(before Z34-3578
and Z34N-4261)
LEFT
Drive motor
Circuits crossing
no connection
LS1
NOHC
Limit switch
normally open
held closed
A1
Relay contact
normally closed
Fuse
ENGINE
START
T-circuits
connect
Relay contact
normally open
HORN
Horn button
normally open
Auxiliary lift pump
KS1
PLATFORM
FS1
BLK
Emergency
Stop button
normally closed
6 - 10
Tilt sensor
-
P1
Diode
6V
Battery
GROUND
Key switch
Foot switch
(after Z34-3577
and Z34N-4260)
PSI
Pressure
switch
Part No. 36540
Hydraulic Symbols Legend
N.O.
COM
N.C.
Pressure switch
Solenoid operated 3 position,
4 way, directional valve
(D01 or D03)
Hydraulic filter
Normally closed
poppet valve
Check valve
Normally open
poppet valve
Fixed displacement
pump
0.045"
(1.14 MM)
Orifice with size
3000 PSI
(207 bar)
3:1
Counterbalance valve
Bi-directional
motor
Brake
Solenoid operated
dump valve
Differential
sensing valve
Double acting
cylinder
M
Pump prime mover
(motor)
2800 psi
(193 bar)
Relief valve
Solenoid operated
proportional valve
25 PSI
(1.7 bar)
Filter with by-pass
Part No. 36540
Solenoid operated
2 position, 3 way
directional valve
6 - 11
First Edition Second Printing
6 - 12
Part No. 36540
A
WHT - FS
RED/WHT-3
ORG-1
BLU/WHT-1
GRN OR BRN GROUND
WHT - FS
FS1
SET TO "N"
LVI / BCI
OPTION
UP
PRIMARY BOOM
DOWN
UP
DOWN
ORG/BLK
RED
WHT
GRN/WHT
TB10
TB1
TB2
RED#1
RED/BLK#2
BLU#10
BLU/BLK#11
WHT/BLK#5
GRN/BLK
7
CR1
4
A2
A1
CR1
8
PR1
MOTOR
RED-3
RED/BLK-3
CR3
FB
S2
MOTOR
S1
DISCHARGE
LVI
SET TO "A"
TB11
TB4
WHT#4
BLK/RED#9
RED/BLK#28
REV
PR2
WHT#23
FWD
RED#R1
ORG/BLK#41
PR4
PUMP
TS12
SECONDARY BOOM
RIGHT
B+
PUMP
ORG
UP
DOWN
PRIMARY BOOM
BLU-3
BLU/BLK-3
TS11
TURNTABLE ROTATE
TB9
TB23
24V
A2
PR1
LEFT
AP1 ( + )
RESET
CR3
TB5
TB28
F3
50A
AP2 ( - )
WHT/BLK-3
1
B-
WHT-3
TS10
WHT#23
PR3
3
WHT-2
LS1
N.O.H.C.
BLK/RED-3
RED/BLK-1
ORG/BLK#41
RED/WHT#3
RED#20
TB49
BLK#49 BLK#49
LS2
N.O.H.C.
WHT#40
48V
M-
RED
CR3
TB40
GROUND
TB3
UP
F1
400A
TS3
SECONDARY BOOM
15 A
CIRCUIT
BREAKER
TB22
DOWN
PLATFORM
TS2
RIGHT
F2
100A
CB1
TB20
P3
HORN
TS1
LEFT
AP2 ( + )
KS1
KEY SWITCH
P1
EMERGENCY
STOP
BCI
TURNTABLE ROTATE
F4
10A
LIFT/DRIVE
SELECT
OPTION
O/B
BLK-2
A1
TILT
ALARM
TB42
TS18
O/R
ORG-1
RED/WHT-3
ORG/RED-1
P2
EMERGENCY
STOP
BLK
A1
A2
S2
A3
H2
S1
(GND)
AP1 ( - )
PRIMARY BOOM UP
PRIMARY BOOM DOWN
SECONDARY BOOM UP
SECONDARY BOOM DOWN
DECENT ALARM
OPTION
TURNTABLE ROTATE RIGHT
TURNTABLE ROTATE LEFT
HORN COIL
TILT LEVEL SENSOR
FLASHING BEACON
OPTION
Part No. 36540
HORN
DRIVE MASTER
RELAY
DRIVE MOTOR
SYSTEM
PRIMARY
PUMP MOTOR
6 - 13
AUXILIARY
PUMP MOTOR
1
WHT
RED/WHT-1
ORG - 1
BLU/WHT-1
GRN OR BRN (GROUND)
WHT
DRIVE
ENABLE
UP
EXTEND
DOWN
PLATFORM LEVEL
UP
LEFT
PLATFORM ROTATE
RIGHT
GRN-JIB
DOWN
JIB BOOM
DE
RETRACT
ORG/BLK
7
GRN - GROUND
RED#R2
BLK#7
ORG/BLK#15
ORG#14
BLU/WHT#48
WHT/RED#6
GRN/WHT#R2
WHT/RED#32
BLU#36
BLU/BLK#37
WHT#30
WHT/BLK#31
RED/WHT#29
RED
RED#47
RED#16
6
BLK/WHT#8
A2
WHT#13
BLK#12
RED
TB16
BLU/RED-3
ORG/BLK-1
RED#27
GRN/WHT
HM
TB13
TB12
GRN/WHT
RED/WHT
UP
DOWN
JIB BOOM
RIGHT
LEFT
PLATFORM ROTATE
UP
DOWN
PLATFORM LEVEL
EXTEND
PRIMARY BOOM
RETRACT
PS1
BLU/WHT-3
ORG/RED-3
GRN-2
RED/WHT-1
WHT/BLK-1
WHT-1
BLU/BLK-1
BLU-1
WHT/RED-1
RED-1
GRN/WHT-3
WHT/RED-3
BLU/WHT-1
GRN-1
GRN/BLK-1
GRN/BLK-3
GRN-3
ORG-3
ORG/BLK-3
BLK-3
BRAKE
RELEASE
3
BLK/WHT-3
TB41
ORG/BLK
RED
WHT
PRIMARY BOOM EXTEND
PLATFORM LEVEL DOWN
PLATFORM LEVEL UP
PLATFORM ROTATE
LEFT
PLATFORM ROTATE
RIGHT
JIB BOOM
UP
JIB BOOM
DOWN
PROPORTIONAL FLOW
CONTROL COIL
LIFT PUMP RELAY COIL
AUXILIARY PUMP RELAY COIL
AUXILIARY CONTROL RELAY COIL
PRESSURE SWITCH
BRAKE RELEASE PROPORTIONAL
STEER LEFT
STEER RIGHT
DRIVE REVERSE RELAY COIL
DRIVE FORWARD RELAY COIL
BRAKE RELEASE HALF STROKE
TRAVEL ALARM (option)
BRAKE RELEASE N.C.
HOUR METER
DRIVE ENABLE
8
PRIMARY BOOM RETRACT
6 - 14
Part No. 36540
TB31 TB29
LS3
PR4
2
PRIMARY BOOM
CR2
TB30
TB36
TB46
TB37
TB27
TB47
PR3
GRN/BLK
TB48
5
TB6
TB43
TB18
TB14
TB7
TB44
TB17
TB15
TB8
TB19
TB19
GRN/WHT
4
J1
TB32
TS17
TS16
TS15
TS14
DP1
TS9
L1
R
BOOM
FUNCTION
SPEED
CONTROLLER
AUX.
PUMP
TS13
WHT-JIB
BLK-JIB
ORG-JIB
YEL-JIB
BP1
A
AUXILIARY
PUMP
TS7
TS6
TS5
TS4
RED
GRN
BLK/RED
WHT
DRIVE
BOARD
JOYSTICK
BRAKE
BOARD
TS8
A
B
C
D
E
F
G
H
I
J
K
L
M
N
RED
(GND)
A
P2
1 2 3 4
EMERGENCY
STOP
RED/BLK
LOAD SENSE PCB

1 2
3 4 5 6 7 8 9 10 11 12
FS1
LVI
RED-3
RED/BLK-3
BLU-3
BLU/BLK-3
WHT/BLK-3
WHT-3
WHT#23
ORG/BLK
RED
RED
WHT
UP
DOWN
PRIMARY
BOOM
UP
DOWN
SECONDARY
BOOM
TS12
ORG/BLK
TB10
TB5
WHT#23
PR1
24V
RIGHT
LEFT
LS1
N.O.H.C.
B+
A2
TURNTABLE
ROTATE
10 A
BLK#49
CB2
1
B-
TS11
TS10
FUNCTION
ENABLE
BLK#49
M-
WHT#23
WHT-2
BLK/RED-3
RED/BLK-1
TS19
TB49
SET TO "N
LVI / BCI
OPTION
TB52
PR3
DISCHARGE
RED
WHT#23
RED
LS4
N.O.H.C.
3
ORG
BCI
SET TO "A
WHT#52
O/B
RESET
UP
DOWN
PRIMARY
BOOM
UP
DOWN
RIGHT
LEFT
SECONDARY
BOOM
TB22
N.O.H.C.
TB1
TB9
TB2
TB11
TB4
TB28
TB23
RED#1
RED/BLK#2
BLU#10
BLU/BLK#11
WHT/BLK#5
WHT#4
BLK/RED#9
FB
RED/BLK#28
RED#23
REV
PR2
RED#R1
FWD
ORG/BLK#41
PR4
GRN/BLK
CR1
A2
A1
PUMP
PUMP
S2
MOTOR
S1
BLK/RED#R1
PR1
MOTOR
A1
A2
S2
S1
H2
AP1 ( - )
A3
TB50
PRIMARY
BOOM UP
PRIMARY
BOOM DOWN
SECONDARY
BOOM UP
SECONDARY
BOOM DOWN
DECENT ALARM
OPTION
TURNTABLE
ROTATE RIGHT
TURNTABLE
ROTATE LEFT
HORN COIL
TILT LEVEL SENSOR
FLASHING BEACON
(OPTION)
Part No. 36540
HORN
BRN
DRIVE
MASTER RELAY
DRIVE MOTOR
SYSTEM
PRIMARY
LIFT PUMP MOTOR
AUXILIARY
LIFT PUMP MOTOR
6 - 15
HORN
TS3
TS2
CR3
WHT#52
ORG/BLK#41
RED/WHT#3
RED#20
F3
100A
TS1
BLK#40
LS2
P3
GROUND
48V
AP1 ( + )
A1
TILT
ALARM
BLK-22
PLATFORM
EMERGENCY STOP
TB20
AP2 ( - )
WHT - FS
RED/WHT-3
ORG-1
BLU/WHT-1
BRN
WHT
TURNTABLE
ROTATE
KEY
SWITCH
10 A
F1
400A
BLK-2
KS1
P1
CB1
LIFT/DRIVE
SELECT
OPTION
LOAD SENSE OPTION

(SEE DETAIL AT LEFT)
TB40
O/R
ORG-1
ORG/RED-1
RED/WHT-3
BLK
TB3
TS18
P2
F4
10A
EMERGENCY STOP
AP2 ( + )
FS1
TB42
F2
100A
OL
LOAD SENSE
OPTION DETAIL
RED/BLK
BLK
WHT-2
BRN
CR6
BLK/RED-3
CR6
3A
WHT
-2
BLK
WHT
RED/WHT
1
WHT - FS
BLU/WHT-3
BLU/RED-3
ORG/RED-3
ORG/BLK-1
GRN/BLK-3
GRN-3
ORG-3
ORG/BLK
RED/WHT
AUXILARY
UP
EXTEND
DOWN
PLATFORM
LEVEL
UP
LEFT
PLATFORM
ROTATE
RIGHT
DOWN
JIB BOOM
TB46
RETRACT
TB13
WHT#13
BLK#12
RED#12
RED/WHT
RED/WHT#29
WHT/BLK#31
WHT#30
BLU/BLK#37
BLU#36
WHT/RED#32
GRN/WHT
RED#27
GRN/WHT
RED
RED
RED#R2
BRN
RED#16
TB16
7
GRN/WHT
RED#47
ORG/BLK#47
GRN/WHT#R8
RED#20
WHT/RED#6
BRN
GRN/BLK#44
BLK#7
ORG/BLK#15
ORG#14
LS3
BLK/WHT#8
PRIMARY BOOM EXTEND
PLATFORM LEVEL DOWN
PLATFORM LEVEL UP
PLATFORM ROTATE
LEFT
PLATFORM ROTATE
RIGHT
JIB BOOM DOWN
JIB BOOM UP
PROPORTIONAL FLOW
CONTROL COIL
LIFT PUMP RELAY COIL

LIFT PUMP
CONTACTOR RELAY
AUXILIARY PUMP
RELAY COIL
AUXILIARY CONTROL
RELAY COIL
PRESSURE SWITCH
BRAKE RELEASE
PROPORTIONAL
STEER LEFT
STEER RIGHT
DRIVE REVERSE
RELAY COIL
DRIVE FORWARD
RELAY COIL
BRAKE RELEASE N.O.

HALF STROKE
TRAVEL ALARM
BRAKE RELEASE N.C.
HOUR METER
DRIVE ENABLE
8
PRIMARY BOOM RETRACT
6 - 16
Part No. 36540
WHT/YEL
GRN/BLK-1
GRN-1
WHT/RED-3
GRN/WHT-3
RED-1
WHT-1
ORG/BLK-3
TB29
TB37
WHT/GRN
DRIVE
ENABLE
UP
DOWN
JIB BOOM
BRN-JIB
RIGHT
LEFT
PLATFORM
ROTATE
UP
DOWN
TB30
PRIMARY
BOOM
A2
HM
PR4
PR3
3
RED/WHT-3
BLK-3
CR8
GRN/BLK#44
6
CR4
TB41
TB31
TB36
PLATFORM
LEVEL
EXTEND
TB19
PS1
CR2
5
TB27
TB47
PLATFORM LEVEL
CUT-OUT OPTION
N.C.
N.C.
TB44
WHT/BLK-1
BLK/WHT-3
BRAKE
RELEASE
TB12
TB6
TB43
TB18
N.O.
ORG
TB14
TB7
TB17
TB15
TB8
BLU-1
4
J1
WHT#23
ORG/BLK
RED
RED#20
WHT#23
DE
RETRACT
LS2
TB19
ORG/BLK
TB32
TS17
BLK
NO
PRIMARY
BOOM
YEL-JIB
TS16
TS15
TS14
TS13
WHT/RED-1
BRN-2
BLU/BLK-1
WHT-JIB
BLK-JIB
ORG-JIB
L1
DP1
BLK
+
NO
STEER
NC
NO
1
NO
RED/WHT
NC
RED
R
D
X
NC
POWER
2
BP1
DRIVE/BRAKE CONTROL
RED
TS7
TS6
BOOM
FUNCTION
SPEED
CONTROLLER
2
NO
TS5
NC
CR5
LCR
RED
WHT/RED
WHT/BLK
FWD/REV
NC
AUXILIARY
PUMP
RED
TS9
TS8
WHT
TS4
RED
BRN
BLK/RED
Z-34/22: Control Relay CR5 was

added after serial number 551
Z-34/22N: Control Relay CR5 was
added after serial number 689
NOTE
BLU/WHT-1
BRN
WHT
A
B
C
D
E
F
G
H
I
J
K
L
M
N

RED/WHT-3
ORG-1
BRN
A
C
RED/WHT
LOAD SENSE OPTION
1 2 3 4
P2
LOAD SENSE PCB
3A
OL L4
FS1
RED/BLK
BLK-FS
1 2 3 4 5 6 7 8 9 10 1112
WHT
CR17
LOAD SENSE OPTION

(DETAIL AT LEFT)
RED-FS
P2
WHT-FS
WHT
FS1
EMERGENCY STOP
ORG/RED-1
BLK-FS
WHT-FS
CR17
BRN
RED/WHT-3
RED/BLK
RED
KS1
P1
KEY
SWITCH
EMERGENCY
STOP
CB1
BLK-2
PLATFORM
P3
HORN
BLK #22
TB22
10 A
A1
TILT
ALARM
GROUND
TB31
RED
WHT-1
WHT/BLK-1
TB32
WHT/RED-1
TB30
RED/WHT-1
TB29
TB40
F4
10A
TB42
86
ORG/RED
RED/WHT
86
30
87
85
FB
F2
BLK
BLK/RED
PUMP
ORG/RED #CR2
87
A1
WHT
CR4
30
F1
MOTOR
A1
85
LS1*
MOTOR
F1
RED/BLK #28
A2
RED
A2
RED/WHT #23
WHT
RED
RED
F2
F2
B+
85
CR1
86
WHT-7
M-
*Shown
with boom
extended
86
BLK/RED #CR4
5
B-
BLK-7
CURTIS 1244
BLK
20
17
RED
CR2
30
87
TB9
BLK-6
SEPEX MOTOR CONTROLLER

F1
PR2
14
BLK
PR3
16
TB28
TB49
GRN
BLU/WHT #12
RED
RED
TS55
LS2
BRAKE/REL
11
BLK
10
POT. LOW
1
-
OFF-LIMIT SPEED INPUT
24V
AP1
INTERLOCK
F3
100A
2-WIRE POT.
RED
REVERSE
+48V INPUT
BLK
FORWARD
DIODE RETURN
BLK
RED
RED/WHT
TB50
F2
100A
RED/BLK-1
TB23
WHT-6
WHT-2
PR1
WHT-23A
BLK/RED-3
BLK #22
LS4
WHT-8
ORG/RED #42
ORG/RED
RED/BLK
WHT/RED #32
ORG #40
BLU/WHT #12
RED/WHT #29
WHT/BLK #31
F1
500A
AP2
WHT #30
ORG/RED
RED #CB1
CR5
85
48V
BLK-8
AP2 (+)
TB3
PUMP
H2
BRN
BRN
FUNCTION
ENABLE
48V POWER
RELAY CR2
48V POWER
RELAY CR1
TILT
SENSOR
FLASHING
BEACON
(OPTION)
HORN
RELAY
PRIMARY BOOM
LIMIT SWITCH LS2
SECONDARY
BOOM
LIMIT SWITCH LS4
CONTROLLER
FAULT INDICATOR
LIGHT
DRIVE
CONTACTOR
COIL
DRIVE CONTACTOR
Part No. 36540
TB52
HORN
48V BATTERY
CHARGER
10 A
BRN
BLK
PRIMARY
LIFT PUMP
CB2
BLK
EXTEND/RETRACT
LIMIT SWITCH LS1
BLK
AP1 ( - )
AUXILIARY
LIFT PUMP
6 - 17
BLK
BLK
BRN
Jumper
AUXILIARY
PUMP
BRN
BLU/WHT-3
RED
BLU-1
BLU/BLK-1
RED-1
GRN-1
GRN/BLK-1
GRN/BLK-3
GRN-3
BLU/RED-3
BLK-5
ORG/RED-3
ORG/RED
RED/WHT
WHT-5
RED/WHT #48
PS1
GRN/WHT-3
WHT/RED-3
RED-5
BRN-5
RED
RED
WHT #4
WHT/BLK #5
BLU/BLK #11
BLU #10
RED/BLK #2
RED #1
BLK/WHT # 8
BLK #7
ORG/BLK #15
ORG #14
GRN/WHT
WHT/RED #6
GRN/WHT
RED/WHT #48
RED/WHT
BLU #36
BLU/BLK #37
WHT/BLK
RED #27
GRN/WHT
GRN/WHT #19
JIB BOOM
UP
DOWN
LEFT
UP
DOWN
PLATFORM LEVEL
EXTEND
RETRACT
PRIMARY BOOM
UP
DOWN
PRIMARY BOOM
UP
SECONDARY BOOM
DOWN
RIGHT
TB16
21
LS3*
14
RED/WHT
TB48
WHT/BLK
PLATFORM ROTATE
RIGHT
TB27
8
TURNTABLE
ROTATE RIGHT
TURNTABLE
ROTATE LEFT
DESCENT
ALARM
(OPTION)
SECONDARY
BOOM UP
SECONDARY
BOOM DOWN
PRIMARY
BOOM UP
PRIMARY
BOOM DOWN
PRIMARY BOOM
EXTEND
PRIMARY BOOM
RETRACT
PLATFORM
LEVEL UP
PLATFORM
LEVEL DOWN
PLATFROM
LEVEL
CUTOUT
(CE OPTION)
PROPORTIONAL
FLOW CONTROL
PR3 AUXILIARY
LIFT PUMP
CONTACTOR
PR2 LIFT PUMP

CONTACTOR
CR20 LIFT PUMP

CONTACTOR
RELAY
CR3 AUXILIARY
LIFT PUMP
CONTACTOR
RELAY
HOUR METER
STEER RIGHT
STEER LEFT
PS1 BRAKE
PRESSURE
SWITCH
BRAKE RELEASE
N.O. VALVE
BRAKE RELEASE
N.C. VALVE
TRAVEL ALARM
(OPTION)
DRIVE ENABLE
LIMIT SWITCH
TB52
5
AUXILIARY
PUMP
30
6 - 18
Part No. 36540
RED
O/B
O/R
ORG
ORG/RED
WHT
UP
JIB BOOM
DOWN
RIGHT
PLATFROM ROTATE
LEFT
ORG-3
TB19
TURNTABLE ROTATE
FUNCTION
MANIFOLD
GROUND
PR2
TB36
TB13
GRN/WHT #19
LEFT
rotated past either

non-steer wheel
85
87A
A2
A3
UP
ORG/BLK-3
BLK-3
BLK/WHT-3
RED-3
RED/BLK-3
BLU-3
BLU/BLK-3
WHT/BLK-3
WHT-3
PLATFORM LEVEL
DOWN
EXTEND
PRIMARY BOOM
RETRACT
UP
PRIMARY BOOM
DOWN
SECONDARY BOOM
UP
DOWN
TURNTABLE ROTATE
7
86
87
PR3
*Shown with the boom

85
CR20
30
85
86
CR10B
87A
30
85
14
CR5
RED
+
HM
86
30
CR10A
LS2
RED-6
13
TB12
4
BRN-2
BRN-JIB
6
86
CR3
30
WHT/RED #6
87A
87
ORG-6
(OPTION)
3
RED
WHT-1
WHT/BLK-1
1
(remove for CE version)
LVI / BCI OPTION
22
TB18
TB17
TB14
TB15
TB7
TB8
TB1
TB2
TB10
TB5
TB4
13
TB6
TB44
TB43
TB11
87
PLATFORM
CONTROL BOX
GROUND
TS51
BLU/WHT #12
RED
RED
STEER
8 7 6 5 4 3 2 1
TB37
TS58
TS57
TS59
DP1
DRIVE
ENABLE
TS15
L
R
FWD
J1
BRAKE
RELEASE
JIB
MANIFOLD GROUND
BCI
+
RED
BP1
SET TO "N
SET TO "A
BRN
GRN
BOOM
FUNCTION
BLK/RED
SPEED
CONTROLLER
BLK-JIB
WHT-JIB
BLU-JIB
ORG-JIB
4
4
TS63
TS61
TS60
TS62
CR19
WHT/RED-1
CR19
6
RED/WHT-1
ORG/RED
LVI
2
REV
RIGHT
RED
4 5 3
DRIVE
ENABLE
LED
DISCHARGE
RESET
CR19
DRIVE CONTROLLER
BCI
DRIVE
6
7
8
9
10
LIFT
1
2
3
4
5
TS1
TS8
TS7
TS9
TS13
TS11
TS10
TS12
BLK
LEFT
BRN
WHT
ORG/RED-1
A
B
C
D
E
F
G
H
I
J
K
L
M
N
WHT-FS
BRN
A
E
P2
FS1
LOAD SENSE OPTION
BLK-FS
BLK #22
KS1
CB1
TB22
GND
ORG/RED-1
+
A1
ORG/RED-1
P1
10A
WHT
RED
P3
HORN
WHT-2
RED/WHT
LOAD SENSE PCB

