Terex Genie Z-33/18 Installations- und Betriebsanleitung

Service and Repair Manual

Z®-33/18

DC Power

Part No. 1268514GT

Rev A4

January 2020

From Z331815M-101 to

Z331816M-1299

Serial Number Range

From Z3318M-1300

to Z3318M-2668

From Z3318M-2669

This manual includes:

Repair procedures

Fault Codes

Electrical and Hydraulic

Schematics

For detailed maintenance

procedures, Refer to the

appropriate Maintenance

Manual for your machine.

ii Z®-33/18 Part No. 1268514GT

January 2020

Compliance

Machine Classification

Group B/Type 3 as defined by ISO 16368

Machine Design Life

Unrestricted with proper operation, inspection and

scheduled maintenance.

Important

Read, understand and obey the safety rules and

operating instructions in the Genie Z-33/18

Operator's Manual before attempting any

maintenance or repair procedure.

This manual provides troubleshooting and repair

procedures for qualified service professionals.

Basic mechanical, hydraulic and electrical

skills are required to perform most procedures.

However, several procedures require specialized

skills, tools, lifting equipment and a suitable

workshop. In these instances, we strongly

recommend that maintenance and repair be

performed at an authorized dealer service center.

Technical Publications

Genie has endeavored to deliver the highest

degree of accuracy possible. However, continuous

improvement of our products is a Genie policy.

Therefore, product specifications are subject to

change without notice.

Readers are encouraged to notify Genie of errors

and send in suggestions for improvement. All

communications will be carefully considered for

future printings of this and all other manuals.

Find a Manual for this Model

Go to http://www.genielift.com

Use the links to locate Operator's, Parts or Service

Manuals.

http://www.genielift.com

e-mail: [email protected]

Introduction

1268514GT Rev A4 January 2020

First Edition, First Printing

"Genie" and "Z" are registered trademarks of Terex

South Dakota, Inc. in the USA and many other countries.

Printed on recycled paper

January 2020

Part No. 1268514GT Z®-33/18 iii

Revision Date Section Procedure / Page / Description

A 09/2015 Initial Release

A1 06/2016 Section 2 Specifications 2-3, 2-4

A1 06/2016 Section 3 Repair Procedure 3-37, 3-40

A1 06/2016 Section 4 Fault Codes 4-12

A1 06/2016 Section 5 Schematics 5-4, 5-5, 5-6, 5-7, 5-8, 5-9, 5-10, 5-11, 5-12

A2 09/2016 Introduction Serial Number Legend

A3 12/2017 Section 5 Schematics 5-4, 5-5, 5-6, 5-7, 5-8, 5-9, 5-10, 5-11, 5-12,

5-13, 5-14

A4 01/2020 Section 3 Repair Procedure 3-37

A4 01/2020 Section 4 Fault Codes 4-13,4-14, 4-15, 4-16, 4-17, 4-18, 4-19,

4-20, 4-21, 4-22, 4-23, 4-24, 4-25, 4-26

A4 01/2020 Section 5 Schematics 5-15, 5-16

REFERENCE EXAMPLES:

Section 2_Specifications, Machine Specifications

Section 3_Repair Procedure, 3-2

Section 4_Fault Codes, 4-4

Section 5_Schematics, 5-7

Electronic Version

Click on any procedure or page number

highlighted in blue to view the update.

Revision History

iv Z®-33/18 Part No. 1268514GT

January 2020

REVISION HISTORY, CONTINUED

Revision Date Section Procedure / Schematic Page /

Description

REFERENCE EXAMPLES:

Section 2_Specifications, Machine Specifications

Section 3_Repair Procedure, 3-2

Section 4_Fault Codes, 4-4

Section 5_Schematics, 5-7

Electronic Version

Click on any procedure or page number

highlighted in blue to view the update.