PLT
WHT-FS
RED/WHT-3
RED
+
-
BLK-FS
WHT
NO
FS1
P2
BLK-2
NC
C
LOAD SENSE OPTION (SEE DETAIL)
WHT-FS
RED/BLK
TILT
ALARM
RED
RED
RED
TB30
WHT #30
TB31
WHT/BLK #31
WHT-1
WHT-1
WHT/BLK-1
WHT/BLK-1
3
RED/WHT #29
TB29
WHT/RED #32
TB32
ORG #40
TB40
RED/WHT-1
RED/WHT-1
WHT/RED-1
WHT/RED-1
BLK-8
TB3
ORG/RED #CR2
TB42
LS4
ORG/RED
RED/WHT
WHT
NOTES:
CR4
2 SWITCH SHOWN WITH BOOM EXTENDED
86
87
3 SWITCH SHOWN WITH BOOM ROATED PAST EITHER NON STEER WHEEL
BLK
85
4 COIL SUPPRESION DIODE FOR PR1 IS INSIDE CONTROLLER BETWEEN J1-9 AND J1-17.
5. CONTROLED DOCUMENT. ANY CHANGES MUST BE APPROVED BY FACTORY MUTUAL FOR EE CERTIFICATION.
BRN
F2
RIGHT MOTOR
H2
TB52
BRN
BLK
BLK
BLK
10A
BLK
(GND)
BRN
CB2
AP1
CR2 48V DC
POWER
RELAY
CR1 48V DC
POWER
RELAY
TILT
SENSOR
FLASHING
BEACON
OPTION
Part No. 36540
HORN
RELAY
HORN
48V DC
BATTERY
CHARGER
PRIMARY
LIFT PUMP
AUXILIARY
LIFT PUMP
6 - 19
87
1. ALL LIMIT SWITCHES WITH BOOM IN STOWED POSITION EXCEPT AS NOTED
BLK/RED
A1
BLK
PUMP
A1
GROUND
BLK
RED/BLK #28
F1
30
F1
LEFT MOTOR
RED
30
FB
PUMP
RED
A2
RED/WHT #23
F2
BLK #22
WHT
RED
RED
A2
85
WHT-7
DRIVE
CONTACTOR
F2
BLK/RED #CR4
BLK-7
B+
PR2
M-
BLK-6
F1
PR3
LS1
13
CR1
85
14
DRIVE
CONTROLLER
STATUS LED
(L3)
B-
24V
+24V
5 STATUS LED
SEPEX CONTROLLER
DRIVE
CONTACTOR
COIL-PR1
RED
AP1
86
TB9
TB49
20
17
BLK
F3
100A
86
LS2
BLK
CR2
87
22
GRN
14
TS55
FUNCTION
ENABLE
30
TB28
21
BRAKE/REL
16
RED/BLK
11
POT. LOW
INTERLOCK
RED
10
2-WIRE POT.
AP2
REVERSE
BLK
FORWARD
+48V INPUT
DIODE RETURN
BLK
RED #CB1
RED
TB23
WHT-6
F2
100A
RED/WHT
TB50
4
RED/BLK-1
+48V
86
21
BLK/RED-3
PR1
CR5
WHT-8
RED
85
ORG/RED #42
F1
500A
ORG/RED
AP2
BLU/WHT #12
F4
10A
ORG/RED
RED
BLU/WHT #12
22
N
A
1
LVI/BCI OPTION
JP1 (REMOVE FOR CE VERSION)
WHT
ORG/RED-1
DP1
RED
PLATFORM
ROTATE
TS7
JIB
BOOM
TS8
BLK
DN
UP
RET
UP
DN
EXT
LIFT
7
2
REV
TS1
FWD
L
10
RESET
6
RED
CR19
CR19
7
8
DRIVE
UP
DN
3
UP
DN
WHT
PLATFORM
LEVEL
TS9
ORG
PRIMARY
BOOM
TS13
O/R
PRIMARY
BOOM
TS11
O/B
SECONDARY
BOOM
TS10
ORG/RED
WHT
TURNTABLE
ROTATE
TS12
BCI
L.V.I.
CR19
SET TO "B"
TS15
STEER
DISCHARGE
AUX.
PUMP
SET TO "N"
DRIVE
ENABLE
ORG/RED
BRN
RED
L1
BLU/WHT-3
WHT-1
WHT/BLK-1
BLU-JIB
BLK-JIB
+
BRN
GRN
BLK/RED
RED
GRN/BLK-1
JIB
MANIFOLD
GROUND
BCI
(OPTION)
RED
ROTARY
OEM
FLOW
CONTROL
BLU-1
BP1
BLU/BLK-1
WHT-JIB
GRN-1
GRN-3
ORG-3
ORG/BLK-3
BLK-3
BLK/WHT-3
RED-3
RED/BLK-3
BLU-3
BLU/BLK-3
WHT/BLK-3
WHT-3
ORG-JIB
GRN/BLK-3
WHT/RED-1
CONTROL BOX
GROUND
BRN-JIB
J1
BRAKE
RELEASE
JACK
BLU/WHT #12
TB12
AUX.
PUMP
TB5
RED/WHT
TB48
LS3
21
3
13
22
RED-5
HM
BRN-5
87
CR20
RED/WHT
30
14
RED/WHT #48
A3
ORG #14
ORG/BLK #15
85
87A
BLU #36
87
RED
BLU/BLK #37
CR10
86
GRN/WHT
CR3
RED
30
TB6
WHT/RED #6
13
WHT/RED #6
RED-6
14
BLK #7
RED #1
BLK/WHT #8
LS2
WHT/BLK
RED #27
RED/BLK #2
BLU #10
BLU/BLK #11
WHT/BLK #5
WHT #4
TB14
TB15
ORG-6
TB27
WHT-5
TB44
TB17
TB13
TB19
TB43
TB18
TB8
WHT/RED-3
TB1
GRN/WHT
TB2
GRN/WHT #19
GRN/WHT #19
TB7
TB11 TB10
TB4
TB37
UP
BRN-2
DN
RED
BLK-5
TS58
R
ORG/RED-3
TS57
UP
DN
ORG/RED
TS59
EXT
RET
RED/WHT
UP
DN
CR5
30
PS1
UP
87
TB36
RED
TS63
TS61
DN
JIB
BOOM
PLATFORM
ROTATE
RED-1
TS60
TS62
PLATFORM
LEVEL
PRIMARY
BOOM
PRIMARY
BOOM
GRN/WHT-3
SECONDARY
BOOM
TURNTABLE
ROTATE
BLU/RED-3
RED/WHT #48
TS51
RED
RED
RED
RED/WHT-1
TB16
85
86
+
A2
(GND)
FUNCTION
MANIFOLD
GROUND
(GND)
7
TB52
BRN
DRIVE
ENABLE LED
DRIVE ENABLE
LIMIT SWITCH
TRAVEL ALARM
(OPTION)
BRAKE RELEASE
N.C. VALVE
BRAKE RELEASE
N.O. VALVE
STEER LEFT
BRAKE RELEASE
PRESSURE SWITCH
STEER RIGHT
HOUR METER
CR3 AUXILIARY
LIFT PUMP
CONTACTOR
RELAY
CR20 LIFT PUMP

CONTACTOR
RELAY
PR2 LIFT PUMP

CONTACTOR
PR3 AUXILIARY
LIFT PUMP
CONTACTOR
PROPORTIONAL
FLOW
CONTROL
PLATFORM
LEVEL CUTOUT
(CE OPTION)
PLATFORM
LEVEL DOWN
PLATFORM
LEVEL UP
PRIMARY
BOOM EXTEND
PRIMARY
BOOM
RETRACT
PRIMARY
BOOM UP
PRIMARY
BOOM DOWN
SECONDARY
BOOM UP
SECONDARY
BOOM DOWN
DESCENT
ALARM
(OPTION)
TURNTABLE
ROTATE RIGHT
TURNTABLE
ROTATE LEFT
Part No. 36540
6 - 20
A
F
FS1
P2
BLK-FS
LOAD SENSE OPTION
NO
WHT
RED/WHT
FS1
BLK #22
GND
ORG/RED-1
+
A1
ORG/RED-1
RED
P3
HORN
TB22
CB1
BLK-FS
WHT-2
KS1
P1
10A
WHT-FS
LOAD SENSE PCB
RED/WHT-3
RED
P2
BLK-2
WHT
RED/BLK
LOAD SENSE OPTION (SEE DETAIL)
WHT-FS
NC
PLT
TILT
ALARM
RED
RED
ORG/RED #CR20
RED
TB30
WHT #30
TB31
WHT/BLK #31
WHT-1
WHT-1
WHT/BLK-1
WHT/BLK-1
3
RED/WHT #29
TB29
WHT/RED #32
TB32
TB40
ORG #40
RED/WHT-1
RED/WHT-1
WHT/RED-1
WHT/RED-1
BLK-8
TB3
ORG/RED #CR2
TB42
BLU/WHT #12
22
LS4
WHT
NOTES:
85
2 SWITCH SHOWN WITH BOOM EXTENDED

FB
3 REDUNDANT COIL SUPPRESION DIODE FOR PR1 IS INSIDE CONTROLLER BETWEEN J1-9 AND J1-17.
NOTE: DIODE INSTALLED AFTER SERIAL NUMBER 3819.
BRN
BRN
10A
BRN
(GND)
(GND)
BRN
BLK (24V)
PR2
PR3
TB52
CB2
AP1
CR2
48V DC
POWER
RELAY
CR1
48V DC
POWER
RELAY
TILT
SENSOR
FLASHING
BEACON
(OPTION)
Part No. 36540
HORN
RELAY
HORN
PR1, DRIVE
CONTACTOR
48V DC
BATTERY
CHARGER
PRIMARY
LIFT PUMP
AUXILIARY
LIFT PUMP
ORG/RED
RED/BLK #28
86
BRN
BLK
87
H2
BLK
BLK
BLK
BLK
GROUND
85
RED
30
BLK
RIGHT MOTOR
RED
F2
RED/WHT #23
A1
87
BLK
LEFT MOTOR
A1
CR4
30
F1
BLK/RED
WHT
RED
RED
F1
PUMP
A2
BLK #22
A2
86
WHT-7
PR2
F2
BLK/RED #CR4
LS1
13
CR1
85
14
STATUS LED
F2
B+
TB9
BLK-7
DRIVE
CONTROLLER
STATUS LED
M-
86
BLK-6
20
17
DRIVE
CONTACTOR
COIL, PR1
F1
CR2
87
TB49
BPR3
BLK
GRN
21
22
BRAKE/REL
14
RED/BLK
16
POT. LOW
FUNCTION
ENABLE
30
TB28
LS2
SEPEX CONTROLLER
PUMP
6 - 21
INTERLOCK
F3
100A
24V
+24V
11
2-WIRE POT.
10
REVERSE
FORWARD
RED
AP1
BLK
BLK
RED
DIODE RETURN
+48V INPUT
BLK
RED #CB1
1
AP2
+
L3
RED/WHT
F2
100A
TS55
TB23
WHT-6
RED
RED/WHT
TB50
+48V
BLK/RED-3
86
21
WHT-8
CR5
RED/BLK-1
ORG/RED #42
PR1
85
ORG/RED
F1
500A
48V
RED
BLU/WHT #12
AP2
RED
ORG/RED
F4
10A
N
A
1
LVI/BCI OPTION
WHT
ORG/RED-1
RED
PLATFORM
ROTATE
TS7
JIB
BOOM
TS8
BLK
DP1
UP
RET
EXT
UP
DN
LIFT
UP
DN
2
REV
FWD
L
10
RESET
5 CR19
6 CR19
RED
7
8
DRIVE
AUX.
PUMP
TS1
3
DN
UP
DN
WHT
PLATFROM
LEVEL
TS9
ORG
PRIMARY
BOOM
TS13
O/R
PRIMARY
BOOM
TS11
O/B
SECONDARY
BOOM
TS10
ORG/RED
WHT
TURNTABLE
ROTATE
TS12
BCI
5
TS15
STEER
DISCHARGE
DRIVE
ENABLE
L.V.I.
CR19
SET TO "B"
SET TO "N"
ORG/RED
BRN
ORG/RED
L1
WHT-1
WHT/BLK-1
3
RED
RED/WHT-1
GRN-1
GRN/BLK-1
GRN/BLK-3
GRN-3
ORG-3
ORG/BLK-3
BLK-3
BLK/WHT-3
RED-3
RED/BLK-3
BLU-3
BLU/BLK-3
WHT/BLK-3
WHT-3
ROTARY
OEM
FLOW
CONTROL
JIB
MANIFOLD
GROUND
CR5
BCI
OPTION
RED
+
BRN
GRN
BLK/RED
J1
BRAKE
RELEASE
JACK
CONTROL BOX
GROUND
BRN-JIB
BLU/RED-3
BP1
BLU/WHT-3
WHT-JIB
RED
ORG-JIB
WHT/RED-1
BLU-1
BLK-JIB
BLU/BLK-1
BLU-JIB
BLU/WHT #12
TB12
TB13
TS51
RED
AUX.
PUMP
87
CR5
TS63
TS58
TS57
TS59
PS1
GRN/WHT #19
TB19
TB5
TB2
TB1
TB7
TB8
TB18
TB17
TB27
TB44
TB43
ORG/RED (48V)
TB10
TB11
RED/WHT #48
RED/WHT
BLU #36
21
22
BRN-5
RED-5
GRN/WHT
A3
*LS3
13
85
ORG #14
ORG/BLK #15
14
87A
RED
87
RED
CR10
86
30
CR3
13
WHT/RED #6
TB6
RED-6
WHT/RED #6
BLU/BLK #37
BLK #7
BLK/WHT #8
RED #1
RED/BLK #2
BLU #10
BLU/BLK #11
WHT/BLK #5
WHT #4
ORG-6
14
LS2
RED #27
TB14
TB15
RED/WHT
TB48
WHT/BLK
GRN/WHT
TB4
BRN-2
TB37
GRN/WHT #19
WHT-5
UP
RED
BLK-5
DN
ORG/RED-3
UP
ORG/RED
DN
RED/WHT
EXT
RET
30
RED/WHT #48
UP
DN
UP
TB36
RED
DN
GRN/WHT-3
TS61
TS60
JIB
BOOM
PLATFORM
ROTATE
PLATFORM
LEVEL
WHT/RED-3
TS62
RED
PRIMARY
BOOM
PRIMARY
BOOM
RED-1
SECONDARY
BOOM
TURNTABLE
ROTATE
HM
TB16
30
87
CR20
85
*Switch shown with
boom rotated past
either non-steer wheel.
86
+
A2
(GND)
(GND)
TB52
BRN
BLK (24V)
PR2
PR3
DRIVE ENABLE
LED
DRIVE ENABLE
LIMIT SWITCH
TRAVEL ALARM
BRAKE RELEASE
N.C. VALVE
BRAKE RELEASE
N.O. VALVE
STEER LEFT
BRAKE PRESSURE
SWITCH
STEER RIGHT
HOUR METER
CR3
AUXILIARY
LIFT PUMP
CONTACTOR
RELAY
CR20
LIFT PUMP
CONTACTOR
RELAY
PR2
PRIMARY
LIFT PUMP
PR3
AUXILIARY
LIFT PUMP
PROPORTIONAL
FLOW CONTROL
JIB BOOM
DOWN
JIB BOOM
UP
PLATFORM
ROTATE RIGHT
PLATFORM
ROTATE LEFT
PLATFORM
LEVEL CUTOUT
(CE OPTION)
PLATFORM
LEVEL DOWN
PLATFORM
LEVEL UP
PRIMARY
BOOM RETRACT
PRIMARY
BOOM EXTEND
PRIMARY
BOOM UP
PRIMARY
BOOM DOWN
SECONDARY
BOOM DOWN
SECONDARY
BOOM UP
DESCENT
ALARM
(OPTION)
TURNTABLE
ROTATE LEFT
TURNTABLE
ROTATE RIGHT
FUNCTION
MANIFOLD
GROUND
Part No. 36540
6 - 22
First Edition First Printing
A
BL/WH-1
TB134
FS1
P2
BLK-FS
BLK-2
1
RED #134B
WHT-FS
ORG/RED-1
4
U33
TB22
BLK #22
12
8
P3
HORN
CB1
H6
GND
RED
WHT-2
PLT
H1
L4
D39
BLU/RED-1
L48
D40
L45
RED
TILT
ALARM
ORG/RED-1
LS18
KS1
P1
RED/WHT-3
10A
WHT
ORG/RED
ORG/RED #CR20
TB30
WHT #30
WHT-1
TB31
WHT/BLK #31
WHT-1
WHT/BLK-1
WHT/BLK-1
BLU/WHT #12
RED/WHT #29
TB29
RED/WHT-1
RED/WHT-1
WHT/RED #32
TB32
WHT/RED-1
WHT/RED-1
ORG #40
TB40
BLK-8
TB3
ORG/RED #CR2
TB42
BLU/WHT #12
22
LS4
+
+
CR4
87
86
RIGHT
MOTOR
FB1
BLK
F2
85
BLK/RED
A1
30
F1
BLK
PUMP
A1
85
C
RED
WHT
RED
RED
PUMP
F1
CR1
86
WHT
WHT-7
87
LEFT
MOTOR
86
85
CR2
87
13
30
A2
A2
RED
ORG/RED
BLK #22
RED/BLK #28
LS1
RED/WHT #23
BLK/RED #CR4
BLK-7
DRIVE
CONTROLLER
STAUS LED
DRIVE
CONTACTOR
COIL
F2
B+
PR2
F2
FUNCTION
ENABLE
RED/WHT
BLK-6
30
14
STATUS LED
5
B-
M-
RED/WHT
WHT-6
20
17
F1
TB28
TB9
TB49
24V
PR3
BLK
GRN
TS55
LS2
BRAKE/REL
14
RED/BLK
POT. LOW
2-WIRE POT.
REVERSE
INTERLOCK
FORWARD
+48V INPUT
16
21
RED
11
TB23
22
CURTIS 1244
SEPEX CONTROLLER
F3
100A
AP1
10
+
L37
BLK
AP2
+24V
DIODE RETURN
BLK
RED #CB1
1
BLK
DRIVE
CONTACTOR
F2
100A
RED/BLK-1
TB50
PR1
3
BLK/RED-3
86
RED
21
WHT-8
+48V
CR5
PR1
AP2
ORG/RED #42
F1
500A
RED
85
ORG/RED
RED
ORG/RED
F4
10A
H2
BRN
BRN
GROUND
BLK
BLK
BLK
BLK
BLK
(GND)
10A
BRN
BRN
TB52
(GND)
CB2
AP1
BRN
BLK (24V)
PR2
48V POWER
RELAY (CR2)
24V POWER
RELAY (CR1)
TILT
SENSOR
FLASHING
BEACON
(OPTION)
HORN
RELAY
HORN
EXTEND/RETRACT
LIMIT SWITCH
LS1
PRIMARY
UP/DOWN
LIMIT SWITCH
LS2
SECONDARY
UP/DOWN
LIMIT SWITCH
LS4
48V BATTERY
CHARGER
6 - 23
PRIMARY
LIFT PUMP
AUXILIARY
LIFT PUMP
PR3
NOTES:
ADD D40 ONLY IF UNIT HAS L4 & L48.
ANSI/CSA
LIMIT SWITCH SHOWN WITH BOOM ROTATED PAST

EITHER NON-STEER WHEEL
SWITCH SHOWN WITH BOOM EXTENDED
REDUNDANT COIL SUPPRESION DIODE FOR PR1 IS INSIDE CONTROLLER BETWEEN J1-9 AND J1-17.
CE & PLATFORM LOAD SENSE OPTION.
Part No. 36540
ES34DCL
N
A
1
LVI/BCI OPTION
WHT
ORG/RED-1
RED
JIB
BOOM
TS8
BLK
DOWN
UP
LEFT
RIGHT
DOWN
UP
EXT
RET
UP
DOWN
UP
DOWN
LEFT
RIGHT
RESET
6
CR19
CR19
AUX.
PUMP
REV
FWD
7
8
DRIVE
9
R
DISCHARGE
STEER
SET TO "N"
ORG/RED
SET TO "B"
6
LIFT
10
TS15
DRIVE
ENABLE
L.V.I.
7 CR19
DP1
1
TS1
WHT
PLATFORM
ROTATE
TS7
ORG/RED
PLATFORM
LEVEL
TS9
ORG
PRIMARY
BOOM
TS13
O/R
PRIMARY
BOOM
TS11
O/B
SECONDARY
BOOM
TS10
WHT
TURNTABLE
ROTATE
TS12
BCI
5
BRN
L1
DRIVE
ENABLE
LED
ORG/RED
WHT-1
WHT/BLK-1
RED/WHT-1
RED
BLU-JIB
BLK-JIB
BLU/RED-3
BRN
BLK/RED
BLU/WHT-3
+
GRN
ORG/RED-3
RED
BLU-1
GRN/BLK-1
GRN-3
ORG-3
ORG/BLK-3
BLK-3
BLK/WHT-3
RED-3
RED/BLK-3
BLU-3
BLU/BLK-3
ROTARY
OEM
FLOW
CONTROL
BLU/BLK-1
WHT-JIB
BP1
GRN-1
ORG-JIB
WHT/BLK-3
WHT-3
GRN/BLK-3
WHT/RED-1
E
BCI
JIB
MANIFOLD
GROUND
CONTROL BOX
GROUND
BRN-JIB
BLU/WHT #12
TB12
TS51
RED
AUX.
PUMP
87
CR5
TS59
TS58
TS57
RED/WHT #48
RED/WHT
BLU #36
BLU/BLK #37
LS3
+
HM
ORG #14
TB16
30
CR20
87
85
86
+
H3
FUNCTION
MANIFOLD
GROUND
(GND)
BRN-5
85
7
22
13
RED-5
ORG/BLK #15
H4
87A
RED
1
+
WHT/BLK
CR10
87
GRN/WHT
RED
86
30
21
14
CR3
WHT/RED #6
WHT/RED #6
13
RED-6
14
TB6
RED/WHT
TB48
RED #27
BLK #7
BLK/WHT #8
RED #1
RED/BLK #2
BLU #10
BLU/BLK #11
WHT/BLK #5
WHT #4
TB15
ORG-6
BRN-2
TB43
WHT-5
TB44
TB14
LS2
BLK-5
TB17
TB2
TB13
TB27
ORG/RED (48V)
TB18
ORG/RED
RED/WHT
TB19
TB8
GRN/WHT
TB11
TB1
GRN/WHT #19
GRN/WHT #19
RED
TB7
TB10
TB4
30
TB37
PS1
DN
UP
UP
DN
EXT
RET
UP
TB5
TB36
JIB
BOOM
RED
TS63
PLATFORM
ROTATE
PLATFORM
LEVEL
RED-1
TS61
DN
L R
UP
DN
RED
PRIMARY
BOOM
GRN/WHT-3
TS60
TS62
PRIMARY
BOOM
WHT/RED-3
SECONDARY
BOOM
TURNTABLE
ROTATE
(GND)
TB52
BRN
BLK (24V)
PR2
PR3
DRIVE ENABLE
LED
DRIVE ENABLE
LIMIT SWITCH
TRAVEL ALARM
BRAKE RELEASE
N.C. VALVE
BRAKE RELEASE
N.O. VALVE
STEER LEFT
BRAKE
PRESSURE SWITCH
STEER RIGHT
HOUR METER
CR3
AUXILIARY
LIFT PUMP
RELAY
CR20
PRIMARY
LIFT PUMP
RELAY
PR2
PRIMARY
LIFT PUMP
CONTACTOR
PR3
AUXILIARY
LIFT PUMP
CONTACTOR
PROPORTIONAL
FLOW CONTROL
JIB BOOM
UP
JIB BOOM
DOWN
PLATFORM
ROTATE RIGHT
PLATFORM
ROTATE LEFT
PLATFORM
LEVEL CUTOUT
(CE OPTION)
PLATFORM
LEVEL UP
PLATFORM
LEVEL DOWN
PRIMARY BOOM
EXTEND
PRIMARY BOOM
RETRACT
PRIMARY
BOOM DOWN
PRIMARY
BOOM UP
SECONDARY
BOOM UP
SECONDARY
BOOM DOWN
DESCENT
ALARM
(OPTION)
TURNTABLE
ROTATE RIGHT
TURNTABLE
ROTATE LEFT
Part No. 36540
6 - 24
A
N
C29JSH RD/WH
C32JSL WH/RD
C31REV WH/BK
C30FWD WH
TB134
FS1
P2
BK-(FS)
C9P-1 BK
C7P-1
RD-(FS)
C9P-3
WH-(FS)
C9P-2
P24BAT WH
P26BAT RD
R42BAT OR/RD
C132PLI BL/WH
P1
P182BAT RD
C1B-12
10 A
TB22
KS1
RD
PLATFORM
P22BAT BK
RD
C1P-12
TILT
ALARM
H1
P3
HORN
L48
CB2
C2B-4
86
A
13
14
H2
LS1
(EXT)
2
FB
33W
BRN
BK
PR2
BK 2 GA
C48-3
10A
BRN
BRN
BRN
AC POWER
PR3
BK
21
22
WH
LS2
(PRI)
CHARGER
33W
RD
RIGHT
MOTOR
85
R19LPE GR/WH
A1
F1
C10-1 BK-7
A1
F2
C10-2 WH-7
A2
30
OR/RD
C3B-3
85
87
CR20
C11-4 WH-6
F1
A2
87
CR1
RD/WH
87
CR4
C11-3 BK-6
WH
F2
GROUND
RD
86
87
LEFT
MOTOR
RD/BK
30
B-
F2
RD
C49-1 R27AUX RD
22
PR2
PUMP
C49-11 C19LPE GR/WH
20
17
16
14
11
10
PR3
B+
30
85
30
86
87
87a
86
85
J1-WH
M-
30
CR3
LS4 21
(SEC)
R42BAT OR/RD
C1B-2
C9HRN BK/RD
BK
P22LS BK
J2-BK
C52-1 BK-8
C52-2 WH-8
C49-7 C178CSL BK
C49-2 C48BRK RD/BK
C3BAT RD/WH
C7B-2
CR2
U6A
MOTOR CONTROLLER
F1
C19LPE GR/WH
TB42
P42BAT OR/RD C48-2
CONTROLLER STATUS
LED L3
CR5
C182PWR GR
INTERLOCK
POT. HI
POT. LOW
REVERSE
FORWARD
DIODE RETURN
+48V INPUT
F3
100A
C19LPE GR/WH
OR/RD
OR/RD
86
OFF-LIMT SPD INP
BL/WH
RD 20
+
+
C2P-4
C28TTA RD/BK
CR5
C12DRE BL/WH
OR/RD
C49-9
C49-8
RD/WH
WH/RD
WH
WH/BK
+
+
C3P-3
P23BAT WH
TB134
C134PWR RD
R42BAT OR/RD
85
F2
100 A
PUMP
C7P-2
C3B-9
C1P-2
C9HRN BK/RD
C49-3
RD
TB40
C40LS
C3P-9
C49-6
GR/BK
C2B-1
C1B-3
C49-5
C133PLA BL/RD
C1B-6
C49-4
C2P-1
C29JSH RD/WH
C1B-5
C7B-1
C32JSL WH/RD
C1B-4
RD
C1P-3
C31REV WH/BK
7
5
PR1
24 V
RIGHT
BOX
P22BAT BK
C1P-6
C30FWD WH
R42BAT OR/RD
48V
F4
500A
AP2
P42BAT OR/RD
PR1
+24 V
12
C49-10
AP2
AP1
U33
P42BAT OR/RD
+48 V
1
4
C12FTS
F5
10A
LEFT
BOX
C1P-5
C48-1 P182BAT RD
C1P-4
GROUND
TB52
GND BR
CB3
48V POWER
RELAY CR2
Part No. 36540
48V POWER
RELAY CR1
FLASHING BEACON
OPTION
6 - 25
TILT SENSOR
4. ALL SOLENOID AND RELAY COILS ARE 24VDC EXCEPT WHERE NOTED.
BASE CONTROL
BOX GROUND
SWITCH SHOWN WITH BOOM EXTENDED.

SWITCH SHOWN WITH BOOM ROTATED PAST EITHER NON-STEER WHEEL.
AUXILIARY LIFT
PUMP PR3
2
3
PRIMARY LIFT PUMP

CONTACTOR RELAY
1. ALL LIMIT SWITCHES SHOWN WITH BOOM IN STOWED POSITION EXCEPT AS NOTED.
PRIMARY LIFT
PUMP PR2
HORN
RELAY
HORN
LS1-EXT/RET
LS2-PRI. UP/DWN
LS4-SEC. UP/DWN
CHASSIS GROUND
BRAKE RELEASE
RELAY CR5
PR1 DRIVE
CONTACTOR
PRIMARY
LIFT PUMP
AUXILIARY
LIFT PUMP
NOTES:
CR3
P182BAT BK
AP1
N
C29JSH RD/WH
C29JSH RD/WH
C32JSL WH/RD
C32JSL WH/RD
C31REV WH/BK
C31REV WH/BK
C30FWD WH
C30FWD WH
LVI/BCI OPTION
P24BAT WH
P24BAT WH
R42BAT OR/RD
DP1
JIB
BOOM
TS8
UP
DOWN
RIGHT
LEFT
UP
DOWN
EXTEND
RETRACT
UP
DOWN
UP
DOWN
RIGHT
LEFT
6
CR19
20K
FWD
AUXILIARY
PUMP
TS1
DISCHARGE
L.V.I.
SET TO "B"
1
L1
7
8
30
UP
DOWN
RIGHT
LEFT
UP
DOWN
PS1
EXTEND
RETRACT
UP
DOWN
UP
DOWN
RIGHT
LEFT
C19LPE
TB11
TB10
TB2
TB7
TB8
TB1
GR/WH
TB19
TB48
GR/WH
RD
TB19
TB5
87
TB36
C27AUX RD
TB27
GR/WH
TB4
CR5
TB37
TB14
TB15
R48BRK
86
TB6
CR3
85
TB16
LS3
21
C7B-3 BATGND BRN
(GND)
C8-2
A2
A3
BRN-5
OR
OR/BK
OR
DRIVE
ENABLE
LIMIT
SWITCH
22
C8-1
+
HM
_
3
14
86
85
87
13
RD-5
85
CR10B
RD/WH
CR10A 86
87
30
13
WH/RD
30
RD-6
R48BRK RD/WH
CE RD C11-1
BL
14
BL/BK
BR-6
WH/BK
BK
BK/WH
RD
RD/BK
BL
BL/BK
WH/BK
WH
CE OG/BK C11-2
LS2
WH-5
TS58
C7P-3 BATGND BRN
TS57
C8-4
TS59
BRN
TS63
C13DEL BL/RD
TS61
C4B-1
TS60
C13DEL BL/RD
TS62
BK-5
JIB
BOOM
C8-3
PLATFORM
ROTATE
4
C12FTS BL/WH
PLATFORM
LEVEL
OR/RD
PRIMARY
BOOM
RD
PRIMARY
BOOM
C19LPE GR/WH
SECONDARY
BOOM
C16DE OR/RD
RD
TURNTABLE
ROTATE
C4B-4
FUNCTION
ENABLE
C3B-12
TS55
TB12
AUXILIARY
PUMP
TS51
RD
C16DE OR/RD
C1B-10
C19LPE GR/WH
C12FTS BL/WH
C36SCC BL
C4B-7
C1B-11
C19LPE GR/WH
C3B-6
C2B-5
C2B-6
C4B-5
C4B-6
C4B-2
C4B-3
C3B-7
C3B-8
C3B-1
C3B-2
C3B-10
C3B-11
C3B-4
C3B-5
C6MFV WH/RD
BCI OPTION
C37SCW BL/BK
BCI
C1B-1
F
E
C27AUX RD
C4P-7
C43JU GR
C44JD GR/BK
C44JD WH
C43JU BK
C18PRL OR
C17PRR BL
C17PRL GR
C18PRR GR/BK
C14PLU OR
C15PLD OR/BK
C7PBE BK
C8PBR BK/WH
C1PBU RD
C2PBD RD/BK
C11SBD BL/BK
C10SBU BL
C5TRR WH/BK
C4TRL WH
C3P-6
C4P-1
BRN
C4P-4
9
10
CE OPTION:
REMOVE
JUMPER
AND ADD
RELAY
C3P-12
GR
BK/RD
4
5
C1P-10
RD
DRIVE
ENABLE
TS15
2
3
C1P-11
L R
STEER
C1P-1
C2P-5
C2P-6
C47-3
C47-4
C47-1
C47-2
C4P-6
C4P-5
C4P-2
C4P-3
C3P-7
C3P-8
C3P-1
C3P-2
C3P-10
C3P-11
C3P-5
C3P-4
JIB MANIFOLD
CR5
C12DRE BL/WH
ROTARY
OEM
FLOW
CONTROL
6
LIFT
SET TO "N"
DRIVE
BP1
RD
RESET
CR19
5
CR19
BCI
5
REV
7
RD
PLATFORM
ROTATE
TS7
RD-AUX
PLATFORM
LEVEL
TS9
OR/RD
PRIMARY
BOOM
OR/RD
TS13
ORG
PRIMARY
BOOM
TS11
OR/BK
SECONDARY
BOOM
TS10
WH
TURNTABLE
ROTATE
TS12
TB52
CR3
TRAVEL ALARM
BRAKE RELEASE
NC COIL
BRAKE RELEASE
NO COIL
Part No. 36540
BRAKE RELEASE
PRESSURE SWITCH
STEER RIGHT
STEER LEFT
SETUP ENABLE: USE TO SET THE BATTERY INDICATOR PROFILES.
HOUR METER
ALL SOLENOID AND RELAY COILS ARE 24VDC EXCEPT WHERE NOTED.
AUXILIARY CONTROL
RELAY
4.
PROPORTIONAL
CONTROL VALVE
ALL LIMIT SWITCHES SHOWN WITH BOOM IN STOWED POSITION EXCEPT AS NOTED.
PLATFORM ROTATE RIGHT/

JIB BOOM UP
1.
PLATFORM ROTATE LEFT/

JIB BOOM DOWN
PLATFORM LEVEL
CUT-OUT OPTION
PLATFORM LEVEL
UP COIL
PLATFORM LEVEL
DOWN COIL
BOOM RETRACT
BOOM EXTEND
PRIMARY
BOOM UP
PRIMARY
BOOM DOWN
SECONDARY
BOOM UP
SECONDARY
BOOM DOWN
DESCENT ALARM
OPTION
TURNTABLE
ROTATE LEFT
TURNTABLE
ROTATE RIGHT
NOTES:
6 - 26

A
N
C29JSH RD/WH
C32JSL WH/RD
C31REV WH/BK
C30FWD WH
TB134
FS1
P2
BK-(FS)
C9P-1 BK
C7P-1
RD-(FS)
C9P-3
WH-(FS)
C9P-2
P24BAT WH
P26BAT RD
R42BAT OR/RD
P1
P182BAT RD
C1B-12
10 A
TB22
KS1
LS18
RD
PLATFORM
P22BAT BK
RD
C1P-12
C132PLI BL/WH
TILT
ALARM
H1
L4
P3
HORN
L48
D39
D40
CB2
13
14
LS1
(EXT)
2
FB
PR3
33W
BRN
PR2
BK 2 GA
C48-3
10A
BRN
BRN
BRN
AC POWER
BK
21
22
H2
C
WH
LS2
(PRI)
33W
RD
RIGHT
MOTOR
CHARGER
BK
85
R19LPE GR/WH
A1
F1
C10-1 BK-7
A1
F2
C10-2 WH-7
F1
A2
C11-4 WH-6
F2
A2
GROUND
86
CR20
C11-3 BK-6
WH
PUMP
30
B-
85
OR/RD
C2B-4
87
87
RD/WH
86
87
+
PUMP
RD
30
PR2
LEFT
MOTOR
87
CR1
C49-1 R27AUX RD
22
CR4
F2
30
85
85
C49-11 C19LPE GR/WH
20
B+
86
30
86
87
87a
LS4 21
(SEC)
17
16
14
11
10
M-
F1
30
CR3
RD/BK
C9HRN BK/RD
BK
P22LS BK
J2-BK
C52-1 BK-8
C52-2 WH-8
C49-7 C178CSL BK
C49-2 C48BRK RD/BK
C182PWR GR
R42BAT OR/RD
C3B-3
CR2
J1-WH
PR3
RD
P42BAT OR/RD C48-2
CONTROLLER STATUS
LED L3
85
CR5
PR1
INTERLOCK
POT. HI
POT. LOW
REVERSE
FORWARD
+48V INPUT
DIODE RETURN
OFF-LIMT SPD INP
BL/WH
RD 20
F3
100A
C19LPE GR/WH
TB42
OR/RD
OR/RD
OR/RD
C49-9
C49-8
RD/WH
WH/RD
WH/BK
WH
86
+
+
C2P-4
C3BAT RD/WH
C1B-2
C12DRE BL/WH
R42ABT OR/RD
U6A
MOTOR CONTROLLER
24 V
C3P-3
C7B-2
C49-3
C28TTA RD/BK
C49-6
P23BAT WH
C1B-3
C49-5
C7P-2
C1B-6
C49-4
C1P-2
C1B-5
R42BAT OR/RD
F4
500A
AP2
RIGHT
BOX
C3B-9
C1B-4
C48-1 P182BAT RD
48V
F2
100 A
+24 V
CR5
C19LPE GR/WH
P42BAT OR/RD
PR1
AP1
TB134
C134PWR RD
C49-10
+48 V
RD
TB40
C40LS
P42BAT OR/RD
AP2
GR/BK
C12FTS
F5
10A
LEFT
BOX
L45
C9HRN BK/RD
C3P-9
12
C2B-1
C29JSH RD/WH
7
5
C133PLA BL/RD
C32JSL WH/RD
C2P-1
C1P-3
C31REV WH/BK
5
U33
H6
C7B-1
C1P-6
C30FWD WH
RD
C1P-5
1
P22BAT BK
C1P-4
GROUND
TB52
GND BR
CB3
48V POWER
RELAY CR2
48V POWER
RELAY CR1
FLASHING BEACON
OPTION
TILT SENSOR
Part No. 36540
BASE CONTROL
BOX GROUND
AUXILIARY LIFT
PUMP PR3
6 - 27
PRIMARY LIFT PUMP

CONTACTOR RELAY
4. ALL SOLENOID AND RELAY COILS ARE 24VDC EXCEPT WHERE NOTED.
PRIMARY LIFT
PUMP PR2
ADD D40 ONLY IF UNIT HAS L4 AND L48.
HORN
RELAY
CE & PLATFORM LOAD SENSE OPT.
HORN
LS1-EXT/RET
LS2-PRI. UP/DWN
LS4-SEC. UP/DWN
CHASSIS GROUND
NOTES:
1. ALL LIMIT SWITCHES SHOWN WITH BOOM IN STOWED POSITION EXCEPT AS NOTED.
BRAKE RELEASE
RELAY CR5
PR1 DRIVE
CONTACTOR
PRIMARY
LIFT PUMP
AUXILIARY
LIFT PUMP
CR3
P182BAT BK
AP1

N
C29JSH RD/WH
C29JSH RD/WH
C32JSL WH/RD
C32JSL WH/RD
C31REV WH/BK
C31REV WH/BK
C30FWD WH
C30FWD WH
LVI/BCI OPTION
P24BAT WH
P24BAT WH
R42BAT OR/RD
DP1
JIB
BOOM
TS8
UP
DOWN
RIGHT
LEFT
UP
DOWN
EXTEND
RETRACT
UP
DOWN
UP
DOWN
RIGHT
LEFT
6
CR19
20K
FWD
AUXILIARY
PUMP
TS1
DISCHARGE
L.V.I.
SET TO "B"
1
L1
7
8
UP
DOWN
RIGHT
LEFT
UP
DOWN
PS1
EXTEND
RETRACT
UP
DOWN
UP
DOWN
RIGHT
LEFT
C19LPE
GR/WH
TB5
TB11
TB10
TB2
TB7
TB8
TB1
GR/WH
TB19
TB48
GR/WH
RD
TB19
TB4
CR5
87
TB36
C27AUX RD
TB27
TB14
TB15
R48BRK
86
TB6
CR3
85
TB16
3
14
86
85
OR
OR/BK
OR
+
A2
A3
(GND)
C7B-3 BATGND BRN
+
HM
_
DRIVE
ENABLE
LIMIT
SWITCH
22
C8-2
CR10B
87
21
BRN-5
30
LS3
C8-1
85
13
RD-5
87
RD/WH
CR10A 86
13
WH/RD
30
R48BRK RD/WH
LS2
RD-6
BL
14
BL/BK
BR-6
WH/BK
BK
BK/WH
RD
RD/BK
BL
BL/BK
WH/BK
WH
CE OG/BK C11-2
CE RD C11-1
WH-5
30
TB37
C7P-3 BATGND BRN
TS58
C8-4
TS57
BRN
TS59
C13DEL BL/RD
TS63
C4B-1
TS61
C13DEL BL/RD
TS60
C4P-1
TS62
BK-5
JIB
BOOM
C8-3
PLATFORM
ROTATE
4
C12FTS BL/WH
PLATFORM
LEVEL
OR/RD
PRIMARY
BOOM
RD
PRIMARY
BOOM
C19LPE GR/WH
SECONDARY
BOOM
C16DE OR/RD
RD
TURNTABLE
ROTATE
C4B-4
FUNCTION
ENABLE
C3B-12
C4B-7
TS55
TB12
AUXILIARY
PUMP
TS51
RD
C16DE OR/RD
C19LPE GR/WH
C3B-6
C19LPE GR/WH
C12FTS BL/WH
C1B-10
C6MFV WH/RD
BCI OPTION
C4P-4
C36SCC BL
BCI
CE OPTION:
REMOVE
JUMPER
AND ADD
RELAY
C3P-12
C1P-10
C1B-11
F
E
C2B-5
C2B-6
C4B-5
C4B-6
C4B-2
C4B-3
C3B-7
C3B-8
C3B-1
C3B-2
C3B-10
C3B-11
C3B-4
C3B-5
C37SCW BL/BK
C4P-7
C3P-6
C43JU GR
C44JD GR/BK
C44JD WH
C43JU BK
C18PRL OR
C17PRR BL
C17PRL GR
C18PRR GR/BK
C14PLU OR
C15PLD OR/BK
C7PBE BK
C8PBR BK/WH
C1PBU RD
C2PBD RD/BK
C11SBD BL/BK
C10SBU BL
C5TRR WH/BK
C4TRL WH
C1P-11
9
10
BRN
+
4
5
C1B-1
GR
BK/RD
DRIVE
ENABLE
TS15
2
3
C27AUX RD
L R
STEER
C1P-1
C2P-5
C2P-6
C47-3
C47-4
C47-1
C47-2
C4P-6
C4P-5
C4P-2
C4P-3
C3P-7
C3P-8
C3P-1
C3P-2
C3P-10
C3P-11
C3P-5
C3P-4
JIB MANIFOLD
CR5
C12DRE BL/WH
ROTARY
OEM
FLOW
CONTROL
RD
6
LIFT
SET TO "N"
DRIVE
BP1
RD
RESET
CR19
5
CR19
BCI
5
REV
7
RD
PLATFORM
ROTATE
TS7
RD-AUX
PLATFORM
LEVEL
TS9
OR/RD
PRIMARY
BOOM
OR/RD
TS13
ORG
PRIMARY
BOOM
TS11
OR/BK
SECONDARY
BOOM
TS10
WH
TURNTABLE
ROTATE
TS12
TB52
CR3
TRAVEL ALARM
BRAKE RELEASE
NC COIL
BRAKE RELEASE
NO COIL
Part No. 36540
BRAKE RELEASE
PRESSURE SWITCH
STEER RIGHT
STEER LEFT
SETUP ENABLE: USE TO SET THE BATTERY INDICATOR PROFILES.
HOUR METER
ALL SOLENOID AND RELAY COILS ARE 24VDC EXCEPT WHERE NOTED.
AUXILIARY CONTROL
RELAY
4.
PROPORTIONAL
CONTROL VALVE
ALL LIMIT SWITCHES SHOWN WITH BOOM IN STOWED POSITION EXCEPT AS NOTED.
PLATFORM ROTATE RIGHT/

JIB BOOM UP
1.
PLATFORM ROTATE LEFT/

JIB BOOM DOWN
PLATFORM LEVEL
CUT-OUT OPTION
PLATFORM LEVEL
UP COIL
PLATFORM LEVEL
DOWN COIL
BOOM RETRACT
BOOM EXTEND
PRIMARY
BOOM UP
PRIMARY
BOOM DOWN
SECONDARY
BOOM UP
SECONDARY
BOOM DOWN
DESCENT ALARM
OPTION
TURNTABLE
ROTATE LEFT
TURNTABLE
ROTATE RIGHT
NOTES:
6 - 28

Ground Control Panel Legend

A
1
A3
A2
2
4
7
1
3 5
4 6
RED-TB27D
7
8
GRN/YEL-GROUND
RED-PR4
GRN/WHT-PR3
CR1
P1
7
1
3 5
4 6
BLK/RED-TB9D
7
8
BLK-TILT AL.
GRN/YEL-TB51
BLK-LS1
BLU/WHT-MH
RED-B.R.V.
GRN/YEL-GROUND
BLK-HORN
NC
RED-SP
HM
WHT-HORN
NC
LIMIT SWITCH
WIRING
LS2
LS1
TS17
BRAKE
EXTEND/RETRACT
LIMIT SWITCH
PRIMARY BOOM
LIMIT SWITCH
KS1
N.O.
RELEASE
NO NO
BLK#49-TB49D
N.O.
N.C.
5
TS15
WHT#40-TB40D
N.C.
BLK#49-TB49C
WHT#23-TB23D
LS3
LS4
DRIVE ENABLE
LIMIT SWITCH
SECONDARY BOOM
LIMIT SWITCH
OG/RD-POW.
ORG/BLK-PR1
WHT-LS2
BLU/BLK-S.V.
BLU-STEER V.
WT/RD-BK.F.C.
WT/BK-PR2
WHT-PR2
RD/WT-B.V.
WHT-T. AL.
RED-CR2
WHT-LS1
N.O.
BLK#12-TB12A
N.O.
N.C.
GRN-GROUND
N.C.
BLK#40-TB40B
GRN/WHT-CR2
WHT#52-TB52B
Note: LS4 added after serial number 950
TS14
ORG/BLK-4
ORG-4
TS12
CB1
LABEL
TS16
TS11
GRN/YEL-2
GR/YL-PUMP
BLK-LS2
BLU/WHT-1
RED-S.P. AL.
RD/WT-TB29
GRN/BLK-1
GRN-1
ORG/RED-1
ORG/BLK-1
ORG-1
BLU/BLK-1
BLU-1
WHT/RED-1
WHT/BLK-1
WHT-1
R/W-1
RED/BLK-1
RED-1
RED-TILT AL.
RED-POWER
GN/WT-P.S.
TS13
WHT#13-TB13A
RED#16-TB16D
P1
KS1
TS10
TS11
TS12
TS13
TS14
TS15
TS16
TS17
CB1
HM
CR1
CR2
A2
A3
TS10
BLU/BLK-4
BLU-4
BLK/WHT-4
BLK-4
W/R-4
WHT/BLK-4
WHT-4
R/W-CURTIS
RED/BLK-4
BLK/RED-3
BLK/WHT-3
BLK-3
WHT/RED-3
WHT/BLK-3
WHT-3
RED/WHT-3
RED/BLK-3
RED-4
RED-3
DESCRIPTION
KEY SWITCH
SECONDARY BOOM SWITCH
PRIMARY BOOM SWITCH
JIB SWITCH
AUXILIARY SWITCH
15amp. CIRCUIT BREAKER
HOUR METER
CONTROL RELAY, HORN
CONTROL RELAY, AUXILIARY PUMP
TRAVEL ALARM
DESCENT ALARM
Part No. 36540
GRN/WHT-3
GRN/BLK-3
GRN-3
ORG/RED-3
ORG/BLK-3
ORG-3
BLU/RED-3
BLU/WHT-3
BLU/BLK-3
BLU-3
6 - 29
GRN/WHT-TB19D
CR2
51 GRN/YEL-CR2
50 GRN/YEL-S.P.
49
48
47 RD/WT-TB46
46 RD/WT-TB47
44 GR/BK-S.P.
43 GRN S.P.
42
41
40
37
36
32
31
30
29 R/W-TB46
28
27 RED-S.P.
23 WT-S.P.
22 BLK S.P.
20 RED S.P.
19 GR/WT-TB36&37
19 GR/WT S.P.
18 GR/BK S.P.
17 GRN S.P.
16
15 OG/BK S.P.
14 ORG S.P.
13
12 RED S.P.-H.M.
11 BU/BK S.P.
10 BLU S.P.
9
8
BK/WT S.P.
7
BLK S.P.
6
WT/RD S.P.
5
WT/BK S.P.
4
WHT S.P.
3
2
RD/BK S.P.
1 RED S.P.
B
GRN/YEL-TB50
GRN/YEL-LS3
GROUND
LIMIT SWITCH
OR/B-TB41
RD/WT S.P.
GR/BK-D.A.
ORG/BLK-TB47
BL/BK-TB19
BU-TB19
WHT-2
BLK-2
BRAKE RELEASE N.C.

EMERGENCY BRAKE RELEASE N.C.
JIB DOWN
JIB UP
48V SUPPLY
DRIVE COIL PR1
LIMIT SWITCH
STEER LEFT
STEER RIGHT
BRAKE F.C.
REVERSE PR2
FORWARD PR2
BRAKE H.S.
TILT ALARM
AUXILIARY POWER PR4
KEY SWITCH POWER
POWER TO PLATFORM
12V BATTERY SUPPLY
LIFT PUMP PR3

PLATFORM ROTATE RIGHT
PLATFORM ROTATE LEFT
RED-LS3
WHT-LS3
BLK-LS3
BU/BK-D.A.
BK/RD-CR1
RD/BK-D.A.
A
PLATFORM LEVEL DOWN

PLATFORM LEVEL UP
DRIVE ENABLE LIGHT
DRIVE ENABLE / HOUR METER
SECONDARY BOOM DOWN
SECONDARY BOOM UP
HORN
BOOM RETRACT
BOOM EXTEND
LIFT FLOW CONTROL
DRIVE FLOW CONTROL
PRIMARY BOOM DOWN
PRIMARY BOOM UP

N
H
CR2
1
A3
A2
3 5
4 6
AUXILIARY PUMP
7
5
RED-TB27D
7
8
BRN-CR4
GRN/WHT-TB19D
RED-CH
GRN/WHT-CH
CR1
1
2
4
7
1
3 5
4 6
WHT-LS2
HORN
5
BLK/RED-TB9A
7
8
BRN-MH
BLK-HORN
RED-SP
WHT-HORN
BLK-LS1
BLU/WHT-MH
RED/WHT-TB46
RED/WHT-TB47
P1
GRN/BLK#44
NC
RED#47
NC
HOUR
METER
CR4 (PLATFORM LEVEL CUT-OUT OPTION)

1
RED#12
2
4
RED-CR1
7
1
3 5
4 6
ORG-TB14D
RED-LS2
7
8
BRN-TB51A
BRN-CR2
BRN-GROUND
BLK#7
BLK#22
ORG/BLK-TB15D
ORG/BLK-MH
ORG-MH
J1
KS1
TS17
RED/WHT#46
NO NO
WHT#23
LS1
LS2
EXTEND/RETRACT
LIMIT SWITCH
PRIMARY BOOM
LIMIT SWITCH
BLK/WHT#8
N.O.
WHT/RED#6
N.C.
BLK#49-TB49D
N.O.
ORG-TB14D+TB15D
N.C.
BLK-TB49C
WHT#40-TB40D
RED-CR4
WHT#23-TB23C
TS15
TS13
CB1
GRN#17
GRN/WHT#19
TS14
TS12
ORG/BLK#15
LS3
LS4
DRIVE ENABLE
LIMIT SWITCH
SECONDARY BOOM
LIMIT SWITCH
TS19
N.O.
BLK#12-TB12B
N.O.
N.C.
BRN-TB50B
N.C.
WHT#13-TB13B
ORG#14
LABEL
RED#1
WHT#4
TS16
BLU#10
RED#20
BLU/BLK#11
WHT/BLK#5
WHT-TILT ALARM
RED-CR3
TS11
TS10

KEY SWITCH
TS10
TS11
TS12
TS13
TS14
TS15
TS16
TS17
TS19
CB1

SECONDARY BOOM UP/DOWN SWITCH
PRIMARY BOOM UP/DOWN SWITCH
BOOM EXTEND/RETRACT SWITCH
JIB UP/DOWN SWITCH
AUXILIARY SWITCH
FUNCTION ENABLE SWITCH
CIRCUIT BREAKER, CONTROLS, 10A
HM
CR1
CR2
CR4
CH
MH
SP
A2
A3
J1
HOUR METER
CONTROL RELAY - HORN
CONTROL RELAY - AUXILIARY PUMP
PLATFORM LEVEL CUT-OUT (CE OPTION)
WHT/RED-1
WHT/BLK-1
WHT-1
RED/WHT-1
RED/BLK-1
RED-1
WHT-LS1
GRN/WHT-PS
GRN/WHT-CR2,CR3
BLU/BLK-MH
BLU-MH
DESCRIPTION
P1
KS1
ORG-1
BLU/BLK-1
BLU-1
RED-CH
BLK#40-TB40B
WHT#52-TB52B
RED#16-TB16B
GRN#43
BLU-CH
WHT/RED-CH
WHT/BLK-CH
WHT-CH
RED/WHT-CH
ORG/BLK-CR4
ORG-CR4
RED/BLK#2
GRN/BLK#44
BLU/BLK-CH
RED-TILT ALARM
RED#27
GRN/BLK#18
ORG/RED-CH
ORG/BLK-CH
BLK-TILT ALARM
BRN-CH
BLK-LS2
BLU/WHT-1
RED-CH
RED/WHT-TB29
GRN/BLK-1
GRN-1
ORG/RED-1
ORG/BLK-1
BLK/WHT-MH
GRN/WHT-3
GRN/BLK-3
GRN-3
ORG/RED-3
ORG/BLK-3
ORG-3
BLU/RED-3
BLU/WHT-3
BLU/BLK-3
BLU-3
BLK/RED-3
BLK/WHT-3
BLK-3
WHT/RED-3
WHT/BLK-3
BLK-MH
WHT/RED-MH
WHT/BLK-MH
WHT-MH
RED/WHT-CH
WHT-3
RED/WHT-3
RED/BLK-MH
RED-MH
RED/BLK-3
RED-3
52 WHT-LS4
51 BRN-2
50 BRN-LS3
49
48
47 RED-SP ALARM
46
44 GRN/BLK-A3
43
42
41
40 BLK-LS4
37
36
32
31
30
29
28
27
23
22
20
19
19
18
17
16
15
14
13
12
11
10
9
8
7
6
5
4
3
2
ORG/BLK-TB41
RED/WHT-SP
GRN/BLK-SP
GRN-SP
ORG/BLK-TB47
BLU/BLK-TB19
BLU-TB19
LIMIT SWITCH
HOUR METER
BRAKE RELEASE N.C.
BRAKE RELEASE REMOTE
JIB DOWN
JIB UP
48V SUPPLY
DRIVE COIL PR1
LIMIT SWITCH
STEER LEFT
STEER RIGHT
BRAKE FLOW CONTROL
REVERSE PR2
FORWARD PR2
BRAKE HS
TILT ALARM
RED-SP
AUX PWR PR4
WHT-2
BLK-2
WHT-SP
BLK-SP
RED-SP
PWR TO PLATFORM
12V BATT SUPPLY
TB36 & 37
BLU+BLU/BLK
GRN/WHT-SP
GRN/BLK-SP
GRN-SP
LIFT PUMP PR3