January 2020

Part No. 1268514GT Z®-33/18 v

Serial Number Legend

To August 31, 2016

1 Model

2 Model year

3 Facility code

4 Sequence number

5 Serial label (stamped on chassis)

6 Serial number (located under cover)

From September 1, 2016

1 Model

2 Facility code

3 Sequence number

4 Serial label (stamped on chassis)

5 Serial number (located under cover)

Z3318 15 M - 0101

Model:

Serial number:

Model year:

Electrical schematic number:

Manufacture date:

Machine unladen weight:

Rated work load (including occupants):

Maximum number of platform occupants:

Maximum allowable side force:

Maximum allowable inclination of the chassis:

Z331815M-0101

1/2/15 2015

1 2 3 4

Z3318 M - 1300

Model:

Serial number:

Electrical schematic number:

Year of manufacture:

Machine unladen weight:

Rated work load (including occupants):

Maximum number of platform occupants:

Maximum allowable side force:

Maximum allowable inclination of the chassis:

Z3318M-1300

2016

1 2 3

vi Z®-33/18 Part No. 1268514GT

January 2020

This page intentionally left blank.

January 2020

Part No. 1268514GT Z®-33/18 vii

Section 1 • Safety Rules

Danger

Failure to obey the instructions and safety rules

in this manual and the appropriate Operator's

Manual on your machine will result in death or

serious injury.

Many of the hazards identified in the

Operator’s Manual are also safety hazards

when maintenance and repair procedures are

performed.

Do Not Perform Maintenance

Unless:

You are trained and qualified to perform

maintenance on this machine.

You read, understand and obey:

- manufacturer’s instructions and safety rules

- employer’s safety rules and worksite

regulations

- applicable governmental regulations

You have the appropriate tools, lifting

equipment and a suitable workshop.

Safety Rules

viii Z®-33/18 Part No. 1268514GT

January 2020

Section 1 • Safety Rules

Personal Safety

Any person working on or around a machine must

be aware of all known safety hazards. Personal

safety and the continued safe operation of the

machine should be your top priority.

Read each procedure thoroughly. This

manual and the decals on the machine,

use signal words to identify the following:

Safety alert symbol—used to alert

personnel to potential personal

injury hazards. Obey all safety

messages that follow this symbol

to avoid possible injury or death.

Indicates an imminently

hazardous situation which, if not

avoided, will result in death or

serious injury.

Indicates a potentially hazardous

situation which, if not avoided,

could result in death or serious

injury.

Indicates a potentially hazardous

situation which, if not avoided,

may cause minor or moderate

injury.

Indicates a potentially hazardous

situation which, if not avoided,

may result in property damage.

Be sure to wear protective eye wear and

other protective clothing if the situation

warrants it.

Be aware of potential crushing hazards

such as moving parts, free swinging or

unsecured components when lifting or

placing loads. Always wear approved

steel-toed shoes.

DANGER

WARNING

CAUTION

NOTICE

Workplace Safety

Be sure to keep sparks, flames and

lighted tobacco away from flammable and

combustible materials like battery gases

and engine fuels. Always have an

approved fire extinguisher within easy

reach.

Be sure that all tools and working areas

are properly maintained and ready for

use. Keep work surfaces clean and free of

debris that could get into machine

components and cause damage.

Be sure any forklift, overhead crane or

other lifting or supporting device is fully

capable of supporting and stabilizing the

weight to be lifted. Use only chains or

straps that are in good condition and of

ample capacity.

Be sure that fasteners intended for one

time use (i.e., cotter pins and self-locking

nuts) are not reused. These components

may fail if they are used a second time.

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.