PLAT ROTATE RIGHT
PLAT ROTATE LEFT
RED-LS3
ORG-LS2
(OPT) ORG/BLK-SP
(OPT) ORG-SP
ORG-LS2
WHT-LS3
RED SP-HM
BLK-LS3
BLU/BLK-A3
BLU/BLK-SP
BLU-SP
BLK/RED-CR1
BLK/WHT-SP
BLK-SP
WHT/RED-SP
WHT/BLK-SP
WHT-SP
RED/BLK-A3
BRN-SP
RED/WHT-TB46
LIMIT SWITCH
GROUND CR4
RED/BLK-SP
RED-SP
KEYSWITCH PWR
PLAT LEVEL DOWN

PLAT LEVEL UP
DRIVE ENABLE LIGHT
DRIVE ENABLE / HOUR METER
SECONDARY BOOM DOWN
SECONDARY BOOM UP
HORN
BOOM RETRACT
BOOM EXTEND
LIFT FLOW CONTROL
TURNTABEL ROTATE LEFT
TURNTABEL ROTATE RIGHT
DRIVE FLOW CONTROL

PRIMARY BOOM DOWN
PRIMARY BOOM UP
CHASSIS HARNESS
MANIFOLD HARNESS
SWITCH PANEL
TRAVEL ALARM
DESCENT ALARM
BRAKE RELEASE JACK
Part No. 36540
6 - 30


A
BRN
1
RED/WHT
BRN
A2
A3
ORG
LABEL
BLK [OPTION 2]
BRN-CB2
BRN-5
BRN-2
HM
J1
KS1
NO
TS51
NO
TS55
FUNCTION ENABLE TOGGLE SWITCH
BLK-7
BLK-6
49
LS1-LS2 JUNCTION
RED/WHT-SP
BRAKE RELEASE
GRN/BLK-SP
JIB DOWN
GRN-1
43
GRN-SP
JIB UP
ORG/RED-1
42
TS58
TS59
TS60
SECONDARY BOOM UP/DOWN TOGGLE SWITCH
TS61
PRIMARY BOOM UP/DOWN TOGGLE SWITCH
ORG/RED-L3
SWITCHED 48V
ORG-CH
OFF-LIMIT SPEED
TS62
37
BLU/BLK-MH
STEER RIGHT
TS63
BOOM EXTEND/RETRACT TOGGLE SWITCH
BLU-19D
BLU-1
36
BLU-MH
STEER LEFT
CB1
ORG/RED-CH
WHT/RED-1
32
WHT/RED-CH
JOYSTICK POT. LOW
WHT/BLK-1
31
WHT/BLK-CH
REVERSE
WHT-1
30
WHT-CH
FORWARD
RED/WHT-CH
2-WIRE POT.
RED/WHT-1
29
WHT-TILT
RED/BLK-1
28
RED-CR3
RED-1
27
BRN-52A
NC
HM
WHT-2
WHT-SP
WHT-7
BLK-2
22
BLK-CR4
BLK-SP
+24V TO PLATFORM
TB36/TB37
GRN/WHT-CR3
19
GRN/WHT-MH
LIFT PUMP
GRN/WHT-3
19
GRN/WHT-SP
LIFT PUMP
BLK-22A
GRN/BLK-3
18
GRN/BLK-SP
PLAT. ROTATE RIGHT
RED-27A
GRN-3
17
GRN-SP
PLAT. ROTATE LEFT
KEYSWITCH POWER
KEYSWITCH POWER
16
ORG/RED-CR5
DRIVE ENABLE
15
ORG/BLK-MH *
ORG/BLK-SP
PLAT. LEVEL DOWN
14
ORG-MH *
ORG-SP
PLAT. LEVEL UP
WHT/RED-6A
WHT-5
BLU/RED-3
13
DRIVE ENABLE LIGHT
GRN/BLK-18A
BLK-5
BLU/WHT-3
12
BLU/BLK-3
11
BLU-3
10
BLU/WHT-CH
FOOTSWITCH
BLU/BLK-MH
BLU/BLK-SP
SEC. BOOM DOWN
BLU-MH
BLU-SP
SEC. BOOM UP
BLK/RED-3
BLK/WHT-3
BLK/WHT-MH
BLK/WHT-SP
BOOM RETRACT
BLK-3
BLK-MH
BLK-SP
BOOM EXTEND
HORN
WHT/RED-MH
WHT/RED-SP
BOOM FUNCTION F.C.
WHT/BLK-3
WHT/BLK-MH
WHT/BLK-SP
TURN. ROTATE RIGHT
WHT-MH
WHT-SP
TURN. ROTATE LEFT
WHT-3
RED/WHT-3
RED/BLK-3
RED/BLK-MH
RED/BLK-SP
PRIMARY BOOM DOWN
RED-3
RED-MH
RED-SP
PRIMARY BOOM UP
48V RELAY COIL PWR.
TRAVEL ALARM
A3
DESCENT ALARM (OPTION)

CONTROLLER STATUS LED
TS57
TS63
GRN-17A
L
GRN/WHT-19A
CB1
RED-1A
ORG/BLK-15A
RED
TS61
TS59
ORG-14A
TS55
WHT/BLK-5A
GRN/BLK-44A
TS60
TS58
TS62
BLU/BLK-11A
GRN/WHT-19C
GRN/WHT-CH
A2
L3
BLK/WHT-8A
GRN-43A
CONTROL RELAY
WHT-4A
[* SEE OPTIONAL WIRING]

[
DENOTES TEST PORT]
RED-27D
SWITCH PANEL
CR
RED
ORG
ORG/RED-CH
MANIFOLD HARNESS
SP
RED/BLK-2A
WHT/RED-3
NO
CIRCUIT BREAKER, CONTROLS RETURN, 10A
BLK-7A
ORG-3
KS1
NO
ORG/BLK-3
CHASSIS HARNESS
WHT-23A
TS62
CH
TS51
RED/WHT-48A
ORG
BRAKE RELEASE JACK

HOURMETER
J1
23
RED/WHT-CR1
J1
HM
MH
RED-TILT
TS55
CB2
P1
RED
AUXILIARY PUMP SELECT
23
ORG/RED-3
NC
TILT ALARM
RED-SP
[OPTION 2]
TS61
TS60
TS57
WHT/BLK-19D/48D
40
BLK/RED-CR4
TS58
48
44
BLU/BLK-1
ORG
TS59
RED/WHT-MH
RED/WHT-CR5
GRN/BLK-1
BLU/BLK-19D
RED-5
CB1
KEY SWITCH
TS51
LS2-LS4 JUNCTION
4
TS63
KS1
BRN-SP
BRN-MH
DESCRIPTION
GROUND
WHT/BLK-SP
TS57
P1
GROUND
52
NC
GROUND
50
BLK-8
NC
BRN-CH
BRN-CR4
WHT-8
ORG/RED-CR1
P1
52
52
WHT-6
WHT/BLK-SP
BRN
A2
BLK-22B
BLU-10A
RED-CH
BRN-52A
DESCENT ALARM WIRING (OPTION)
RED/WHT-TB3D
SWITCH PANEL
BLK/RED-HORN
ORG/RED-42D
CONTROL RELAY I.D.
SPARE WIRE LIST
CR1 - SECONDARY 48V POWER

CR2 - PRIMARY 48V POWER
CR3 - AUXILIARY PUMP
CR4 - HORN
CR5 - BRAKE RELEASE
CR10A - PLATFORM LEVEL CUTOUT (CE OPTION)
CR10B - PLATFORM LEVEL CUTOUT (CE OPTION)
BLK-1
BLK/WHT-1
BLK/RED-1
BLU/WHT-1
BLU/RED-1
ORG-1
ORG/BLK-1
GRN/WHT-1
RED-CH
RED/WHT-48C
ORG/BLK-MH
ORG-MH
10B
10A
RED-6
RED/BLK-CH
TILT SENSOR
ORG/RED-16A
RED-23D
WHT-28D
BLK
ORG/BLK-15B
ORG-14B
OPTION NUMBERS
1 - PLATFORM LEVEL CUTOUT
2 - FLASHING BEACON
3 - DESCENT ALARM
ORG-6
L3
CB2
BRN-52D
ORG/BLK-3
15
ORG/BLK-CR10B
ORG/BLK-SP
PLATFORM LEVEL DOWN
ORG-3
14
ORG-CR10A
ORG-SP
PLATFORM LEVEL UP
PLATFORM LEVEL CUTOUT (CE OPTION)
6 - 31
BLK/RED-9D
Part No. 36540
BRN-CH
BLK-CH
ORG/RED-42A
BRN-CB2

N
RED/WHT
BRN-CB2
BLK-[OPTION 2]
52
BRN-CH
BRN-CR4
GROUND
BRN-5
BRN-2
52
BRN-MH
BRN-SP
GROUND
WHT-6
WHT-8
50
BRN
A2
BLK-7
ORG
WHT/BLK-SP
ORG/RED-CR1
BLK-6
49
RED/WHT-CR5
48
GRN/BLK-1
GRN-1
RED/BLK-TILT
(Z34/22N after serial number 4008)
(Z34/22 after serial number 3308)
CB1
TS51
RED/WHT-TILT
(Z34/22N after serial number 4008)
(Z34/22 after serial number 3308)
J1
ORG/RED-L3
SWITCHED 48V
ORG-CH
OFF-LIMIT SPEED
STEER RIGHT
WHT/BLK-19D/48D
STEER LEFT
BRN-52A
WHT/RED-1
32
WHT/RED-CH
JOYSTICK POT. LOW
WHT/BLK-1
31
WHT/BLK-CH
REVERSE
WHT-1
30
WHT-CH
FORWARD
RED/WHT-1
29
RED/WHT-CH
2-WIRE POT.
WHT-TILT
RED/BLK-1
28
RED-CR3
RED-1
27
RED-SP
CB1
TRACTION CONTROL
23
KEYSWITCH POWER
RED-CH
TS51
22
BLK-SP
+24V TO PLATFORM
19
GRN/WHT-MH
LIFT PUMP
GRN/WHT-3
19
GRN/WHT-SP
LIFT PUMP
GRN/BLK-3
18
GRN/BLK-SP
PLAT. ROTATE RIGHT
WHT-23A
GRN-3
17
GRN-SP
PLAT. ROTATE LEFT
BLK-22A
ORG/RED-3
16
ORG/RED-CR5
DRIVE ENABLE
KEYSWITCH POWER
KS1
RED
RED/WHT-48A
NO
J1
NO
RED
RED-27A
ORG/BLK-15A
ORG/BLK-3
15
ORG/BLK-MH *
ORG/BLK-SP
PLAT. LEVEL DOWN
ORG-3
14
ORG-MH *
ORG-SP
PLAT. LEVEL UP
BLK/WHT-8A
WHT-5
BLU/RED-3
13
DRIVE ENABLE LIGHT
WHT/RED-6A
BLK-5
BLU/WHT-3
12
BLU/BLK-3
11
BLU-3
10
FOOTSWITCH
BLU/BLK-MH
BLU/BLK-SP
SEC. BOOM DOWN
BLU-MH
BLU-SP
SEC. BOOM UP
BLK/RED-3
9
8
BLK/WHT-MH
BLK/WHT-SP
BOOM RETRACT
ORG-14A
BLK-3
BLK-MH
BLK-SP
BOOM EXTEND
GRN/BLK-18A
WHT/RED-3
WHT/RED-MH
WHT/RED-SP
BOOM FUNCTION F.C.
GRN/WHT-19A
GRN/BLK-44A
WHT/BLK-MH
WHT/BLK-SP
TURN. ROTATE RIGHT
WHT-3
WHT-MH
WHT-SP
TURN. ROTATE LEFT
RED/WHT-3
RED/BLK-3
RED/BLK-MH
RED/BLK-SP
PRIMARY BOOM DOWN
RED-3
RED-MH
RED-SP
PRIMARY BOOM UP
48V RELAY COIL PWR.
TS63
CB1
CHASSIS HARNESS
MANIFOLD HARNESS
SP
SWITCH PANEL
CR_
CONTROL RELAY
A2
TRAVEL ALARM (OPTION)
A3
L3
TS58
GRN-43A
RED/BLK-2A
RED-1A
GRN-17A
TS62
WHT-4A
D
TS55
GRN/WHT-19C
TS60
TS55
BLU/BLK-11A
BLK-22B
TS57
WHT/BLK-5A
GRN/WHT-CH
CH
MH
TS61
[* SEE OPTIONAL WIRING]
CR3
TS62
WHT/BLK-3
CR2
TS61
TS59
HORN
RED-27D
D
R
BLK/WHT-3
TS60
BLK-7A
TS63
BLU/WHT-CH
HOURMETER
BATTERY LIGHT
TS62
TS59
HM
25
BLK-CR4
TS58
WHT-2
CR1
TS57
BRAKE RELEASE JACK
24
ORG/RED-CH
J1
GRN/WHT-CR3
TS55
BLK-2
RED/WHT-CR1
KEY SWITCH
TS51
CB2
LIFT LOCKOUT
23
HM
NC
TB36/TB37
TS57
KS1
TILT ALARM
WHT-7
ORG
NC
26
WHT-SP
P1
RED-TILT
ORG
TS60
ORG/RED-CH
40
BLU-MH
TS59
ORG
JIB UP
BLU/BLK-MH
BLK/RED-CR4
TS61
GRN-SP
36
RED-5
TS58
43
SWITCH PANEL
37
NO
TS63
JIB DOWN
BLU-1
WHT/BLK-SP
NO
GRN/BLK-SP
BLU/BLK-1
[OPTION 2]
KS1
BRAKE RELEASE
44
BLU-19D
HM
P1
LS1-LS2 JUNCTION
RED/WHT-MH
BLU/BLK-19D
P1
NC
LS2-LS4 JUNCTION
RED/WHT-SP
42
ORG/RED-1
BLK-8
NC
BRN
A2
A
DESCRIPTION
LABEL
BRN
A3
CR4
BLU-10A
BRN-52A
RED/WHT-TB3D
BLK/RED-HORN
ORG/RED-42D
RED-CH
RED/WHT-48C
CONTROL RELAY I.D.

CR4 - HORN
CR5 - BRAKE RELEASE
OPTION NUMBERS
SPARE WIRE LIST

BLK-1
BLK/WHT-1
BLK/RED-1
BLU/WHT-1
BLU/RED-1
GRN/WHT-1
ORG-1
ORG/BLK-1
Z34/22N after serial number 4008

Z34/22 after serial number 3308
ORG/BLK-MH
ORG-MH
Z34/22N before serial number 4009

Z34/22 before serial number 3309
CR10B
CR10A
CR5
BLK/RED-9D
RED-6
RED/BLK-CH
ORG/RED-16A
TILT SENSOR
RED
WHT
ORG/BLK-15B
ORG-14B
ORG-6
BLK
ORG/BLK-3
15
ORG/BLK-CR10B
ORG/BLK-SP
PLATFORM LEVEL DOWN
ORG-3
14
ORG-CR10A
ORG-SP
PLATFORM LEVEL UP

2 - FLASHING BEACON
3 - DESCENT ALARM
C
B
BRN-CH
TILT SENSOR
RED/WHT-23D
RED-23D
RED/BLK-28D
WHT-28D
BRN-CB2
6 - 32
BLK
BRN-CB2
L3
CB2
BRN-52D
PLATFORM LEVEL CUTOUT (CE VERSION ONLY)
L3
CB2
BLK-CH
ORG/RED-42A
Part No. 36540
BRN-52D
BRN-CH
BLK-CH
ORG/RED-42A


A
[OPTION 2]
A3
BRN
A2
WHT-2
134
RED-A6
RED-KSI
KEYSWITCH POWER
BLK [OPTION 2]
52
BRN-CH
BRN-CR4
GROUND
BRN-5
BRN-2
52
BRN-MH
BRN-SP
GROUND
WHT-6
WHT-8
50
ORG/RED-CR1
J1
RED/WHT-48A
TS55
FUNCTION ENABLE SWITCH
TS57
44
GRN/BLK-SP
JIB DOWN
TS58
JIB UP/DOWN SWITCH
43
GRN-SP
JIB UP
TS59
ORG/RED-L3
SWITCHED 48V
ORG/RED-CH
BRAKE RELEASE
RED/WHT-SP
TS60
STEER RIGHT
TS61
BLU-19D
BLU-1
36
BLU-MH
STEER LEFT
TS62
WHT/RED-1
32
WHT/RED-CH
JOYSTICK POT. LOW
WHT/BLK-1
31
WHT/BLK-CH
REVERSE
TS63
BOOM EXTEND/RETRACT SWITCH
30
WHT-CH
FORWARD
CB1
P1
RED/WHT-1
29
RED/WHT-CH
2-WIRE POT.
CB2
CIRCUIT BRKR., CONTROLS RETURN, 10A
NC
RED/BLK-TILT
RED/BLK-1
28
RED-CR3
RED-1
J1
BRAKE RELEASE JACK
NC
HM
HOURMETER
ORG-CH
OFF-LIMIT SPEED
RED-SP
LIFT LOCKOUT
25
BATTERY LIGHT
24
TRACTION CONTROL
BLK-C23-4
22
GRN/WHT-CR3
19
RED-5
BLK-CR4
GRN/BLK
WHT/BLK-19D/48D
CH
CHASSIS HARNESS
MH
MANIFOLD HARNESS
SWITCH PANEL
BLK-SP
+24V TO PLATFORM
SP
GRN/WHT-MH
LIFT PUMP
BRN-52A
CR_
CONTROL RELAY
A2
BRK. REL./TRAVEL ALARM
CB1
KS1
19
GRN/WHT-SP
LIFT PUMP
GRN/BLK-3
18
GRN/BLK-SP
PLAT. ROTATE RIGHT
GRN-3
17
GRN-SP
PLAT. ROTATE LEFT
A3
ORG/RED-3
16
ORG/RED-CR5
DRIVE ENABLE
A6
PLATFORM OVERLOAD ALARM
BLK-22A
L3
ORG/BLK-15A
L45
PLATFORM OVERLOAD LED
BLK/WHT-8A
ORG/BLK-3
15
ORG/BLK-MH *
ORG/BLK-SP
PLAT. LEVEL DOWN
ORG-3
14
ORG-MH *
ORG-SP
PLAT. LEVEL UP
WHT-5
BLU/RED-3
13
BLK-5
BLU/WHT-3
12
BLU/BLK-3
11
BLU-3
10
BLK/RED-3
BLK/WHT-3
BLK/WHT-MH
BLK/WHT-SP
BOOM RETRACT
BLK-3
BLK-MH
BLK-SP
BOOM EXTEND
WHT/RED-3
WHT/RED-MH
WHT/RED-SP
BOOM FUNCTION F.C.
WHT/BLK-3
WHT/BLK-MH
WHT/BLK-SP
TURN. ROTATE RIGHT
WHT-MH
WHT-SP
DRIVE ENABLE LIGHT
HM
RED-CH
GRN/WHT-3
TS51
L45
RED/134A
RED-C23-6
RED-27A
BLK-7A
WHT/RED-6A
TS59
TS63
BLK/RED-CR4
BLU/WHT-CH
FOOTSWITCH
BLU/BLK-MH
BLU/BLK-SP
SEC. BOOM DOWN
BLU-MH
BLU-SP
SEC. BOOM UP
TS61
TS58
TS57
ORG
RED/WHT-CR1
D
R
U
ORG-14A
GRN/BLK-18A
4
3
RED/BLK-3
RED/BLK-MH
RED/BLK-SP
PRIMARY BOOM DOWN
RED-3
RED-MH
RED-SP
PRIMARY BOOM UP
GRN-43A
RED/BLK-2A
48V RELAY COIL PWR.
WHT/BLK-5A
D
RED-C23-7
GRN/WHT-19C
CR1
RED-27D
GRN/WHT-CH
CR2
CR3
BLK-22B
BLU-10A
CR4
8 12
BRN-52A
RED/WHT-TB3D
SWITCH PANEL
C23
BLK/RED-HORN

ORG/RED-42D
U33
SPARE WIRE LIST

CR4 - HORN
CR5 - BRAKE RELEASE
BLK-1
BLK/WHT-1
BLK/RED-1
BLU/WHT-1
BLU/RED-1
GRN/WHT-1
ORG-1
ORG/BLK-1
ORG/BLK-MH
ORG-MH
CR5
BLK/RED-9D
RED-CH
RED/WHT-48C
CR10A
CR10B
RED-6
RED/BLK-CH
ORG/RED-16A
TILT SENSOR
WHT
ORG-6
BLK
OPTION NUMBERS
ORG/BLK-3
15
ORG/BLK-CR10B
ORG/BLK-SP
PLATFORM LEVEL DOWN

2 - FLASHING BEACON
3 - DESCENT ALARM
ORG-3
14
ORG-CR10A
ORG-SP
PLATFORM LEVEL UP
L3
CB2
BRN-52D
6 - 33
RED
ORG/BLK-15B
ORG-14B
Part No. 36540
L
U
BLU/BLK-11A
CONTROL RELAY I.D.
TS60
TS55
ORG/RED-CH
TS62
WHT-4A
TS55
TS57
GRN-17A
BRN/GND
GRN/BLK H6
BLK-2
BLU/WHT-1
RED-1A
BLK 22C
TS62
TS61
TURN. ROTATE LEFT
WHT-3
RED/WHT-3
TS58
GRN/BLK-44A
RED A6
TS60
HORN
ORG
TS59
TS63
GRN/WHT-19A
ORG
A6
TILT ALARM
26
TB36/TB37
BRN
A2
BLU/BLK-MH
40
27
N
RED 134B
37
NO
AUXILIARY SWITCH
GRN-1
WHT-7
RED C23-1
BLU/BLK-1
WHT/BLK-SP
NO
LS1-LS2 JUNCTION
RED/WHT-MH
23
TS51
BLU/RED-1
LS2-LS4 JUNCTION
GRN/BLK-1
CB1
KS1
KEY SWITCH
TS51
48
42
BLU/BLK-19D
P1
HM
KS1
49
WHT-1
NC
BLK-6
ORG/RED-1
DESCRIPTION
P1
RED/WHT-CR5
BLK-8
NC
KEYSWITCH POWER
BRN-CB2
WHT/BLK-SP
ORG
134A
RED/WHT-TILT
BLK-7
LABEL
BRN
BRN-CH
BLK-CH
ORG/RED-42A
A
C
B
RED/WHT-23D
RED/BLK-28D
BRN-CB2

N
A
1
SWITCH PANEL
RD C23-1
RD/WH-48A
TILT SENSOR
RD
WH
BK
A3
A
C
B
A2
A6
RD/WH-134D
BR-52A
RD/BK-C1B-2
BR-CB2
BR-52A
A2
RD 134B
L3
BL/RD C2B-1
CB2
BR-52D
BK-C49-7
BR-C48-3
OR/RD-42A
GN/BK
WH/BK-19D/48D
BR-52A
BR C32-12
NC
P1
HM
NC
TO TERMINAL BASE
AND CONNECTORS
HM
P1
NC
RD-C48-1
CB1
NC
TS51
KS1
CB1
L45
RD/134A
BK-22A
TS51
RD-C23-6
RD-27A
OR/BK-15A
L45
BK-7A
KS1
BK/WH-8A
LABEL
WH/RD-6A
DESCRIPTION
TS59
TS63
TS63
TS59
OR
TS58
TS61
TS57
OR
KEY SWITCH
TS51
TS55
D
R
TS57
TS58
TS59
TS60
BL/WH C1-12
TS61
BK 22C
GN-43A
TS62
BK C7-1
RD/BK-2A
BR HM(-)
HM
HOURMETER
CH
CHASSIS HARNESS
MH
MANIFOLD HARNESS
SP
SWITCH PANEL
CR
CONTROL RELAY
A2
TRAVEL ALARM
A3
A6
PLATFORM OVERLOAD (CE OPTION)
L3
L45
GN/BK A6
CB2
TS61
GN/BK-44A
BR/GND
GN/WH-19A
BK P22BAT
GN/BK-18A
RD-C23-6
TS63
CB1
OR-14A
BL/WH C132PLI
TS62
KS1
BK 22C
TS60
TS55
RD A6
OR
P1
TS57
TS58
RD-1A
GN-17A
WH/BK-5A
TS62
WH-4A
D
TS60
L
TS55
BL/BK-11A
RD-C32-7
BL-10A
12
C32
U33
PLATFORM OVERLOAD
(OPTION)
Part No. 36540
6 - 34


N
C52
TERMINAL BASE (TB)
LS4-SECONDARY
UP/DOWN
RD/WH (FLASH. BEACON OPT.)
C8
LS3-DRIVE ENABLE
C10
C134PWR
RD-A6 (CE OPTION)
RD-KSI-4
KEYSWITCH POWER
C134PWR
BR-CB2
BK (FLASH. BEACON OPT.)
52
BR- MH
BR-CR4
GROUND
BATGND
BR C7B-3
52
BR
BR-SP
GROUND
BATGND
48
RD/WH-MH
RD/WH-SP
BRAKE RELEASE
C48BRK
OR/RD C49-10
WH/BK-SP
OR/RD C2B-4
42
OR/RD-L3
SWITCHED 48V
R42BAT
BL/BK-19D
BL/BK C1B-11
37
BL/BK-MH
STEER RIGHT
C37SCW
BL-19D
BL C1B-10
36
BL-MH
STEER LEFT
C36SCC
RD-CR3
RD C1B-1
27
RD-SP
C27AUX
WH C10-2
BK-C23-4
22
BK-CR4
+24V TO PLATFORM
P22BAT
BK-SP
GR/WH-CR3
19
GR/WH-MH
LIFT PUMP
C19LPE
GR/WH C4B-7
19
GR/WH-SP
LIFT PUMP
C19LPE
OR/RD C8-1
OR/RD C4B-4
16
OR/RD-CR5
DRIVE ENABLE
C16DE
(CE OPTION)
OR/BK C4B-3
15
OR/BK-MH
OR/BK-SP
PLATFORM LEVEL DOWN
C15PLD
(CE OPTION)
OR C4B-2
14
OR-MH
OR-SP
PLATFORM LEVEL UP
C14PLU
BK C8-3
BL/WH C3B-12
12
BL/WH-CH
FOOTSWITCH
C12FTS
BL/BK C3B-11
11
BL/BK-MH
BL/BK-SP
SECONDARY BOOM DOWN
C11SBD
BL C3B-10
10
TB36/TB37
C7B
BL-MH
BL-SP
SECONDARY BOOM UP
C10SBU
BK/WH C3B-8
BK/WH-MH
BK/WH-SP
BOOM RETRACT
C8PBR
BK C3B-7
BK-MH
BK-SP
BOOM EXTEND
C7PBE
WH/RD C3B-6
WH/RD-MH
WH/RD-SP
BOOM FUNCTION F.C.
C6MFV
WH/BK C3B-5
WH/BK-MH
WH/BK-SP
C5TRR
WH C3B-4
WH-MH
WH-SP
C4TRL
RD/BK C3B-2
RD/BK-MH
RD/BK-SP
PRIMARY BOOM DOWN
C2PBD
RD C3B-1
RD-MH
RD-SP
PRIMARY BOOM UP
C1PBU
WIRES FROM CONNECTOR TO CONNECTOR

CIRCUIT#
FROM
TO
1
DESC.
WH
J2
C11-4
C10-2
BK
J1
C11-3
C52-1
LS1-LS2 JUNCTION
C44JD
C2B-6
SP
JIB DOWN
GR
C43JU
C2B-5
SP
JIB UP
OR
C40LS
C52-2
CH
OFF-LIMIT SPEED
WH/RD
C32JSL
C1B-6
CH
JOYSTICK POT. LOW
WH/BK
C31REV
C1B-5
CH
REVERSE
WH
C30FWD
C1B-4
CH
FORWARD
RD/WH
C29JSH
C1B-3
CH
2-WIRE POT.
GR/BK
LS2-LS4 JUNCTION
RD/BK
C28TTA
TILT-C
C1B-2
TILT ALARM
GR/BK
C18PRR
C4B-6
SP
PLATFORM ROTATE RIGHT
GR
C17PRL
C4B-5
SP
PLATFORM ROTATE LEFT
BL/RD
C13DEL
C8-4
C4B-1
DRIVE ENABLE LIGHT
BK/RD
C9HRN
CR4
C3B-9
HORN
RD/WH
C3BAT
CR1
C3B-3
48V RELAY COIL PWR.
BL/WH
C132PLI
C1B-12
C32-3
PLAT OVERLOAD INPUT (OPTION)
BL/RD
C133PLA
C2B-1
A6(-)
PLAT OVERLOAD ALARM (OPTION)
WIRES
BR C8-2
WH/BK-SP
LS1-PRIMARY
EXTEND/RETRACT
CIRCUIT #
KEYSWITCH POWER
WH C7B-2
OR/RD-CR1
LS2-PRIMARY
UP/DOWN
DESCRIPTION
RD-C32-1
134
134
RD/WH-TILT
RD/WH-CR5
C11
CABLE#2
C4B
CABLE#3
C3B
TO TERMINAL BASE
RD-27D
GR/WH-19C
OR/RD-C48-2
C2B
GR/WH-C49-11
OR RELAY BLOCK
CR1
CR2
CR3
BK-22A
CR4
CABLE#1
BR-52A
C1B
RD/WH-C3B-3
BK/RD-MH-HORN
OR/RD-42D
CONTROL RELAY I.D.

CR4 - HORN
CR5 - BRAKE RELEASE
CR10A - PLAT. LEVEL CUTOUT (CE ONLY)
CR10B - PLAT. LEVEL CUTOUT (CE ONLY)
BK/RD-C3B-9
RD-C49-1
RD/WH-48D
CR10A
CR5
REF.
OR/BK-MH
OR-MH
30
CR10B
RD-C11-1
RD/BK-C49-2
86
85
87A
OR/RD-16A
87
BR-52D
MANIFOLD
HARNESS
(MH)
OR/BK-15A
OR-14A
C48
OR/BK C11-2
CHASSIS
HARNESS
(CH)
C49
OR/BK C4B-3
15
OR/BK-CR10B
OR/BK-SP
PLAT. LEVEL DOWN
OR C4B-2
14
OR-CR10A
OR-SP
PLAT. LEVEL UP
Part No. 36540
6 - 35


A
1
TS9
L.V.I./B.C.I.
(OPTION)
TS8
TS1
NC
TS4
TS3
4
5
DISCHARGE
P2
SET TO "N"
TILT
ALARM
NO
BCI
L1
7
6
LVI
P3
RESET
SET TO "A"
2
1
TS2
NC
CABLE
110
#3
TS6
TS7
TS5
RED
BCI
(OPTION)
FOOT
SWITCH
CABLE
#2
TS18
(OPTION)
BCI
BLK/RED
GRN
RED
MAXOUT
THRESHOLD
-+
LABEL
P2
RED
BP1
R
+
L
RED
RED
RED/WHT
D
X
BLK
+
B
4
2
3
CR5
DESCRIPTION
P3
HORN BUTTON
DP1
DRIVE CONTROLLER
BP1
BOOM SPEED CONTROLLER
TS1
TS2
TS3
TS4
EXTEND/RETRACT TOGGLE SWITCH
TS5
TS6
TS7
JIB BOOM UP/DOWN TOGGLE SWITCH
TS8
AUXILIARY POWER TOGGLE SWITCH
TS9
L1
DRIVE ENABLE LIGHT
BCI
TS18
LIFT/DRIVE SELECT (OPTION)
GRN/WHT#45-1
BLU/RED#39-1
BLU/WHT#48-1
BLK/RED#35-1
BLK/WHT#34-1
RED-JIB
BLK#33-1
BRN-F.S.
ORG/RED-3
RED/BLK-1
BRN
WHT-FS
CR3 COIL +
ORG/RED-1
BLU/WHT-3
WHT-FS
WHT/BLK-3
WHT-3
BLU/BLK-3
BLU-3
GRN/BLK#44-1
GRN#43-1
GRN/WHT-3
Part No. 36540
WHT/RED-3
ORG/BLK-3
ORG-3
RED/BLK-3
RED-3
BRN-2
BLK/WHT-3
BLUE-JIB
GRN/BLK-3
ORG-JIB
GRN-3
BLK-3
BLU/RED-3
BLK/RED-3
ORG/RED#42-1
WHT#30-1
WHT/BLK#31-1
WHT/RED#32-1
ORG/BLK#41-1
RED/WHT-3
ORG#40-1
BLU/BLK#37-1
6 - 36
RED/WHT#29-1
BLU#36-1
BRN-JIB
RED-TILT ALARM
WHT-2
BLK-FS
BLK-2
RED#27-1
WHT-JIB
BLK-JIB
WHT
DP1
WHT/BLK
JIB
#1
CABLE
SPARE
WIRES

N
A
1
WHT
TS15
ORG/BLK
TS1
RED
TS12
P3
A1
L1
NO
RED
3
TS11
TS13
NC
P2
CABLE
#3
TS10
NC
TS7
TS9
110
4
CABLE
#2
TS8
BCI
F.S.
RED
BRN
GRN
BLK/RED
BRN-JIB
CABLE
#1
JIB
BP1
BRN
9 10
DESCRIPTION
HORN BUTTON
DRIVE CONTROLLER
JIB BOMM UP/DOWN TOGGLE SWITCH
EXTEND/RETRACT TOGLE SWITCH
TILT ALARM
DRIVE ENABLE LIGHT
RED/BLK-1
BLU/WHT-3
ORG/RED
WHT/BLK-3
ORG/BLK-1
WHT-3
BLU/BLK-3
BLU-3
GRN/BLK-1
GRN-1
GRN/WHT-3
WHT/RED-3
ORG/BLK-3
ORG-3
RED-3
RED/BLK-3
GRN-3
GRN/BLK-3
BLK/WHT-3
BLK-3
BLU/RED-3
BLU/BLK-1
BLU-1
WHT-FS
WHT-1
WHT/BLK-1
WHT/RED-1
ORG/RED-1
RED/WHT-1
RED/WHT-3
WHT-2
BLK-F.S.
BLK-2
BLK/RED-3
BLUE-JIB
RED-1
ORG-JIB
WHT-JIB
BLK-JIB
REMOVE THIS WIRE WHEN

LOAD SENSE OPTION IS REQUIRED.
BRN-2
L
1
LABEL
P2
P3
DP1
BP1
TS1
TS7
TS8
TS9
TS10
TS11
TS12
TS13
TS15
A1
L1
BCI
REMOVE JUMPER JP1 FOR CE VERSION.
Part No. 36540
6 - 37


A
WHT
WHT
SPARE WIRES
________________
BLK-1
BLK/WHT-1
BLK/RED-1
BLU/WHT-1
BLU/RED-1
GRN/WHT-1
ORG-1
ORG/BLK-1
TS15
TS1
L1
TS7
TS9
TS12
A1
NO
WHT
P3
3
CABLE
#3
NC
TS10
NC
TS13
F.S.
CABLE
#2
ORG/RED
LOAD SENSE
(OPTION)
RED
RED
TS11
P2
TS8
BRN
BP1
BLK/RED
RED
GRN
JIB
CABLE
#1
BCI
(OPTION)
BRN-JIB
BRN
6
RED
BRN-2
DP1
DESCRIPTION
LABEL
P2
P3
HORN BUTTON
DP1
DRIVE CONTROLLER
BP1
TS1
TS7
TS8
JIB BOOM UP/DOWN TOGGLE SWITCH
TS9
TS10
TS11
TS12
TS13
PRIMARY EXTEND/RETRACT TOGGLE SWITCH
TS15
A1
TILT ALARM
L1
DRIVE ENABLE LIGHT
BCI
BATTERY CHARGE INDICATOR (OPTION)
9 10
NOTES:
8
RED/BLK-1
BLU/WHT-3
ORG/RED-3
WHT/BLK-3
BLU/BLK-3
WHT-3
BLU-3
WHT/RED-3
GRN/BLK-3
GRN-3
GRN-1
GRN/WHT-3
RED/BLK-3
GRN/BLK-1
RED-3
Part No. 36540
ORG-3
ORG/BLK-3
BLK-3
BLK/WHT-3
BLU/RED-3
BLU/BLK-1
BLU-1
WHT-FS
WHT/BLK-1
WHT-1
WHT/RED-1
RED/WHT-1
RED/WHT-3
WHT-2
ORG/RED-1
BLK-FS
BLK-2
BLK/RED-3
RED-1
BLUE-JIB
ORG-JIB
WHT-JIB
BLK-JIB
6 - 38
REMOVE THIS WIRE WHEN LOAD SENSE OPTION IS REQUIRED.

N
A
1
WHT
WHT
SPARE WIRES
________________
BLK-1
BLK/WHT-1
BLK/RED-1
BLU/WHT-1
BLU/RED-1
GRN/WHT-1
ORG-1
ORG/BLK-1
TS15
L1
TS1
TS12
TS7
TS9
A1
NO
WHT
P3
CABLE
#3
LOAD SENSE
(OPTION)
RED
RED
TS11
P2
NC
TS10
NC
TS13
F.S.
CABLE
#1
JIB
CABLE
#2
ORG/RED
TS8
BCI
(OPTION)
BRN
BP1
BLK/RED
RED
GRN
LABEL
P2
P3
BRN-JIB
BRN
10
BRN-2
DP1
HORN BUTTON
DP1
DRIVE CONTROLLER
BP1
TS1
TS7
TS8
TS9
PLATFORM LEVEL TOGLE SWITCH
TS10
TS11
RED
DESCRIPTION
TS12
TS13
EXTEND/RETRACT TOGGLE SWITCH
TS15
A1
TILT ALARM
L1
DRIVE ENABLE LIGHT
BCI
7
1
NOTES:
REMOVE THIS WIRE WHEN LOAD SENSE OPTION IS REQUIRED.
RED/BLK-1
ORG/RED-3
BLU/WHT-3
WHT/BLK-3
WHT-3
BLU/BLK-3
BLU-3
WHT/RED-3
GRN/BLK-3
GRN-3
GRN-1
GRN/WHT-3
GRN/BLK-1
RED-3
RED/BLK-3
ORG-3
ORG/BLK-3
BLK-3
BLK/WHT-3
BLU/RED-3
BLU/BLK-1
BLU-1
WHT-FS
WHT/BLK-1
WHT-1
WHT/RED-1
RED/WHT-1
RED/WHT-3
WHT-2
ORG/RED-1
BLK-FS
BLK-2
BLK/RED-3
RED-1
BLUE-JIB
ORG-JIB
WHT-JIB
BLK-JIB
Part No. 36540
6 - 39


N
A
1
WHT
WHT
SPARE WIRES
________________
BLK-1
BLK/WHT-1
BLK/RED-1
ORG-1
ORG/BLK-1
TS15
L1
TS1
TS12
TS7
TS9
A1
LS18
RED
NO
WHT
P3
CABLE
#3
TS11
U
RED
NC
P2
RED
NC
TS10
TS13
F.S.
CABLE
#1
JIB
CABLE
#2
ORG/RED
TS8
BCI
(OPTION)
BRN
LABEL
BLK/RED
RED
GRN
BP1
BRN-JIB
L4
BRN
RED/BLK
RED
10
BRN-2
DP1
DESCRIPTION
P2
P3
HORN BUTTON
DP1
DRIVE CONTROLLER
BP1
TS1
AUXILIARY SWITCH
TS7
TS8
JIB UP/DOWN SWITCH
TS9
TS10
TS11
TS12
TS13
TS15
DRIVE ENABLE SWITCH
A1
TILT ALARM
L1
DRIVE ENABLE LIGHT
BCI
L4
TILT ALARM LED
L48
L48
GRN/BLK
NOTES:
1 REMOVE JUMPER JP1 FOR CE VERSION.
BLU/RED-1
BLU/WHT-1
RED/BLK-1
BLU/WHT-3
WHT-2
WHT/BLK-3
ORG/RED-3
WHT-3
BLU/BLK-3
WHT/RED-3
BLU-3
GRN/BLK-3
GRN-1
GRN-3
GRN/WHT-3
GRN/BLK-1
RED-3
RED/BLK-3
ORG-3
BLK/WHT-3
ORG/BLK-3
BLU/RED-3
BLK-3
BLU/BLK-1
BLU-1
WHT-FS
WHT-1
WHT/RED-1
WHT/BLK-1
RED/WHT-1
RED/WHT-3
ORG/RED-1
BLK-FS
BLK-2
BLK/RED-3
RED-1
BLUE-JIB
ORG-JIB
WHT-JIB
BLK-JIB
Part No. 36540
6 - 40

Hydraulic Schematic
A
N.O.
COM
STEER
CYLINDER
N.C.
BRAKES
S2
S1
0.052
(1.32 mm)
0.040"
(1 mm)
0.085"
(2.15 mm)
BRAKE
P
H
PLATFORM LEVEL
SLAVE CYLINDER
JIB BOOM
CYLINDER
STEER/BRAKE
MANIFOLD
0.025"
(0.63 mm)
ORFICE DELETED
Z-34/22 AFTER SERIAL NUMBER 581
Z-34/22N AFTER SERIAL NUMBER 767
3
PLATFORM
ROTATE
SECONDARY
CYLINDER
4
M
AUXILIARY
PUMP
0.5 GPM
(1.9 L/min)
0.032"
(0.81 mm)
PRIMARY
PUMP
1.7 GPM
(6.4 L/min)
3000 PSI
(207 bar)
8:1
100
MICRON
MESH
EXTENSION
CYLINDER
PRIMARY
CYLINDER
TURNTABLE
ROTATE
MASTER
CYLINDER
2500 PSI
(172 bar)
3:1
2500 PSI
(172 bar)
3:1
5.9 CU. IN.

/REV
TANK, 4 GALLON
(15.1 Liters)
P1
BOOM FUNCTION
MANIFOLD
G1
C1
C2
M1
C5
C6
C7
C8
C
AP
1750 PSI
(121 bar)
AA
3000 PSI
(207 bar)
3:1
AU
AG
AR
AS
1600 PSI
(110 bar)
1400 PSI
(96 bar)
AT
1800 PSI
(124 bar)
AL
AK
AF
AE
AJ
AD
AI
AH
AC
P2
AM
0.050"
(1.27 mm)
T2
T1
AQ
1750 PSI
(121 bar)
25 PSI
(1.7 bar)
6 - 41
C4
T1
AB
5
MICRON
C3
JIB/PLATFORM
ROTATE
MANIFOLD
0.025"
T2
PR1 (0.76 mm) PR2
AN
AO
3200 PSI
(221 bar)
M2
2500 PSI
(172 bar)
3:1
3000 PSI
(207 bar)
3:1
3000 PSI
(207 bar)
1.5:1
Part No. 36540
Hydraulic Schematic
N
F
N.O.
COM
STEER
CYLINDER
N.C.
A
1
BRAKES
S2
S1
0.052
(1.32 mm)
0.040"
(1 mm)
0.085"
(2.15 mm)
BRAKE
P
H
PLATFORM LEVEL
SLAVE CYLINDER
JIB BOOM
CYLINDER
STEER/BRAKE
MANIFOLD
PLATFORM
ROTATE
PRIMARY
CYLINDER
SECONDARY
CYLINDER
M
AUXILIARY
PUMP
0.5 GPM
(1.9 L/min)
PRIMARY
PUMP
1.7 GPM
(6.4 L/min)
100
MICRON
MESH
EXTENSION
CYLINDER
0.032"
(0.81 mm)
3000 PSI
(207 bar)
8:1
TURNTABLE
ROTATE
MASTER
CYLINDER
5.9 CU. IN.

/REV
2500 PSI
(172 bar)
3:1
2500 PSI
(172 bar)
3:1
TANK, 4 GALLON
(15.1 Liters)
P1
G1
C1
C2
M1
M2
BN
BP
BQ
C4
C5
C6
C7
JIB UP/DOWN,
PLATFORM ROTATE
MANIFOLD
0.025
T2
PR1 (0.76 mm) PR2
C8
T1
FUNCTION
MANIFOLD
BO
BB
BA
BS
1400 PSI
(96 bar)
BT
1800 PSI
(124 bar)
F
BG
25 PSI
(1.7 bar)
BU
1500 PSI
(103 bar)
3:1
3000 PSI
(207 bar)
3:1
BK
BL
BF
BE
BJ
BD
BI
BH
0.028
(0.89 mm)
BC
8
P2
BM
C
BR
1600 PSI
(110 bar)
3200 PSI
(221 bar)
5
MICRON
C3
2500 PSI
(172 bar)
3:1
3000 PSI
(207 bar)
3:1
3000 PSI
(207 bar)
1.5:1
0.050"
(1.27 mm)
ORFICE ADDED
Z34/22 AFTER SERIAL NUMBER 781
Z34/22N AFTER SERIAL NUMBER 1030
T2
T1
Part No. 36540
6 - 42
Hydraulic Schematic
Hydraulic Schematic
A
JIB BOOM
CYLINDER
PLATFORM
ROTATE
2
UP 3000 PSI DOWN
(207 bar)
3:1
J1
PR1
C
AUXILIARY
PUMP
0.5 GPM
(1.9 L/min)
PRIMARY
PUMP
2.1 GPM
(7.9 L/min)
STEER
CYLINDER
M
MASTER
CYLINDER
100
MICRON
MESH
COM
CT
P1
BOOM
FUNCTION
MANIFOLD
T
PRIMARY
CYLINDER
EXTENSION
CYLINDER
0.032
(0.81 mm)
5.9 CU. IN.

/REV
CL
HYDRAULIC TANK
5 GALLON
(18.9 L)
TURNTABLE
ROTATE
BRAKES
10
MICRON
SECONDARY
CYLINDER
3000 PSI
(207 bar)
8:1
0.025 inch / 0.64 mm

(before serial number: Z34-1982 and Z34N-2548)
0.022 inch / 0.56 mm
(from serial number: Z34-1892 to 2005 and Z34N-2548 to 2771)
0.030
(0.76 mm)
Orifice removed after

serial number:
Z34-1891 and Z34N-2547
JIB UP/DOWN,
PLATFORM ROTATE
MANIFOLD
PR2
PLATFORM LEVEL
SLAVE CYLINDER
BRAKE
G1
N.O.
N.C.
PS
S1
S2
L2
L1
P2
TR1
CO
3200 PSI
(221 bar)
0.045
(1.14 mm)
CN
CH
CP
3000 PSI
(207 bar)
1.5:1
SC1
SC2
CE
3000 PSI
(207 bar)
3:1
PC1
PC2
CF
2500 PSI
(172 bar)
3:1
RET
EXT
CG
CM
CC
CJ
CQ
TR2
CD
CR
CI
3000 PSI
(207 bar)
3:1
CB
1100 PSI
(76 bar)
0.045
(1.14 mm)
0.8 GPM
(3.6 L/min)
CA
CX
T1
6 - 43
J2
V1 3000 PSI V2
(207 bar)
3:1
CY
1.5 GPM
(6.8 L/min)
1600 PSI
(110 bar)
CU
1400 PSI
(97 bar)
CV
1800 PSI
(124 bar)
CK
CW
T2
Part No. 36540
Hydraulic Schematic
N
JIB BOOM
CYLINDER
1
PLATFORM ROTATE
2
ROTATE MANIFOLD
EXT
PR1
RET
3000 PSI
207 bar
1.5:1
J1
PR2
3300 PSI
228 bar
3:1
J2
PR1
PR2
C 0.3 GPM
PLATFORM LEVEL
SLAVE CYLINDER
1.14 L/min
T
JIB MANIFOLD
PRIMARY
CYLINDER
SECONDARY
CYLINDER
STEER
CYLINDER
EXTENSION
CYLINDER
0.032
0.81 mm
5
TURNTABLE ROTATE
(WORM DRIVE)
BRAKES
3000 PSI
207 bar
4.5:1
5.9 CU. IN./REV

97 cc /REV
MASTER
CYLINDER
6
3000 PSI
207 bar
1.5:1
CL
3000 PSI
207 bar
3:1
N.O.
COM
CT
3200 PSI
221 bar
G1
CO
CR
N.C.
PS
S2
P1
PRIMARY
PUMP
2.1 GPM
8 L/min
S1
AUXILIARY
PUMP
0.5 GPM
1.9 L/min
BRAKE
P2
L2
L1
TR2
TR1
CC
0.045 inch
1.14 mm
CN
CH
10 MICRON
CP
SC2
SC1
PC1
PC2
EXT
RET
CD
CM
CB
CJ
CQ
2500 PSI
172 bar
3:1
3000 PSI
207 bar
3:1
CI
0.045 inch
1.14 mm
1100 PSI
76 bar
CW
100 MESH
CX
0.8 GPM
3 L/min
CA
CY
1600 PSI
110 bar
1400 PSI
110 bar
CE
CF
CU
1800 PSI
124 bar
CG
CV
CK
1.5 GPM
5.7 L/min
Orifice added after serial number:
Z-34/22-2894
Z-34/22N-3517
HYDRAULIC TANK
0.035 inch
0.89 mm
T1
Part No. 36540
CS
T2
6 - 44
Hydraulic Schematic
Hydraulic Schematic
N
A
1
JIB BOOM
CYLINDER
PLATFORM ROTATE
EXT
PR1
RET
3000 PSI
207 bar
1.5:1
J1
PR2
3300 PSI
228 bar
3:1
J2
PR1
PLATFORM LEVEL
SLAVE CYLINDER
PR2
0.3 GPM
1.14 L/min
T
JIB MANIFOLD
EXTENSION CYLINDER
SECONDARY CYLINDER
PRIMARY CYLINDER
0.032
0.81 mm
STEER CYLINDER
BRAKES
TURNTABLE ROTATE
(WORM DRIVE)
3000 PSI
207 bar
4.5:1
0.090 inch
2.28 mm
Regen added after

serial numbers:
Z34-3216
Z34N-3767
5.9 CU. IN./REV

97 cc /REV
MASTER
CYLINDER
.090 orifice added

after serial numbers:
Z34-3327
Z34N-4017
CL
N.O.
COM
CT
3200 PSI
221 bar
G1
CO
CR
BRAKE
PS
S2
P1
PRIMARY
PUMP
2.1 GPM
8 L/min
S1
AUXILIARY
PUMP
0.5 GPM
1.9 L/min
N.C.
P2
L2
L1
TR2
TR1
0.045 inch
1.14 mm
CB
3000 PSI
207 bar
3:1
CJ
CP
CI
0.045 inch
1.14 mm
10 MICRON
100 MESH
CX
CH
PC2
EXT
RET
0.8 GPM
3 L/min
CA
1100 PSI
76 bar
CW
CY
1600 PSI
110 bar
1600 PSI
110 bar
2800 PSI
193 bar
CE
CF
CG
CU
CV
Removed after
serial number:
Z34-3215
Z34N-3766
CM
CC
CN
PC1
CD
CQ
SC2
SC1
2500 PSI
172 bar
3:1
3000 PSI
207 bar
3:1
3000 PSI
207 bar
1.5:1
CK
1.5 GPM
5.7 L/min
HYDRAULIC TANK
0.035 inch
0.89 mm
T1
Part No. 36540
CS
T2
6 - 45
Hydraulic Schematic
Section 7 Repair Procedures
Repair Procedures
About This Section
Most of the procedures in this section should only
be performed by a trained service professional
in a suitably equipped workshop. Select the
appropriate repair procedure after troubleshooting
the problem.
Observe and Obey:

Repair procedures shall be completed by a
person trained and qualified on the repair of
this machine.
Perform disassembly procedures to the point

where repairs can be completed. Then to
re-assemble, perform the disassembly steps in
reverse order.
Symbols Legend

Before Repairs Start:

serious injury.

and operating instructions in the Genie Z-34/22
& Genie Z-34/22N Operator's Manual.
Be sure that all necessary tools and parts are
available and ready for use.

serious injury.
Read each procedure completely and adhere to

the instructions. Attempting shortcuts may
produce hazardous conditions.
Unless otherwise specified, perform each repair
procedure with the machine in the following
configuration:

Machine parked on a flat, level surface

Boom in stowed position

damage.
Turntable rotated with the boom between

the non-steering wheels
Key switch in the OFF position with the key
removed
Wheels chocked
Greenused to indicate operation

or maintenance information.
Indicates that a specific result is expected after
performing a series of steps.
Part No. 36540
7-1
Platform Controls
1-1
Controllers
Drive Controller Adjustments
The drive controller (joystick) is connected by a

control cable to the drive motor controller located
under the non-steer end drive chassis cover.
Maintaining the controllers at the proper setting is
essential to safe machine operation. Each
controller should operate smoothly and provide
proportional speed control through its entire range
of motion. For further information or assistance,
contact the Genie Industries Service Department.
Z-34/22: before serial number 153

Z-34/22N: before serial number 304
Do not adjust the controllers
unless the static battery supply
voltage is above 24V DC.
This procedure will require the use
of two multi-meters. One will be
used for measuring amperage and
the other for voltage.
and other jewelry.
Individual trim potentiometers
(trimpots) are used to adjust
various output signals from the
drive and boom function speed
controllers. The trimpots will be
identified as the following:
d
a
b
c
d
boom function speed controller

drive printed circuit board
drive controller
brake printed circuit board
Max out trim potentiometer (max out trimpot)
High range trim potentiometer (max out trimpot)
Lo range trim potentiometer (lo range trimpot)
Dual range trim potentiometer (lo range trimpot)
Threshold trim potentiometer (threshold trimpot)
Ramp rate trim potentiometer (ramp rate trimpot)
1 Block the steering wheels.

2 Center a lifting jack of ample capacity
(15000 lbs/6804 kg) under the drive chassis
between the non-steering wheels.
7-2
Part No. 36540
PLATFORM CONTROLS
3 Lift the wheels off the ground approximately 1

to 2 inches (2.5 to 5 cm) and place jack stands
under the drive chassis for support.
4 Open the platform control box lid and locate the
brake controller printed circuit board.
6 Connect the black (-) lead from an ammeter to

the white/red wire that was removed from the
brake circuit board. Connect the red (+) lead to
the "A" terminal on the brake controller printed
circuit board.
7 Locate the drive controller printed circuit board.
a
Brake
Drive
a
b
c
d
e
f
g
h
not used
not used
terminal "X",
terminal "-", ground
terminal "+",
terminal "A", proportional output
threshold adjustable trimpot
max out adjustable trimpot
5 Disconnect the white/red wire from the "A"

terminal on the brake controller printed circuit
board.
Part No. 36540
Brake
a
b
c
d
e
f
g
h
i
Drive
max out adjustable trimpot
threshold adjustable trimpot
terminal "A", proportional output
not used
terminal (blank)
not used
terminal "R", activates max out range
lo range adjustable trimpot
8 Connect the red (+) lead from a volt meter to

the "A" terminal on the drive controller printed
circuit board. Connect the black (-) lead to
ground.
7-3
PLATFORM CONTROLS
9 Turn the key switch to platform controls and pull

both Emergency Stop buttons out to the ON
position.
10 Set the threshold on the brake circuit board:
Press down the foot switch and slowly move
the control handle off center until you hear the
pump motor turn ON. Adjust the amperage to
0.16 amps. Turn the threshold trimpot
adjustment screw clockwise to increase the
amperage or counterclockwise to decrease the
amperage.
11 Set the max out on the brake circuit board:
pump motor turn OFF. Adjust the amperage to
0.91 amps. Turn the max out trimpot
amperage.
12 Set the threshold on the drive circuit board:
the control handle off center until you see 0.28
to 0.3 amps on the ammeter. Adjust the
threshold trimpot on the drive circuit board to
0.8 to 0.9V DC. Turn the threshold trimpot
voltage or counterclockwise to decrease the
voltage.
13 Set the max out on the drive circuit board:
the control handle all the way to the FORWARD
position. Adjust the max out trimpot on the
drive circuit board to 5 to 5.2V DC. Turn the
max out trimpot adjustment screw clockwise to
increase the voltage or counterclockwise to
decrease the voltage.
(0.6 m).
7-4
15 Set the lo range on the drive circuit board:

Press down the foot switch and move the
control handle all the way to the FORWARD
position. Adjust the lo range trimpot on the
drive circuit board to 2.4 to 2.7V DC. Turn the
lo range trimpot adjustment screw clockwise to
16 Lower the boom to the stowed position and
remove the jack stands from under the drive
chassis.
(0.6 m).
Choose a reference point on the machine as a
visual reference for use when crossing the start
and finish lines.
19 Bring the machine to top drive speed before
reaching the start line. Begin timing when your
reference point on the machine crosses the
start line.
the reference point crosses the finish line.
21 Adjust the lo range trimpot on the drive circuit
board to achieve a 40 second drive speed time.
Turn the lo range trimpot clockwise to decrease
the time or counterclockwise to increase the
time.
start line.
Part No. 36540
PLATFORM CONTROLS
25 Adjust max out trimpot on the drive circuit

board to achieve the specified drive speed time
(refer to table below). Turn the high range
trimpot clockwise to decrease the time or
counterclockwise to increase the time.
Drive Controller Adjustments

Z-34/22 from serial number 153 to 1733
Z-34/22N from serial number 304 to 2226
Drive controller specifications

Brake board
Threshold
(when pump motor turns
ON)
Max out
OFF)
0.16 amps
This procedure will require the use

of two multi-meters. One will be
used for measuring amperage and
the other for voltage.
0.91 amps

and other jewelry.
Drive board
Threshold
0.8 to 0.9V DC
(when amp output is 0.28 to 0.3 amps)
Max out
5 to 5.2V DC
(with boom stowed and joystick in full forward position)
Lo range
2.4 to 2.7V DC
(with boom raised and joystick in full forward position)
1 Block the steering wheels and center a lifting

jack under the drive chassis between the nonsteer tires.

stowed position
49:1 drive hubs
3.1 mph
5 km/h
40 ft/9.1 sec 12.2 m/9.1 sec
35:1 drive hubs
4 mph
6.4 km/h
40ft/6.8 sec 12.2 m/6.8 sec

stowed position
49:1 drive hubs
2.8 mph
40 ft/10 sec
35:1 drive hubs
3.4 mph
40ft/8 sec
4.5 km/h
12.2 m/10 sec
5.5 km/h
12.2 m/8 sec
Drive speed,
0.6 mph
1 km/h
c
a
b
c
Part No. 36540

drive and brake printed circuit board
drive controller
7-5
PLATFORM CONTROLS
2 Raise the drive chassis approximately 1 to 2

inches (2.5 to 5 cm) off the ground and place
jack stands under the chassis for support.
printed circuit board on the drive controller.
a
b
c
d
e
f
g
h
i
j
k
a
b
c
d
e
f
g
h
i
j
k
terminal "R", activates max out range

terminal "D", drive output
terminal "X"
terminal "+", positive
terminal "B", brake output
drive lo range trimpot
drive threshold trimpot
drive max out trimpot
brake threshold trimpot
brake max out trimpot
4 Disconnect the white/red wire from the "B"

terminal on the printed circuit board.
7-6
5 Connect the black (-) lead from an ammeter to

the white/red wire that was removed from the
circuit board. Connect the red (+) lead to the
"B" terminal on the printed circuit board.
the "D" terminal on the drive controller printed
circuit board. Connect the black (-) lead to
ground.
controls.
8 Set the brake threshold on the circuit board:
pump motor turn ON. Adjust the amperage to
0.16 amps. Turn the threshold trimpot
amperage.
9 Set the brake max out on the circuit board:
pump motor turn OFF. Adjust the amperage to
0.91 amps. Turn the max out trimpot
amperage.
10 Set the drive threshold on the circuit board:
the control handle off center until you see 0.28
to 0.3 amps on the ammeter. Hold the control
handle in this position and adjust the drive
threshold trimpot on the circuit board to 0.8 to
0.9V DC. Turn the threshold trimpot adjustment
screw clockwise to increase the voltage or
counterclockwise to decrease the voltage.
Part No. 36540
PLATFORM CONTROLS
11 Set the drive max out on the circuit board: Press

down the foot switch and slowly move the
position. Adjust the max out trimpot on the
circuit board to 5 to 5.2V DC. Turn the max out
trimpot adjustment screw clockwise to increase
the voltage or counterclockwise to decrease
the voltage.

(0.6 m) to activate the drive limit switch.
23 Adjust max out trimpot on the drive circuit

board to achieve the specified drive speed time
(refer to table below). Turn the max out trimpot
clockwise to decrease the time or
counterclockwise to increase the time.
13 Set the drive lo range on the circuit board:

Press down the foot switch and move the
position. Adjust the drive lo range trimpot on
the circuit board to 2.4 to 2.7V DC. Turn the
lo range trimpot adjustment screw clockwise to
14 Lower the boom to the stowed position and
remove the jack stands from under the drive
chassis.
(0.6 m) to activate the drive limit switch.
Choose a reference point on the machine as a
visual reference for use when crossing the start
and finish lines.
start line.
19 Adjust the drive lo range trimpot on the circuit
board to achieve a 40 second drive speed time.
Turn the lo range trimpot clockwise to decrease
the time or counterclockwise to increase the
time.
Part No. 36540

start line.
Drive controller specifications

Brake board
Threshold
ON)
Max out
OFF)
0.16 amps
0.91 amps
Drive board
Threshold
0.8 to 0.9V DC
(when amp output is 0.28 to 0.3 amps)
Max out
5 to 5.2V DC
(with boom stowed and joystick in full forward position)
Lo range
2.4 to 2.7V DC
(with boom raised and joystick in full forward position)
stowed position
49:1 drive hubs
3.1 mph
5 km/h
40 ft/9.1 sec 12.2 m/9.1 sec
35:1 drive hubs
4 mph
6.4 km/h
40ft/6.8 sec 12.2 m/6.8 sec

stowed position
49:1 drive hubs
2.8 mph
40 ft/10 sec
4.5 km/h
12.2 m/10 sec
35:1 drive hubs
3.4 mph
5.5 km/h
40ft/8 sec 12.2 m/8 sec
7-7
PLATFORM CONTROLS
3 Locate the diode between the black/red wire

from the boom function speed controller and
the white/red wire.
Boom Function Speed

Controller Adjustments

the wire connector of the white/red wire next to
the diode. Connect the black (-) lead to ground.

and other jewelry.
5 Turn the boom function speed controller to the

CREEP position.

controls.
boom function speed controller.
e
b
c
6 Set the threshold: Press down the foot switch,

and move the primary boom toggle switch to
the DOWN position. Adjust the voltage to 8V DC.
Turn the threshold trimpot adjustment screw
clockwise to increase the voltage or
7 Turn the boom function speed controller to
the 9 position.
8 Set the max out: Press down the foot switch,
then move the primary boom toggle switch to
the DOWN position. Adjust the voltage to 15.5V
DC. Turn the max out trimpot adjustment
screw clockwise to increase the voltage or
If equipped:
a
b
c
d
e
f
7-8
black/red wire
diode
white/red wire
max out trimpot
threshold trimpot
9 Set the ramp rate: Turn the ramp rate trimpot to

obtain a 2 second delay from 0 to 15.5V DC.
Turn the trimpot clockwise to increase the time
or counterclockwise to decrease the time.
Boom function speed
controller specifications
Threshold
(controller turned to "CREEP")
8V DC
Max out
(controller turned to "9")
15.5V DC
Ramp
(controller turned to "9")
Added after serial numbers:
Z34-1924
Z34N-2553
2 seconds
Part No. 36540
PLATFORM CONTROLS
3 Press down the foot switch. Connect the leads

from an ohmmeter or continuity tester to each
wire combination listed below and check for
continuity.
1-2
Foot Switch
How to Test the Foot Switch
Test
1 Turn the key switch to the OFF position and

separate the wiring quick disconnect plug from
the platform toe board.
2 Do not press down the foot switch. Connect the
leads from an ohmmeter or continuity tester to
each wire combination listed below and check
for continuity.
Test
Desired result
red to black
no continuity
(infinite )
red to white
no continuity
(infinite )
black to white
continuity
(zero )
Desired result
red to black
continuity
(zero )
red to white
no continuity
(infinite )
black to white
no continuity
(infinite )
FOOT SWITCH
Do not use the color of the

connector as a guide for these
tests. Use the actual wire color
to identify which connector to
use for testing.
Part No. 36540
7-9
PLATFORM CONTROLS
1-3
Toggle Switches
Test
Toggle switches used for single function switching

are single pole double throw (SPDT) switches.
Dual function switching requires a double pole
double throw (DPDT) switch.
terminal 1 to 2, 3, 4, 5 & 6
How to Test a Toggle Switch
terminal 2 to 4, 5 & 6
no continuity
(infinite )
no continuity
(infinite )
terminal 4 to 5 & 6
no continuity
(infinite )
Left position
Continuity is the equivalent of 0 to

3 ohms. A simple continuity tester
may not accurately test the
switch.
This procedure covers fundamental switch testing
and does not specifically apply to all varieties of
toggle switches.
1 Turn the key switch to the OFF position. Tag
and disconnect all wiring from the toggle switch
to be tested.
2 Connect the leads of an ohmmeter to the
switch terminals in the following combinations
listed below to check for continuity.
Left
Single pole
double throw
(SPDT)
Right
Center
terminal 2 to 3
terminal 5 to 6
Center position
no continuity
(infinite )
continuity
(zero )
continuity
(zero )
There are no terminal
combinations that will
produce continuity
(infinite )
Right position
terminal 1 to 2
continuity
(zero )
terminal 1 to 3, 4, 5 & 6
no continuity
(infinite )
no continuity
(infinite )
no continuity
(infinite )
terminal 4 to 5
continuity
(zero )
terminal 4 to 6
no continuity
(infinite )
terminal 5 to 6
no continuity
(infinite )
3
2
Double pole
double throw
(DPDT)
7 - 10
Desired result
Part No. 36540
Platform Components
2-1
Platform
2-2
Platform Leveling Slave Cylinder
How to Remove the Platform
The slave cylinder and the platform rotator are the

two primary supports for the platform. The slave
cylinder keeps the platform level through the
entire range of primary boom motion. It operates
in a closed-circuit hydraulic loop with the master
cylinder. The slave cylinder is equipped with
counterbalance valves to prevent platform
1 Separate the foot switch wiring quick

disconnect plug from the platform toeboard.
2 Remove the platform control box mounting
fasteners, then lower the control box.
If your machine is equipped with
an air line to platform option, the
air line must be disconnected from
the platform before removal.
How to Remove the Slave

Cylinder
3 Place blocks under the platform for support and

carefully lower the platform on the blocks.
Before cylinder removal is

considered, bleed the slave
cylinder to be sure there is no
air in the closed loop hydraulic
circuit.
Specifications.
4 Remove the platform mounting fasteners and

remove the platform.
Component damage hazard.
Platform can be damaged if the
fasteners are overtightened.
Part No. 36540
1 Extend the boom until the slave cylinder

barrel-end pivot pin is accessible.
2 Raise the boom slightly and place blocks under
the platform for support. Lower the boom until
the platform is resting on the blocks.
3 Remove the pin retaining fastener from
the rod-end pivot pin. Do not remove the pin.
7 - 11
PLATFORM COMPONENTS
4 Remove the external snap ring from the

barrel-end pivot pin.
How to Bleed the Slave Cylinder
5 Place a block of wood under the barrel end of

the slave cylinder.
1 Raise the jib boom to a horizontal position.
6 Use a soft metal drift to remove the rod-end

pivot pin.
2 Move the platform level toggle switch up and

down through two platform leveling cycles to
remove any air that might be in the system.
7 Use a soft metal drift to remove the barrel-end

pivot pin.
8 Carefully pull the cylinder out of the boom.
Crushing hazard. The slave
cylinder will fall unless it is
properly supported.
9 Tag and disconnect the hydraulic hoses from
the slave cylinder and connect them together
with a connector. Cap the fittings on the
cylinder.
squirt or spray.
7 - 12
Part No. 36540
PLATFORM COMPONENTS
2-3
Platform Rotator
The platform rotator is a hydraulically activated
helical gear assembly used to rotate the platform
160 degrees.
4 Remove the six mounting bolts from the

platform mounting weldment. Remove the
center bolt and slide the platform mounting
weldment off of the platform rotator.
5 Support the platform rotator with a suitable
lifting device. Do not apply any lifting pressure.
6 Remove the pin retaining fasteners from the jib
boom and leveling links to platform rotator pivot
pins. Do not remove the pins.
How to Remove the

Platform Rotator
Specifications.
7 Support the jib boom, jib boom cylinder and

leveling links with an overhead crane.
8 Use a soft metal drift to drive both pivot pins
out. Remove the platform rotator from the
machine.
1 Remove the platform. See 2-1,

How to Remove the Platform.
Crushing hazard. The platform

rotator may become unbalanced
and fall if it is not properly
supported.

from the platform rotate manifold. Cap the
manifold fittings.
or spray.
3 Support the platform mounting weldment, but
do not apply any lifting pressure.
Part No. 36540
7 - 13
PLATFORM COMPONENTS
How to Bleed the Platform

Rotator
This procedure will require two
people.
position.
Move the primary boom toggle switch in the
up direction until the platform is approximately
6 feet (1.8 m) off the ground.
side and move the primary boom toggle switch
in the UP direction until the platform is
approximately 6 feet (1.8 m) off the ground.
3 Connect a clear hose to the top bleed valve.
Place the other end of the hose in a container
to collect any discharge. Open the top bleed
valve, but do not remove it.

Move the platform rotate toggle switch to the
right for approximately 5 seconds, then release
it. Repeat three times.
side and move the platform rotate toggle switch
to the right for approximately 5 seconds, then
release it. Repeat three times.
Crushing hazard. Keep clear of
the platform during rotation.
a
b
c
a
b
c
d
7 - 14
clear hose
top bleed valve
bottom bleed valve
container
Part No. 36540
PLATFORM COMPONENTS

Move the platform rotate toggle switch to the
left for approximately 5 seconds, then release
it. Repeat three times.
Hold the function enable switch to either side
and move the platform rotate toggle switch to
the left for approximately 5 seconds, then
release it. Repeat three times.
6 Fully rotate the platform to the left and continue
holding the platform rotate toggle switch until
air stops coming out of the bleed valve.
Immediately release the platform rotate toggle
switch and close the bleed valve.
7 Rotate the platform to the right until the
platform is centered.
8 Connect the clear hose to the bottom bleed
valve and open the valve. Do not remove the
valve.
9 Move the platform rotate toggle switch to the
right and continue holding the platform rotate
toggle switch until air stops coming out of the
bleed valve.
Crushing hazard. Keep clear of
the platform during rotation.
10 Close the bleed valve and remove the hose.
11 Rotate the platform full left and right and
inspect the bleed valves for leaks.
clean up any hydraulic oil that may have
spilled.
Part No. 36540
7 - 15
Jib Boom Components

5 Remove the mounting fasteners from the jib
boom/platform rotate manifold. Do not remove
the hoses.
3-1
Jib Boom
Component damage hazard. Hoses

and cables can be damaged if
they are twisted or kinked.
How to Remove the Jib Boom

Specifications.
2 Remove the platform mounting weldment
and the platform rotator. See 2-3, How to
Remove the Platform Rotator.
3 Tag, disconnect and plug the jib boom lift
cylinder hydraulic hoses. Cap the fittings on the
jib boom lift cylinder.
squirt or spray.
6 Attach a lifting strap from an overhead crane to

the jib boom.
7 Remove the pin retaining fastener from the jib
boom pivot pin at the jib boom bellcrank. Use a
soft metal drift to remove the pin, then remove
the jib boom from the jib boom bellcrank.
Crushing hazard. The jib boom will
fall when the pin is removed
if it is not properly supported.
boom lift cylinder rod-end pivot pin. Do not
remove the pin.
9 Remove both of the jib boom compression
arms from the bellcrank.
the rod-end of the jib boom lift cylinder.
11 Use a soft metal drift to remove the jib boom lift
cylinder rod-end pivot pin, then remove the jib
boom lift cylinder from the jib boom bellcrank.
Crushing hazard. The jib boom
lift cylinder will fall when the pin
is removed if it is not properly
supported.
4 Remove the cable cover from the side of the

jib boom.
7 - 16
Part No. 36540
JIB BOOM COMPONENTS
12 Support and secure the jib boom bellcrank to an

appropriate lifting device.
13 Remove the pin retaining fasteners from the
slave cylinder rod-end pivot pin. Do not remove
the pin.
boom mounting weldment at the jib boom
bellcrank. Use a soft metal drift to remove the
pin.
3-2
Jib Boom Bell Crank
Bell Crank
Specifications.
15 Use a soft metal drift to remove the slave

cylinder rod-end pivot pin.
16 Remove the jib boom bellcrank from the boom.
bellcrank may become
unbalanced and fall when the pins
are removed if it is not properly
supported and secured to the
lifting device.
1 Remove the platform. See 2-1, How to Remove

the Platform.
2 Remove the Jib Boom, See 3-1, How to
Remove the Jib Boom.
3 Support and secure the jib boom bell crank to
an appropriate lifting device.
slave cylinder rod-end pivot pin. Do not remove
the pin.
boom bell crank at the extension boom. Use a
soft metal drift to remove the pin.
6 Use a soft metal drift to remove the slave
cylinder rod-end pivot pin.
7 Remove the jib boom bell crank from the
extension boom.
bell crank may become
unbalanced and fall when the pins
lifting device.
Part No. 36540
7 - 17
JIB BOOM COMPONENTS
2 Tag, disconnect and plug the jib boom lift

jib boom lift cylinder.
3-3
Jib Boom Lift Cylinder

squirt or spray.

Lift Cylinder
Specifications.
1 Raise the jib boom slightly and place blocks
under the platform mounting weldment. Lower
the jib boom until the platform is resting on the
blocks.

boom lift cylinder rod-end pivot pin. Do not
remove the pin.
4 Use a soft metal drift to tap the rod-end pivot
pin half way out and lower one of the leveling
links to the ground. Tap the pin the other
direction and lower the opposite leveling link.
Do not remove the pin.
the rod end of the jib boom lift cylinder.
boom lift cylinder barrel-end pivot pin. Use a
soft metal drift to remove the barrel-end pivot
pin.
7 Use a soft metal drift to remove the jib boom lift
cylinder rod-end pivot pin. Remove the jib
boom lift cylinder from the machine.
Crushing hazard. The jib boom lift
cylinder may fall when the pins
supported by the overhead crane.
7 - 18
Part No. 36540
Primary Boom Components

4-1
Plastic Cable Track
4-2
Primary Boom
The primary boom cable track guides the cables

and hoses running up the boom. It can be repaired
link by link without removing the cables and hoses
that run through it. Removing the entire primary
boom cable track is only necessary when
performing major repairs that involve removing the
primary boom.
How to Shim the Primary Boom
How to Repair the Plastic Cable

Track
1 Extend the boom until the wear pads are

accessible.

primary boom cable track can be
damaged if it is twisted.
Measure each wear pad. Replace

the pad if it is less than 0.41 inch
(1 cm) thick. If the pad is more
than 0.41 inch (1 cm) thick,
perform the following procedure.
2 Loosen the wear pad mounting fasteners.

3 Install the new shims under the wear pad to
obtain zero clearance and zero drag.
4 Tighten the mounting fasteners.
5 Extend and retract the boom through an entire
cycle. Check for tight spots that could cause
scraping or binding.
Always maintain squareness

between the outer and inner boom
tubes.
a
b
link separation point

lower clip
1 Use a slotted screwdriver to pry down on the

lower clip.
2 Repeat step 1 for each link.
3 To remove a single link, open the lower clip
and then use a screw driver to pry the link to
the side.
Part No. 36540
7 - 19
PRIMARY BOOM COMPONENTS
6 Open the platform control box.
How to Remove the

Primary Boom
Bodily injury hazard. This
procedure requires specific repair
skills, lifting equipment and a
suitable workshop. Attempting this
procedure without these skills and
tools could result in death or
serious injury and significant
component damage. Dealer
service is strongly recommended.
Specifications.
7 Label and disconnect each wire of the 4 cables

in the platform control box.
and other jewelry.
8 Pull all of the cables out of the platform control
box.
from the slave cylinder.
squirt or spray.
from the jib/rotate manifold.
squirt or spray.
2 Remove the platform rotator. See 2-3, How to

Remove the Platform Rotator.
3 Remove the jib boom. See 3-1,
How to Remove the Jib Boom.
4 Remove the jib boom bellcrank. See 3-2, How
to Remove the Jib Boom Bellcrank.
5 Locate the 4 cables from the primary boom
cable track to the platform control box. Number
each cable and its entry location at the platform
control box.
7 - 20
11 Remove the upper cable track mounting

fasteners from the platform end of the boom.
Part No. 36540
12 Remove the cable track mounting fasteners,

then remove the cable track from the
boom and lay it flat on the ground.
Cables and hoses can be
damaged if they are kinked or
pinched.
20 Attach a similar lifting device to the lift cylinder.

21 Place support blocks under the cylinder, across
the secondary boom.
22 Remove the pin retaining fastener from the
boom lift cylinder rod-end pivot pin. Use a soft
metal drift to remove the pin.
Crushing hazard. The boom lift
cylinder will fall unless it is
properly supported.
13 Remove all of the hose and cable clamps from

the underside of the primary boom.
14 Remove the turntable end cover.
15 Remove the extension boom drive limit switch
from the side of the primary boom at the pivot
end. Do not disconnect the wiring.
16 Pull all of the electrical cables and hydraulic
hoses out of the plastic cable track.
master cylinder rod-end pivot pin. Use a soft
metal drift to remove the pin. Pull the cylinder
back and secure it from moving.
23 Lower the rod end of the lift cylinder onto

support blocks.
primary boom pivot pin.
25 Remove the primary boom pivot pin with a soft
metal drift, then carefully remove the boom
from the machine.
18 Tag, disconnect and plug the extension cylinder

hydraulic hoses. Cap the fittings on the
cylinder.
Crushing hazard. The boom may

become unbalanced and fall when
it is removed from the machine If
the overhead crane is not properly
attached.

squirt or spray.
19 Attach an overhead 5 ton crane to the center
point of the boom.
Part No. 36540
7 - 21
7 Support and slide the extension tube out of the

primary boom tube. Place the extension tube
on blocks for support.
How to Disassemble
the Primary Boom
Complete disassembly of the
boom is only necessary
if the outer or inner boom tubes
must be replaced. The extension
cylinder can be removed without
completely disassembling the
boom. See 4-4, How to Remove
the Extension Cylinder.
1 Remove the boom. See 4-2,
How to Remove the Primary Boom.
2 Place blocks under the extension cylinder for
support.
During removal, the overhead

crane strap will need to be
carefully adjusted for proper
balancing.
8 Remove the retaining rings from the extension
cylinder rod-end pivot pins at the platform end
of the extension tube. Use a soft metal drift to
remove the pins.
9 Support and slide the extension cylinder out of
the pivot end of the boom extension tube.
Place the extension cylinder on blocks for
support.
3 Remove the retaining fasteners from the

extension cylinder barrel-end pivot pin. Use a
4 Remove and label the location of the wear pads
from the top side of the boom tube at the
platform end of the boom.
During removal, the overhead

crane strap will need to be
carefully adjusted for proper
balancing.
10 Remove and label the wear pads from the
extension cylinder.
Pay careful attention to the

location and amount of shims
used with each wear pad.
Pay careful attention to the

location of each wear pad.
5 Carefully rotate the base end of the extension

cylinder until the pin mounting bore is in a
vertical position.
6 Support the extension tube with an overhead
crane at the platform end of the boom.
Crushing hazard. The boom tubes
will fall when they are removed
from the boom if they are not
properly supported.
7 - 22
Part No. 36540
4-3
Primary Boom Lift Cylinder
4 Place a block of wood across the upper

secondary boom to support the cylinder when
the rod-end pivot pin is removed.
The primary boom lift cylinder raises and lowers

the primary boom. The primary boom lift cylinder
is equipped with counterbalance valves to prevent
5 Place a rod through the compression arm pivot

pin and twist to remove the pin. Lower the
compression arm down.
How to Remove the Primary

Boom Lift Cylinder
Specifications.
6 Support the primary boom lift cylinder with a

lifting device.
primary boom lift cylinder rod-end pivot pin.
Then use a soft metal drift to remove the pin.
8 Lower the rod end of the cylinder onto the
blocks that were placed on the upper
secondary boom.
9 Tag, disconnect and plug the primary boom lift
cylinder.
1 Raise the primary boom enough to access the

primary boom lift cylinder rod-end pivot pin.
2 Attach an overhead crane to the primary boom
for support. Do not lift it.

or spray.

ground controls side upper compression arm
pivot pin.
Part No. 36540
7 - 23
10 Support the primary boom lift cylinder with

straps or ropes to restrict it from swinging
freely.
primary boom lift cylinder barrel-end pivot pin
Do not remove the pivot pin.
12 Use the overhead crane to lift the primary
boom 1 inch (2.5 cm). This will relieve pressure
on the barrel-end pivot pin.
13 Place a rod through the barrel-end pivot pin
and twist to remove the pin.
Crushing hazard. The primary

boom lift cylinder will swing down
if it is not properly supported when
the barrel-end pivot pin is
removed.
14 Attach and secure the rod-end of the primary
boom lift cylinder to an overhead crane or
similar lifting device. Carefully lower the straps
and allow the primary boom lift cylinder to
slowly swing down.
15 Carefully remove the cylinder from the machine.
Crushing hazard. The primary
boom lift cylinder may become
unbalanced and fall if it is not
properly supported when the rodend pivot pin is removed.
7 - 24
Part No. 36540
4-4
Extension Cylinder
2 Remove the external snap rings from the

extension cylinder rod-end pivot pins. Use a soft
metal drift to remove the pins.
The extension cylinder extends and retracts the

primary boom extension tube. The extension
cylinder is equipped with counterbalance valves to
prevent movement in the event of a hydraulic line
failure.
3 Remove the front counterweight cover.
How to Remove the

Extension Cylinder
4 Raise the secondary boom until the master

cylinder rod-end pivot pin is accessible.
5 Remove the drive limit switch from the pivot end
of the primary boom. Do not disconnect the
wiring.
6 Remove the retaining fastener from the master
cylinder rod-end pivot pin. Use a soft metal drift
to remove the pin.
7 Manually retract the master cylinder and push it
toward the platform end of the boom to obtain
enough clearance for the extension cylinder
removal.
8 Tag, disconnect and plug the extension cylinder
hydraulic hoses. Cap the fittings on the
cylinder.

Specifications.
1 Raise the primary boom to the horizontal
position. Extend the boom approximately
3 to 4 feet (0.9 to 1.2 m) until the extension
cylinder rod-end pivot pins are accessible.
Part No. 36540

or spray.
9 Remove the retaining fastener from the
extension cylinder barrel-end pivot pin. Use a
7 - 25
10 Carefully pull out and properly support the

extension cylinder from the primary extension
boom tube.
Crushing hazard. The cylinder will
fall if it is not properly supported
when it is pulled out of the
extension boom tube.
To make installation of the
extension cylinder easier, be sure
that the cylinder rod is extended
approximately 3 to 4 feet
(0.9 to 1.2 m).
4-5
Platform Leveling Master
Cylinder
The master cylinder acts as a pump for the slave
cylinder. It is part of the closed circuit hydraulic
loop that keeps the platform level through the
entire range of primary boom motion. The master
cylinder is located inside the upper mid-pivot at the
pivot end of the primary boom.
How to Remove the Platform

Leveling Master Cylinder
Before cylinder removal is
considered, bleed the cylinder to
be sure that there is no air in the
closed loop. See 2-2, How to
Bleed the Slave Cylinder.
Specifications.
7 - 26
Part No. 36540
1 Remove the rear turntable cover.

2 Raise the secondary boom until the master
cylinder barrel-end pivot pin is above the
turntable counterweights.
10 Use a soft metal drift to push the pin to one side

only far enough to remove the cylinder. The pin
should remain in one side of the upper
secondary boom and upper mid-pivot.
Crushing Hazard. The upper
secondary boom and the upper
mid-pivot will fall if the pivot pin is
completely removed.
3 Raise the primary boom until the master

cylinder rod-end pivot pin is accessible.
4 Attach an overhead crane to the pivot end of
the primary boom. Do not lift it.
5 Secure the upper secondary boom to the pivot
end of the primary boom with a strap (this will
prevent the upper secondary boom from falling
when the master cylinder barrel-end pivot pin is
removed from the cylinder).
11 Use the strap around the rod-end lug to lower

the master cylinder out of the machine.
6 Tag, disconnect and plug the master cylinder

hydraulic hoses. Cap the fittings on the master
cylinder.
or spray.
7 Attach a lifting strap to the lug on the rod end of
the master cylinder. Secure the strap to the
primary boom (use this strap to lower the
master cylinder out of the upper mid-pivot).
master cylinder rod-end pivot pin. Use a soft
metal drift to remove the pin.
master cylinder barrel-end pivot pin. Do not
remove the pin from the upper mid-pivot.
Part No. 36540
7 - 27
Secondary Boom Components
Secondary Boom
a
upper mid-pivot
b
upper compression arm
c
compression link
d
lower mid-pivot
e
lower secondary boom
f
turntable pivot
g
lower compression arm
h
upper secondary boom
7 - 28
Part No. 36540
SECONDARY BOOM COMPONENTS
5 Remove the wire loom from the cables at the

platform control box.
5-1
Secondary Boom
6 Locate the 4 cables from the primary boom

cable track to the platform control box. Number
each cable and its entry location at the platform
control box.
How to Disassemble the

Secondary Boom
Bodily injury hazard. The
procedures in this section require
specific repair skills, lifting
equipment and a suitable
workshop. Attempting this
service is required.
Follow the disassembly steps to the point required
to complete the repair. Then re-assemble the
secondary boom by following the disassembly
steps in reverse order.
Specifications.
7 Open the platform control box.

8 Label and disconnect each wire of the 4 cables
in the platform control box.
and other jewelry.
9 Pull the cables out of the platform control box.
10 Pull all of the electrical cables out of the plastic
cable track. Do not pull out the hydraulic hoses.
11 Remove the hose clamps from the bottom side
of the primary boom.
12 Tag, disconnect and plug the platform rotator
hydraulic hoses at the union, located on the
bottom side of the primary boom.
or spray.
1 Lower the boom to the stowed position.

2 Place a lifting device under the front of the
platform.
13 Remove the hose clamp from the side of the

primary boom at the pivot end.
3 Remove the rear turntable cover.

4 Remove the cable cover from the side of the jib
boom.
Part No. 36540
7 - 29
14 Remove the drive speed limit switch

mounted on the side of the pivot end of
the primary boom. Do not disconnect the
wiring.

upper mid-pivot to upper compression arm
pivot pins. Use a soft metal drift to remove the
pins.
15 Attach a strap from an overhead crane to the

pivot end of the primary boom.
23 Swing the compression arms down and out of

the way. Secure them from moving.
16 Carefully lift the secondary and primary boom

assembly until the master and primary lift
cylinder hydraulic hoses are accessible.
24 Remove the pin retainers from the upper

mid-pivot to upper secondary boom pivot pin.
Use a soft metal drift to remove the pin.
17 Remove the cable covers from the top of the

upper secondary boom.
25 Carefully remove the entire primary boom

assembly (primary boom assembly, jib boom
assembly, platform, master cylinder, primary lift
cylinder and upper mid-pivot) from the
machine.
18 Tag, disconnect and plug the primary boom lift

cylinder and master cylinder hydraulic hoses.
or spray.
Crushing hazard. If the overhead

crane is not properly attached, the
primary boom assembly may
it is removed from the machine.
Do not remove the assembly from
machine until it is properly
balanced.
19 Lower the booms to the stowed position.

20 Pull all the cables and hoses through the upper
mid-pivot.
Cables and hoses can be
damaged if they are kinked or
pinched.
26 Place the entire assembly onto a structure

capable of supporting it.
upper compression arm pivot pins. Do not
remove the pins.
21 Position the strap from the overhead crane

approximately 2 feet (0.6 m) from the platform
end of the primary boom. Measure from the
end of the primary boom tube.
7 - 30
Part No. 36540
28 Position the lifting strap from an overhead crane

at the center of the control box side upper
compression arm, then remove it from the
machine. Repeat this step for the engine side
upper compression arm.
upper compression arm may
29 Remove the pin retaining fastener from the rod
end of the secondary boom lift cylinder. Use a
soft metal drift to remove the pin. Secure the
cylinder from moving.
34 Remove the cable covers from the top of the

lower secondary boom. Pull all the cables and
hoses to the back of the turntable.
35 Remove the retaining fasteners from the
secondary boom lift cylinder barrel-end pivot
pins.
36 Attach the strap from the crane to the lug on
the rod end of the secondary boom lift cylinder.
from the secondary boom lift cylinder. Cap the
fittings on the cylinder.
or spray.

lower pivot pin on the compression link. Use a
31 Attach the strap from an overhead crane to the
upper secondary boom.
upper secondary boom to lower mid-pivot pivot
pin. Use a soft metal drift to remove the pin.
38 Use a slide hammer to remove the barrel-end

pins (access the pins from the access holes in
the bulkheads, one on each side). Then
remove the cylinder from the machine.
33 Remove the upper secondary boom with

compression link from the machine.
upper secondary boom with
compression link may become
unbalanced and fall when it is
removed from the machine.
Part No. 36540

secondary boom lift cylinder may
39 Attach the strap from the crane to the lower
mid-pivot.
7 - 31
40 Remove the pin retainers from the lower

mid-pivot to lower compression arm pivot pins.
Use a slide hammer and remove the pin.
47 Remove the pin retainer from the lower

secondary boom to turntable pivot pin. Use a
41 Remove the pin retainers from the lower

mid-pivot to lower secondary boom pivot pins.
48 Remove the lower secondary boom from the

machine.
42 Remove the lower mid-pivot from the machine.

lower mid-pivot may become
unbalanced and fall when it is
removed from the machine.

lower secondary boom may
43 Remove the drive speed limit switch

mounted on the inside of the lower mid-pivot.
Do not disconnect the wiring.
44 Attach the strap from the crane to the control
box side lower compression arm.
45 Remove the pin retainer from the lower
compression arm to turntable pivot pin. Use a
slide hammer and remove the pin. Remove the
arm from the machine. Repeat for the engine
side lower compression arm.
lower compression arms may
46 Attach the strap from the crane to the lower
secondary boom.
7 - 32
Part No. 36540
5-2
Secondary Boom Lift Cylinder
3 Attach the strap from an overhead crane to the

lug on the rod end of the secondary boom lift
cylinder.
The secondary boom lift cylinder raises and

lowers the secondary boom. The secondary
boom lift cylinder is equipped with counterbalance
valves to prevent movement in the event of a
hydraulic line failure.
4 From the bottom side of the cylinder, remove

the retaining fasteners from the secondary
boom lift cylinder barrel-end pivot pins.
How to Remove the Secondary

Lift Cylinder
Specifications.
1 Rotate the turntable to the side until the boom
is centered between the steer and non-steer
tires.
5 Use a slide hammer to remove the barrel-end

pins (access the pins from the access holes in
the bulkheads, one on each side).
secondary boom lift cylinder rod-end pivot pin.
7 Carefully lower the cylinder down through the
secondary boom, enough to access the
hydraulic hoses. Do not pinch the hoses.
Component damage hazard. Hoses
can be damaged if they are kinked
or pinched.
from the secondary boom lift cylinder. Cap the
fittings on the secondary boom lift cylinder.
or spray.
9 Remove the cylinder through the top of the
secondary boom.
2 Raise the primary boom to full height. Do not

extend it.
Part No. 36540
7 - 33
Ground Controls
6-1
Control Relays
Test
terminal 7 to 8
640 to 650
Relays used for dual function switching are double

pole double throw (DPDT) relays.
no continuity
(infinite )
How to Test a Double Pole Double

Throw Relay
no continuity
(infinite )
terminal 3 to 6
no continuity
(infinite )
terminal 2 to 6
continuity
(zero )
terminal 1 to 5
continuity
(infinite )

could cause death or serious
and other jewelry.
This procedure covers fundamental relay testing
and does not specifically apply to all varieties
of relays.
remove the key.
2 Label and then disconnect all the wiring from
the relay to be tested.
3 Connect the leads from an ohmmeter to each
terminal combination and check for continuity.
Terminals 7 and 8 represent the coil and
should not be tested in any other combination.
Desired result
4 Connect 24V DC to terminal 8 and a ground

wire to terminal 7, then test the following
terminal combinations.
Test
Desired result
no continuity
(infinite )
no continuity
(infinite )
terminal 1 to 3
continuity
(zero )
terminal 2 to 4
continuity
(zero )
2
1
4
6
8
7
Bubble number represents the terminal number
Coil
7
7 - 34
Part No. 36540
GROUND CONTROLS
How to Test a Single Pole

Double Throw Relay
4 Connect 24V DC to terminal 85 and a ground

wire to terminal 86. Test the following terminal
combinations.
Relays used for single function switching are

single pole double throw (SPDT) relays.
Test

could cause death or serious
and other jewelry.
Desired result
terminal 87a to 87 & 30

terminal 87 to 30
no continuity
(infinite )
continuity
(zero )
This procedure covers fundamental relay testing

and does not specifically apply to all varieties
of relays.
remove the key.
2 Label and then disconnect all the wiring from
the relay to be tested.
3 Connect the leads from an ohmmeter to each
terminal combination and check for continuity.
Terminals 85 and 86 represent the coil and
should not be tested in any other combination.
Test
terminal 85 to 86
terminal 87 to 87a & 30
terminal 87a to 30
Relay Schematic
Desired result
85 to 95
no continuity
(infinite )
continuity
(zero )
Terminal Numbers
Part No. 36540
7 - 35
GROUND CONTROLS
6-2
Toggle Switches
6-3
Wago Components
See 1-3, Toggle Switches.
How to Remove a Wago

Component
Electrocution/burn hazard.
Contact with electrically charged
circuits may cause death or
serious injury. Remove all rings,
watches and other jewelry.
Wago tools are available from the
Genie Service Parts Department
1 Label the wiring from the component to be
removed.
2 Push the Wago tool firmly into the slot to
release the wire from the component.
3 Locate the removal tab on the bottom or top
side of the component.
4 Use the Wago tool to gently pry up on the tab
of the component and remove it.
7 - 36
Part No. 36540
Hydraulic Pumps
4 Activate any function using auxiliary power.
7-1
Auxiliary Pump
Result: If the pressure gauge reads 3200 psi

(220 bar), immediately stop. The pump is good.
How to Test the Auxiliary Pump

1 Disconnect and plug the high pressure
hydraulic hose from the auxiliary pump.
or spray.
Specifications.
2 Connect a 0 to 5000 psi (0 to 350 bar) pressure
gauge to the high pressure port on the pump.
Result: If pressure fails to reach 3200 psi

(220 bar), the pump is bad and will need to be
serviced or replaced.
5 Remove the pressure gauge and reconnect the
hydraulic hose.
How to Remove the Auxiliary

Pump
from the pump. Cap the fittings on the pump.
or spray.
2 Remove the pump mounting bolts. Carefully
remove the pump.

position at both ground and platform controls.
Part No. 36540
7 - 37
HYDRAULIC PUMPS
7-2
Main Function Pump
How to Test the Main Function
Pump
1 Disconnect and plug the high pressure
hydraulic hose from the main function pump.
or spray.
Specifications.
gauge to the high pressure port on the pump.
controls.
7 - 38

Move any boom function toggle switch at the
ground controls.
Hold the function enable switch to either side
and move any boom function toggle switch at
the ground controls.
Result: If the pressure gauge reads 3200 psi
(220 bar), immediately stop. The pump is good.
Result: If pressure fails to reach 3200 psi
(220 bar),
the external relief valve setting is incorrect or
the pump is faulty and will need to be serviced
or replaced.
Z-34/22 from serial number 153 to 809 and
Z-34/22N from serial number 304 to 1116:
the internal relief valve setting is incorrect or
the pump is faulty and will need to be serviced
or replaced.
the relief valve setting on the function manifold
(item YY) is incorrect or the pump is faulty and
will need to be serviced or replaced.
5 Remove the pressure gauge and reconnect the
hydraulic hose.
Part No. 36540
HYDRAULIC PUMPS
How to Remove the Main

Function Pump
How to Remove the Main

Function Pump


1 Remove the support angle from the side of the

hydraulic power unit.
1 Tag, disconnect and plug the hoses from the

main function pump.
2 Remove the mounting fasteners from the

hydraulic tank and lower the tank.
2 Remove the pump mounting bolts from the

pump. Carefully remove the pump from the
electric motor.
3 Remove the pump mounting bolts. Carefully

remove the pump.
Part No. 36540
7 - 39
Manifolds
8-1
(Z-34/22 before serial number 674 and Z-34/22N before serial number 935)
The function manifold is mounted to the turntable under the ground controls.
Index
No.
Description
Schematic
Item
Function
Differential sensing valve ................. AA ......... Differential sensing circuit ................ 10-12 ft-lbs (14-16 Nm)
Relief valve, 3200 psi (221 bar) ........ AB ......... System relief .................................... 25-30 ft-lbs (34-41 Nm)
2 position 3 way solenoid valve ......... AC ........ Boom retract ...................................... 8-10 ft-lbs (11-14 Nm)
2 position 3 way solenoid valve ......... AD ........ Primary boom up ............................... 8-10 ft-lbs (11-14 Nm)
2 position 3 way solenoid valve ......... AE ......... Secondary boom up .......................... 8-10 ft-lbs (11-14 Nm)
2 position 3 way solenoid valve ......... AF ......... Turntable rotate left ........................... 8-10 ft-lbs (11-14 Nm)
2 position 3 way solenoid valve ......... AG ........ Platform level up ................................ 8-10 ft-lbs (11-14 Nm)
2 position 3 way solenoid valve ......... AH ........ Boom extend ...................................... 8-10 ft-lbs (11-14 Nm)
2 position 3 way solenoid valve ......... AI .......... Primary boom down ........................... 8-10 ft-lbs (11-14 Nm)
10
2 position 3 way solenoid valve ......... AJ ......... Secondary boom down ...................... 8-10 ft-lbs (11-14 Nm)
11
2 position 3 way solenoid valve ......... AK ......... Turntable rotate right ......................... 8-10 ft-lbs (11-14 Nm)
12
2 position 3 way solenoid valve ......... AL ......... Platform level down ........................... 8-10 ft-lbs (11-14 Nm)
13
Orifice 0.050 inch (1.27 mm) ............ AM ........ Turntable rotate circuit
14
Counterbalance valve ........................ AN ........ Platform level down ......................... 35-40 ft-lbs (47-54 Nm)
15
Counterbalance valve ........................ AO ........ Platform level up .............................. 35-40 ft-lbs (47-54 Nm)
Torque
16
Relief valve, 1750 psi (121 bar) ........ AP ......... Turntable rotate left ......................... 25-30 ft-lbs (34-41 Nm)
17
Relief valve, 1750 psi (121 bar) ........ AQ ........ Turntable rotate right ....................... 25-30 ft-lbs (34-41 Nm)
18
Relief valve, 1600 psi (110 bar) ........ AR ........ Secondary boom down .................... 25-30 ft-lbs (34-41 Nm)
19
Relief valve, 1400 psi (97 bar) ......... AS ......... Primary boom down ......................... 25-30 ft-lbs (34-41 Nm)
20
Relief valve, 1800 psi (124 bar) ........ AT ......... Boom extend .................................... 25-30 ft-lbs (34-41 Nm)
21
Proportional solenoid valve ............... AU ........ System flow regulating circuit .......... 10-12 ft-lbs (14-16 Nm)
22
Diagnostic fitting ............................................... Testing
Plug Torque Specifications

Description
Hex Size
Torque
Description
Hex Size
Torque
SAE No. 2
1/ 8
50 in-lbs / 6 Nm
SAE No. 6
1/ 4
18 ft-lbs / 24 Nm
SAE No. 4
3/16
13 ft-lbs / 18 Nm
SAE No. 8
5/16
50 ft-lbs / 68 Nm
7 - 40
Part No. 36540
MANIFOLDS
Part No. 36540
7 - 41
MANIFOLDS
8-2
(Z-34/22 from serial number 674 to 1733 and Z-34/22N from serial number 935 to 2226)
Index
No.
Description
Schematic
Item
Function
Differential sensing valve ................. BA ......... Differential sensing circuit ................ 10-12 ft-lbs (14-16 Nm)
Torque
Relief valve, 3200 psi (221 bar) ........ BB ......... System relief ..................................... 25-30 ft-lbs (34-41 Nm)
2 position 3 way solenoid valve ........ BC ........ Boom retract ....................................... 8-10 ft-lbs (11-14 Nm)
2 position 3 way solenoid valve ........ BD ........ Primary boom up ................................ 8-10 ft-lbs (11-14 Nm)
2 position 3 way solenoid valve ........ BE ......... Secondary boom up ........................... 8-10 ft-lbs (11-14 Nm)
2 position 3 way solenoid valve ........ BF ......... Turntable rotate left ............................. 8-10 ft-lbs (11-14 Nm)
2 position 3 way solenoid valve ........ BG ........ Platform level up ................................. 8-10 ft-lbs (11-14 Nm)
2 position 3 way solenoid valve ........ BH ........ Boom extend ...................................... 8-10 ft-lbs (11-14 Nm)
2 position 3 way solenoid valve ........ BI .......... Primary boom down ........................... 8-10 ft-lbs (11-14 Nm)
10
2 position 3 way solenoid valve ........ BJ ......... Secondary boom down ...................... 8-10 ft-lbs (11-14 Nm)
11
2 position 3 way solenoid valve ........ BK ......... Turntable rotate right .......................... 8-10 ft-lbs (11-14 Nm)
12
2 position 3 way solenoid valve ........ BL ......... Platform level down ............................ 8-10 ft-lbs (11-14 Nm)
13
Orifice 0.050 inch (1.27 mm) ............. BM ........ Turntable rotate circuit
14
Counterbalance valve ....................... BN ........ Platform level down .......................... 35-40 ft-lbs (47-54 Nm)
15
Counterbalance valve ....................... BO ........ Platform level up ............................... 35-40 ft-lbs (47-54 Nm)
16
Counterbalance valve ....................... BP ......... Turntable rotate right ........................ 35-40 ft-lbs (47-54 Nm)
17
Counterbalance valve ....................... BQ ........ Turntable rotate left ........................... 35-40 ft-lbs (47-54 Nm)
18
Relief valve, 1600 psi (110 bar) ........ BR ........ Secondary boom down .................... 25-30 ft-lbs (34-41 Nm)
19
Relief valve, 1400 psi (97 bar) ......... BS ......... Primary boom down ......................... 25-30 ft-lbs (34-41 Nm)
20
Relief valve, 1800 psi (124 bar) ........ BT ......... Boom extend .................................... 25-30 ft-lbs (34-41 Nm)
21
Proportional solenoid valve .............. BU ........ System flow regulating circuit ........... 10-12 ft-lbs (14-16 Nm)
22
Diagnostic fitting ............................................... Testing

Description
Hex Size
Torque
Description
Hex Size
Torque
SAE No. 2
1/ 8
50 in-lbs / 6 Nm
SAE No. 6
1/ 4
18 ft-lbs / 24 Nm
SAE No. 4
3/16
13 ft-lbs / 18 Nm
SAE No. 8
5/16
50 ft-lbs / 68 Nm
7 - 42
Part No. 36540
MANIFOLDS
Part No. 36540
7 - 43
MANIFOLDS
8-3
Index
No.
Description
Schematic
Item
Function
3 position 4 way spool valve ............. CA ........ Platform level up/down ..................... 10-12 ft-lbs (14-16 Nm)
Counterbalance valve ....................... CB ........ Platform level down .......................... 35-40 ft-lbs (47-54 Nm)
Counterbalance valve ....................... CC ........ Platform level up ............................... 35-40 ft-lbs (47-54 Nm)
Relief valve, 1100 psi (75.8 bar) ....... CD ........ Turntable rotate left/right .................. 25-30 ft-lbs (34-41 Nm)
Relief valve, 1600 psi (110 bar) ........ CE ........ Secondary boom down .................... 25-30 ft-lbs (34-41 Nm)
Relief valve, 1400 psi (96.5 bar) ....... CF ......... Primary boom down ......................... 25-30 ft-lbs (34-41 Nm)
(Before serial number: Z34/22-2901 and Z34/22N-3533)
Torque
Relief valve, 1600 psi (110 bar)

(After serial number: Z34/22-2900 and Z/34/22N-3532)
7
Relief valve, 1800 psi (124 bar) ........ CG ........ Primary boom extend ....................... 25-30 ft-lbs (34-41 Nm)
Relief valve, 2800 psi (193 bar)
(From serial number: Z34/22-2901 to 3215 and Z34/22N-3533 to 3766)
Proportional solenoid valve .............. CH ........ System flow regulating circuit ........... 10-12 ft-lbs (14-16 Nm)
Check valve ....................................... CI .......... Brake circuit ...................................... 25-30 ft-lbs (34-41 Nm)
10
Solenoid valve, 3 position 4 way ...... CJ ......... Steer left/right .................................... 10-12 ft-lbs (14-16 Nm)
11
3 position 4 way spool valve ............. CK ........ Primary boom extend/retract ............ 10-12 ft-lbs (14-16 Nm)
12
Pressure switch ................................. CL ......... Brake circuit
13
Solenoid valve, N.C. poppet ............. CM ........ Brake circuit ...................................... 25-30 ft-lbs (34-41 Nm)
14
Orifice, 0.045 inch (1.02 mm) ............ CN ........ Steer/Brake circuit
15
Orifice, 0.045 inch (1.5 mm) .............. CO ........ Brake circuit
16
Solenoid valve, N.O. poppet ............. CP ........ Brake circuit ...................................... 25-30 ft-lbs (34-41 Nm)
17
Differential sensing valve .................. CQ ........ Differential sensing circuit ................ 10-12 ft-lbs (14-16 Nm)
18
Relief valve, 3200 psi (220.6 bar) .... CR ........ System relief ..................................... 25-30 ft-lbs (34-41 Nm)
19
Orifice, 0.035 inch (0.89 mm) ............ CS ........ T2 tank port

(Added after serial number: Z34/22-2894 and Z34/22N-3517)
20
Diagnostic fitting ................................ CT ......... Pressure test port
21
3 position 4 way spool valve ............. CU ........ Secondary boom up/down ............... 10-12 ft-lbs (14-16 Nm)
22
3 position 4 way spool valve ............. CV ........ Primary boom up/down .................... 10-12 ft-lbs (14-16 Nm)
23
Flow regulator valve,

1.5 gpm (5.7 l/min) ............................ CW ....... Turntable rotate circuit ...................... 10-12 ft-lbs (14-16 Nm)
24

0.8 gpm (3 l/min) ............................... CX ........ Jib boom/platform rotate circuit ........ 10-12 ft-lbs (14-16 Nm)
25
3 position 4 way spool valve ............. CY ........ Turntable rotate left/right .................. 10-12 ft-lbs (14-16 Nm)
7 - 44
Part No. 36540
MANIFOLDS
10
CH
CJ
CK
11
CL
CG
CD
12
CI
CF
CC
CA
CE
CM
CB
CN
14
CO
15
CP
CS
CQ
CR
CT
13
16
17
18
19
20
CU
CV
21
CY
CW
CX
25
Part No. 36540
24
23
22
7 - 45
MANIFOLDS
8-4
Valve Adjustments Function Manifold
How to Adjust the System
Relief Valve
gauge to the test port on the function manifold.
position.
Move the primary boom extend/retract toggle
switch in the retract direction with the primary
boom fully retracted. Observe the pressure
reading on the pressure gauge.
side and move the primary boom extend/retract
toggle switch in the retract direction with the
primary boom fully retracted. Observe the
pressure reading on the pressure gauge.
4 Turn the machine off. Hold the relief valve and

remove the cap
Z-34/22
Before serial number 674: (item AB).
From serial number 674 to 1733: (item BB).
After serial number 1733: (item CR).
Z-34/22N
Before serial number 935: (item AB).
From serial number 935 to 2226: (item BB).
After serial number 2226: (item CR).
5 Adjust the internal hex socket. Turn it clockwise
to increase the pressure or counterclockwise to
decrease the pressure. Install the relief valve
cap.
Tip-over hazard. Do not adjust
the relief valve higher than
specified.
6 Repeat steps 2 and 3 to confirm the relief valve
pressure setting.
System relief valve specifications

Pressure
7 - 46
3200 psi
221 bar
Part No. 36540
MANIFOLDS
How to Adjust the Primary Boom

Down Relief Valve
position.
Move the primary boom up/down toggle switch
in the down direction with the primary boom
fully lowered. Observe the pressure reading on
the pressure gauge.
side and move the primary boom up/down
toggle switch in the down direction with the
primary boom fully lowered. Observe the

remove the cap
Z-34/22
Before serial number 674: (item AS).
From serial number 674 to 1733: (item BS).
After serial number 1733: (item CF).
Z-34/22N
Before serial number 935: (item AS).
From serial number 935 to 2226: (item BS).
After serial number 2226: (item CF).
decrease the pressure. Then install the relief
valve cap.
specified.
pressure setting.
Primary boom down relief valve specifications

Before serial number:
Z34/22-2901
Z34/22N-3533
Pressure
1400 psi
97 bar
After serial number:

Z34/22-2900
Z/34/22N-3532
Pressure
1600 psi
110 bar
Part No. 36540
7 - 47
MANIFOLDS
How to Adjust the Secondary

Boom Down Relief Valve
position.
Move the secondary boom up/down toggle
switch in the down direction with the secondary
boom fully lowered. Observe the pressure
side and move the secondary boom up/down
toggle switch in the down direction with the
secondary boom fully lowered. Observe the

remove the cap
Z-34/22
Before serial number 674: (item AR).
From serial number 674 to 1733: (item BR).
After serial number 1733: (item CE).
Z-34/22N
Before serial number 935: (item AR).
From serial number 935 to 2226: (item BR).
After serial number 2226: (item CE).
cap.
specified.
pressure setting.
Secondary boom down relief valve specifications

Pressure
7 - 48
1600 psi
110 bar
Part No. 36540
MANIFOLDS
How to Adjust the Primary Boom

Extend Relief Valve
position.
Move the primary boom extend/retract toggle
switch in the extend direction with the primary
boom fully extended. Observe the pressure
side and move the primary boom extend/retract
toggle switch in the extend direction with the
primary boom fully extended. Observe the

remove the cap
Z-34/22
Before serial number 674: (item AT).
From serial number 674 to 1733: (item BT).
From serial number 1733 to 3215: (item CG).
Removed after serial number 3215.
Z-34/22N
Before serial number 935: (item AT).
From serial number 935 to 2226: (item BT).
From serial number 2226 to 3766: (item CG).
Removed after serial number 3766.
cap.
specified.
pressure setting.
Primary boom extend relief valve specifications

Before serial number:
Z34/22-2901
Z34/22N-3533
Pressure
1800 psi
124 bar
After serial number:

Z34/22-2900
Z34/22N-3532
Pressure
2800 psi
193 bar
Part No. 36540
7 - 49
MANIFOLDS
How to Adjust the Turntable

Rotate Relief Valves
position.
Move the turntable rotate right/left toggle
switch in the RIGHT direction until turntable stops
against the rotation stop. Observe the pressure
side and move the turntable rotate right/left
toggle switch in the RIGHT direction (until
turntable stops against the rotation stop).
Observe the pressure reading on the pressure
gauge.

remove the cap
Z-34/22
Before serial number 674: (items AP and AQ).
After serial number 1733: (item CD).
Z-34/22N
Before serial number 935: (items AP and AQ).
After serial number 2226: (item CD).
cap.
the relief valves higher than
specified.
pressure setting.
Repeat steps 2 through 6 to adjust the
turntable rotate left relief valve.
Turntable rotate relief valve specifications

Z-34/22
1750 psi 121 bar

Not adjustable
1100 psi
76 bar
Z-34/22N
1750 psi 121 bar

Not adjustable
1100 psi
76 bar
7 - 50
If adjusting the turntable rotate

left, hold the switch to the left and
adjust the left relief valve (item
AQ, function manifold).
Part No. 36540
MANIFOLDS
8-5
The jib boom/platform rotate manifold is mounted to the jib boom.
1
Solenoid valve, 2 position 3 way ....... A ........... Jib boom up ....................................... 8-10 ft-lbs (11-14 Nm)
Solenoid valve, 2 position 3 way ...... B ........... Platform rotate right ............................ 8-10 ft-lbs (11-14 Nm)
Orifice plug, 0.025 inch (0.76 mm) .... C ........... Platform rotate circuit
Solenoid valve, 2 position 3 way ....... D ........... Platform rotate left ............................. 8-10 ft-lbs (11-14 Nm)
Solenoid valve, 2 position 3 way ....... E ........... Jib boom down ................................... 8-10 ft-lbs (11-14 Nm)
Orifice plug, 0.030 inch (0.89 mm) .... F ........... Jib boom/platform rotate circuit
(Added after serial number: Z-34/22-781 and Z-34/22N-1030)
F
6
C
5
E
D
Valve Coil Resistance

Specification

Description
Hex Size
SAE No. 2
1/8
SAE No. 4
3/16
Part No. 36540
Torque
50 in-lbs (6 Nm)
13 ft-lbs (18 Nm)
Description
2 position 3 way valve - 20V
(schematic items A, B, D and E)
Measurement
23.5 to 24.5
7 - 51
MANIFOLDS
8-6
1
Solenoid valve, 2 position 3 way ....... A ........... Jib boom up ...................................... 8-10 ft-lbs (11-14 Nm)
Solenoid valve, 2 position 3 way ...... B ........... Platform rotate right ........................... 8-10 ft-lbs (11-14 Nm)
Orifice plug, 0.025 inch (0.64 mm) .... C ........... Platform rotate circuit
Orifice plug, 0.022 inch (0.56 mm)
(From serial number: Z34/22-1892 to 2005 and Z34/22N-2548 to 2771)
Solenoid valve, 2 position 3 way ...... D ........... Platform rotate left .............................. 8-10 ft-lbs (11-14 Nm)
Solenoid valve, 2 position 3 way ...... E ........... Jib boom down .................................. 8-10 ft-lbs (11-14 Nm)
Orifice plug, 0.030 inch (0.89 mm) .... F ........... Jib boom/platform rotate circuit

Specification

Description
Hex Size
SAE No. 2
1/ 8
SAE No. 4
3/16
7 - 52
Torque
50 in-lbs (6 Nm)
13 ft-lbs (18 Nm)
Description
(schematic items A, B, D and E)
Measurement
23.5 to 24.5
Part No. 36540
MANIFOLDS
8-7
1
Solenoid valve, 3 position 4 way ...... A ........... Jib boom up/down ........................... 20-25 ft-lbs (27-34 Nm)
Solenoid valve, 3 position 4 way ...... B ........... Platform rotate right/left .................... 20-25 ft-lbs (27-34 Nm)

0.3 gpm / 1.14 L/min .......................... C ........... Platform rotate circuit ........................ 20-25 ft-lbs (27-34 Nm)
3
C

Specification
Description
3 position 4 way valve , 20V DC
(schematic items A and B)
Part No. 36540
Measurement
22
7 - 53
MANIFOLDS
8-8
Index
No.
Description
Schematic
Item
Check valve ....................................... G ........... Brake circuit ...................................... 25-30 ft-lbs (34-41Nm)
Normally open poppet valve .............. H ........... Brake circuit ...................................... 25-30 ft-lbs (34-41Nm)
3 position 4 way spool valve ............. I ............ Steer left/right ................................... 10-12 ft-lbs (14-16Nm)
Orifice washer 0.040 inch (1.02 mm) J ............ Brake circuit
Pressure switch ................................. K ........... Brake circuit
Normally closed poppet valve ........... L ........... Brake circuit ...................................... 25-30 ft-lbs (34-41Nm)
Orifice washer 0.052 inch (1.32 mm) M .......... Brake circuit
Proportional solenoid valve ............... N ........... Brake circuit ...................................... 10-12 ft-lbs (14-16Nm)
Function
Torque

Specification

Description
Hex Size
SAE No. 2
1/ 8
SAE No. 4
3/16
7 - 54
Torque
50 in-lbs (6 Nm)
13 ft-lbs (18 Nm)
Normally open poppet valve - 20V

(schematic item H)
23 to 25

(schematic item I)
21 to 23
Normally closed poppet valve - 20V

(schematic item L)
22 to 24
Proportional solenoid valve - 20V

(schematic item N)
18 to 20
Part No. 36540
MANIFOLDS
8-9
Index
No.
Description
Schematic
Item
Normally open poppet valve ............. H ........... Brake circuit ...................................... 25-30 ft-lbs (34-41Nm)
3 position 4 way spool valve ............. I ............ Steer left/right .................................... 10-12 ft-lbs (14-16Nm)
Pressure switch ................................. K ........... Brake circuit
Orifice 0.040 inch (1.02 mm) ............. J ............ Brake circuit
Normally closed poppet valve .......... L ........... Brake circuit ...................................... 25-30 ft-lbs (34-41Nm)
Orifice washer 0.052 inch (1.32 mm) M .......... Brake circuit
Check valve ....................................... G ........... Brake circuit ...................................... 25-30 ft-lbs (34-41Nm)
Proportional solenoid valve .............. N ........... Brake circuit ...................................... 10-12 ft-lbs (14-16Nm)
H
I
Torque
Function
Refer to previous page for Plug

Torque and Valve Coil
Specifications
Part No. 36540
7 - 55
Hydraulic Tank
3 Completely drain the tank into a suitable
container. See capacity specifications.
9-1
Hydraulic Tank
The primary functions of the hydraulic tank are to
cool, clean and deaerate the hydraulic fluid during
operation. It utilizes internal suction strainers for
the pump supply lines and has a return filter
mounted inside the reservoir.
4 Remove the suction strainer and the magnet.

Clean the tank with mild solvent.
5 Clean up any oil that may have spilled.
Hydraulic oil type

The work area and surfaces
where this procedure will be
performed must be clean and
free of debris that could get
into the hydraulic system.
Specifications.
Dexron equivalent

Hydraulic system
(including tank)
5 gallons
18.9 liters
7 gallons
26.5 liters
How to Remove the

Hydraulic Tank
1 Open the tank side turntable cover.
2 Remove the tank mounting fasteners. Remove
the tank from the power unit.
7 - 56
Part No. 36540
HYDRAULIC TANK

from the hydraulic tank filter. Cap the fittings on
the filter.
How to Remove the

Hydraulic Tank

or spray.
1 Open the tank side turntable cover.

2 Close the hydraulic shutoff valve located at the
hydraulic tank.
machine must not be operated
with the hydraulic tank shut-off
valve in the CLOSED position or
component damage will occur. If
the tank valve is closed, remove
the key from the key switch and
tag the machine to inform
personnel of the condition.

severe burns.
7 Remove the hydraulic tank mounting fasteners.
8 Remove the hydraulic tank from the machine.
9 Remove the tank lid retaining fasteners.
Remove the lid from the tank.
3 Place a suitable container under the hydraulic

tank. See capacity specifications.
Component damage hazard. Do

not overtighten the hydraulic tank
mounting fasteners. Torque the
hydraulic tank mounting fasteners
to 5 ft-lbs (6.8 Nm).
4 Disconnect and plug the hydraulic hose from

the hydraulic tank shutoff valve.
or spray.
5 Remove the drain plug from the hydraulic tank
and drain the oil into a suitable container.
severe burns.
Part No. 36540
Torque specification
1/
4
-20 fasteners
5 ft-lbs
6.8 Nm

Hydraulic oil type
Dexron equivalent

Hydraulic system
(including tank)
4 gallons
15.1 liters
6 gallons
22.7 liters
7 - 57
Turntable Rotation Components

10-1
Turntable Rotation Hydraulic
Motor
The turntable rotation hydraulic motor is the only
serviceable component of the turntable rotation
assembly. The worm gear must not be removed
from the housing. In order to remove the housing,
the turntable has to be removed.
How to Remove the Turntable

Rotation Motor
Specifications.
from the turntable rotation motor. Cap the
fittings on the motor.
or spray.
2 Remove the turntable rotation motor mounting
bolts. Remove the motor.
7 - 58
Part No. 36540
Steer Axle Components

4 Remove the lug nuts. Remove the tire and
wheel assembly.
11-1
Yoke and Hub
5 Remove the cotter pin and the clevis pin from

both the steering cylinder and the tie rod.
How to Remove the Yoke

and Hub

clevis pin.
1 Loosen the wheel lug nuts. Do not

remove them.
a
h
a
b
c
d
e
f
g
h
axle
retaining fastener
king pin
yoke
hub
clevis pin and cotter pin
steering cylinder
tie rod
6 Remove the retaining fasteners from the upper

and lower yoke pivot pins. Do not remove the
pins.
7 Support and secure the yoke/hub assembly to
a lifting jack.
8 Place a rod through the yoke pivot pins and
twist to remove the pins.
Crushing hazard. The yoke/hub
assembly may become
unbalanced and fall when the
yoke pivot pins are removed if it is
not properly supported and
secured to the lifting jack.
Torque specifications
Lug nuts, dry
Lug nut torque, lubricated
125 ft-lbs
94 ft-lbs
169.5 Nm
127 Nm
2 Block the non-steering wheels. Center a lifting

jack under the steering axle.
Part No. 36540
7 - 59
STEERING AXLE COMPONENTS
How to Remove the

Hub and Bearings
How to Install the

Hub and Bearings
1 Loosen the wheel lug nuts. Do not remove

them.
When replacing a wheel bearing,

both the inner and outer bearings,
including the pressed-in races,
must be replaced.
2 Block the non-steering wheels and place a

lifting jack under the steering axle.
4 Remove the lug nuts. Remove the tire
and wheel assembly.
5 Remove the dust cap, cotter pin and
castle nut.
castle nut.
6 Pull the hub off the yoke spindle. The washer
and outer bearing should fall loose from the
hub.
7 Place the hub on a flat surface and gently pry
the bearing seal out of the hub. Remove the
inner bearing.
When removing a bearing, always
use a new inner bearing seal.
1 Be sure that both bearings are packed

with grease.
2 Place the large inner bearing into the rear
of the hub.
3 Press the inner bearing seal evenly into the hub
until it is flush.
4 Apply a small amount of grease onto the yoke
spindle.
5 Slide the hub onto the yoke spindle.
Damage to the lip of the seal may
occur if excessive force is applied.
6 Place the outer bearing into the hub.
7 Install the washer and castle nut.
8 Tighten the castle nut to 35 ft-lbs (47 Nm).
9 Loosen the castle nut and tighten to
8 ft-lbs (11 Nm).
10 Install a new cotter pin. Bend the cotter pin
to lock it.
a new one when installing the
castle nut.
11 Install the dust cap. Install the tire and wheel
assembly. Torque the wheel lug nuts to
125 ft-lbs (169.5 Nm).
7 - 60
Part No. 36540
STEERING AXLE COMPONENTS
11-2
Steer Cylinder
11-3
Tie Rod

Specifications.
from the steer cylinder. Cap the fittings on the
cylinder.
How to Remove the Tie Rod

1 Remove the cotter pins. Remove the clevis pin
from each end of the tie rod.
clevis pin.
2 Remove the tie rod from the machine.

squirt or spray.
2 Remove the cotter pins. Remove the clevis pin
from each end of the steer cylinder.
clevis pin.
3 Remove the steer cylinder from the machine.
Part No. 36540
7 - 61
Non-steer Axle Components

12-1
Drive Motor
12-2
Drive Hub
How to Remove a Drive Motor
How to Remove a Drive Hub
A drive motor can only be

removed from the inside of the
drive chassis.
The drive motor must be removed

in order to access the drive hub
mounting bolts.
1 Disconnect the battery packs from the

machine.

Specifications.
2 Remove the chassis cover from the non-steer

end of the machine.
3 Tag and disconnect the power cables from the
drive motor.
and other jewelry.
1 Remove the drive motor. See 11-1,

How to Remove a Drive Motor.
2 Disconnect the hydraulic hose from the brake
and plug it. Cap the fitting on the brake.
4 Remove the drive motor mounting fasteners.

connections very slowly to
allow the oil pressure to
dissipate gradually. Do not
allow oil to squirt or spray.
5 Guide the drive motor shaft out of the brake

and remove the drive motor from the machine.
3 Chock the steer wheels.

4 Loosen the wheel lug nuts on the wheel of the
drive hub to be removed. Do not remove the
lug nuts.
7 - 62
Part No. 36540
NON-STEER AXLE COMPONENTS
5 Center a lifting jack under the non-steer end of

the machine. Raise the machine approximately
6 inches (15 cm) and place blocks under the
6 Remove the wheel lug nuts. Remove the tire
and wheel assembly.
7 Place a second lifting jack under the drive
hub for support. Secure the drive hub to the
lifting jack.
8 Remove the brake mounting bolts. Remove the
brake from the machine.
9 Remove the drive hub mounting bolts. Remove
the drive hub from the machine.
Crushing hazard. The drive
hub may become unbalanced and
fall when the mounting fasteners
lifting jack.
Torque specifications
Lug nuts, dry
Lug nuts, lubricated
125 ft-lbs
94 ft-lbs
169.5 Nm
127 Nm
Drive hub bolts, dry

Drive hub bolts, lubricated
210 ft-lbs
94 ft-lbs
285 Nm
127 Nm
Part No. 36540
7 - 63
Motor Controller
4 Set an ohmmeter to diode test mode.
13-1
Motor Controller
The drive motor controller is located under the nonsteer end drive chassis cover. The drive motor
controller can recognize machine drive
malfunctions and display controller fault codes by
flashing a LED at the ground controls and on the
motor controller. See the Fault Code section of this
manual for a list of fault codes and additional
information. There are no adjustments needed on
the drive joystick controller. For further information
or assistance, consult the Genie Industries Service
Department.
How to Test the Motor Controller

Note: Use the following procedure to test the motor
controller. If the motor controller is found to be
faulty, note which test failed and which fault code
(if any) was present at the time of failure.
1 Turn the key switch to the off position and
disconnect the battery packs from the machine.
2 Tag and disconnect all power cables from the
motor controller.
and other jewelry.
3 Press the release tab on the motor controller
harness connector and remove the motor
controller harness connector from the motor
controller.
7 - 64
5 Connect the leads from an ohmmeter to test

each motor controller terminal combination
listed below and check the forward / reverse
bias (diode test).
Result: All desired results must be within the
specified range. If any test has a result not
within the specified range, replace the motor
controller.
Forward Bias:
Test
Desired result
Positive Lead Negative Lead

M-
B+
0.4 to 0.45
B-
M-
0.4 to 0.45
F1
B+
0.45 to 0.5
F2
B+
0.45 to 0.5
B-
F1
0.45 to 0.5
B-
F2
0.45 to 0.5
Reverse Bias:
Test
Desired result
Positive Lead Negative Lead

B+
M-
Rises to .0L V
M-
B-
Rises to .0L V
B+
F1
Rises to .0L V
B+
F2
Rises to .0L V
F1
B-
Rises to .0L V
F2
B-
Rises to .0L V
Part No. 36540
Distributed By:
Genie North America
Genie China
Genie France
Phone:
425 881 1800
Toll Free in USA 800 536 1800
Toll Free in Canada 800 426 8089
Fax:
425 883 3475
Phone:
Fax:
Phone:
Fax:
86 21 62483040
86 21 62588180
33 237 260 999

33 237 260 998
Genie Japan
Genie Holland
Genie UK Limited
Phone:
Fax:
Phone:
Fax:
Phone:
Fax:
Genie Australia Pty Ltd.
Genie Latin America
Phone:
Fax:
Phone:
Fax:
44 1636 614700
44 1636 614777
81 3 3453 6082
81 3 3453 6083
61 07 3375 1660
61 07 3375 1002
31 7051 78836
31 7051 13993
561-994-0380
561-997-5877

Service Genie Z34

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Service Genie Z34

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Service Manual

Part No. 36540

(before serial number 6291)

(before serial number 5427)

First Edition Third Printing

Copyright 1996 by Genie Industries

First Printing June, 1996

Third Printing August, 2008

"Genie" and "Z" are registered trademarks of

If you have any questions, please contact Genie

Genie Z-34/22 & Genie Z-34/22N

Part No. 36540

First Edition Third Printing

Do Not Perform Maintenance

Part No. 36540

Genie Z-34/22 & Genie Z-34/22N

First Edition Third Printing

Any person working on or around a machine must

Read each procedure thoroughly. This

Be sure to wear protective eye wear and

Redused to indicate the

Be sure that all tools and working areas

Orangeused to indicate the

Be sure any forklift, overhead crane or

Yellow with safety alert symbol

Be sure that fasteners intended for one

Yellow without safety alert

Be sure to properly dispose of old oil or

Indicates special operation or

Genie Z-34/22 & Genie Z-34/22N

Part No. 36540

First Edition Third Printing

The Genie Z-34/22 & Genie Z-34/22N are powered

Part No. 36540

All Z-34/22 and Z-34/22N machines utilize a DC

Genie Z-34/22 & Genie Z-34/22N

First Edition Third Printing

energy is then returned to the batteries.

Genie Z-34/22 & Genie Z-34/22N

Part No. 36540

First Edition Third Printing

Scheduled Maintenance Inspections

Scheduled Maintenance Procedures

Part No. 36540

Inspect the Operators and Safety Manuals ..................................................... 4 - 2

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

Inspect for Damage and Loose or Missing Parts ............................................. 4 - 3

Check the Hydraulic Oil Level ......................................................................... 4 - 3

Genie Z-34/22 & Genie Z-34/22N

First Edition Third Printing

Scheduled Maintenance Procedures, continued

Check for Hydraulic Leaks ............................................................................... 4 - 4

Test the Platform and Ground Controls ............................................................ 4 - 5

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

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

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

A-10 Test the Lift/Drive Select Switch (if equipped) ............................................... 4 - 11

Check the Batteries ....................................................................................... 4 - 12

Inspect the Electrical Wiring .......................................................................... 4 - 13

Confirm the Proper Brake Configuration ......................................................... 4 - 14

Check the Oil Level in the Drive Hubs ........................................................... 4 - 15

Test the Key Switch ...................................................................................... 4 - 16

Test the Emergency Stop Buttons ................................................................. 4 - 16

Test the Ground Control Override .................................................................. 4 - 17