SAFETY RULES

January 2020

Part No. 1268514GT Z®-33/18 ix

Introduction

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

Revision History...........................................................................................iii

Serial Number Legend................................................................................. v

Section 1 Safety Rules

General Safety Rules .................................................................................vii

Section 2 Specifications

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

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

Hydraulic Specifications .........................................................................2 - 3

Hydraulic Component Specifications......................................................2 - 5

Manifold Component Specifications .......................................................2 - 5

Machine Torque Specifications ..............................................................2 - 6

Hydraulic Hose and Fitting Torque Specifications..................................2 - 7

Torque Procedure...................................................................................2 - 8

SAE and Metric Fasteners Torque Charts..............................................2 - 9

Section 3 Repair Procedures

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

Platform Controls

1-1 Joystick.........................................................................................3 - 4

Table of Contents

x Z®-33/18 Part No. 1268514GT

January 2020

Section 3 Repair Procedures, continued

Platform Components

2-1 Platform Leveling Slave Cylinder ...............................................3 - 13

2-2 Platform......................................................................................3 - 14

2-3 Platform Overload System .........................................................3 - 14

2-4 Platform Overload Recovery Message.......................................3 - 16

Primary Boom Components

3-1 Cable Track................................................................................3 - 17

3-2 Primary Boom.............................................................................3 - 19

3-3 Primary Boom Lift Cylinder.........................................................3 - 22

3-4 Primary Boom Extension Cylinder..............................................3 - 23

3-5 Platform Leveling Master Cylinder .............................................3 - 24

Secondary Boom Components

4-1 Secondary Boom........................................................................3 - 26

4-2 Secondary Boom Lift Cylinder....................................................3 - 29

Hydraulic pumps

5-1 Auxiliary Pump ...........................................................................3 - 30

5-2 Function Pump ...........................................................................3 - 31

Manifolds

6-1 Function Manifold Components..................................................3 - 33

6-2 Valve Adjustments - Function Manifold......................................3 - 35

6-3 Valve Coils .................................................................................3 - 39

Turntable Rotation Components

7-1 Turntable Rotation Assembly .....................................................3 - 41

Steer Axle Components

8-1 Hub and Bearings.......................................................................3 - 43

TABLE OF CONTENTS

Inhaltsverzeichnis

Andere Terex Hubarbeitsbühne Handbücher

Terex

Terex Genie Z-60 DC Bedienungsanleitung

Terex

Terex GRJL-2298 Bedienungsanleitung

Terex

Terex Genie GS-2669DC Bedienungsanleitung

Terex

Terex Genie Z-45/25 Bi-Energy Bedienungsanleitung

Terex

Terex L13I Bedienungsanleitung

Terex

Terex Genie Z6215A-101 Bedienungsanleitung

Terex

Terex Genie Z-34/22 IC Installations- und Betriebsanleitung

Terex

Terex Z30NF-23000 Bedienungsanleitung

Terex

Terex Genie GTH-3007 Bedienungsanleitung

Terex

Terex TM Series Bedienungsanleitung

Terex

Terex Genie S-60 FE Bedienungsanleitung

Terex

Terex Genie Z331815M-101 Bedienungsanleitung

Terex

Terex Genie GS-4655 Bedienungsanleitung

Terex

Terex Genie Z-34 Bedienungsanleitung

Terex

Terex Z-30/20N RJ Bedienungsanleitung

Terex

Terex Genie Z-45J DC Bedienungsanleitung

Terex

Terex Genie S-80 J Bedienungsanleitung

Terex

Terex Genie Z-34/22 Bedienungsanleitung

Terex

Terex Genie Z-45XC Bedienungsanleitung

Terex

Terex Genie GTH4016 SR Bedienungsanleitung

Terex

Terex Genie Z-80/60 Bedienungsanleitung

Terex

Terex S40XCH-3292 Bedienungsanleitung

Terex

Terex S8015-12264 Installations- und Betriebsanleitung

Terex

Terex Z-33 Bedienungsanleitung

Beliebte Hubarbeitsbühne Handbücher anderer Marken

Genie

Genie Z-80 Bedienungsanleitung

Genie

Genie Z-45/25 Bedienungsanleitung

JLG

JLG Skytrak 6036 Gebrauchs- und Pflegehandbuch

LGMG

LGMG T65JE Bedienungsanleitung

Genie

Genie Z-135/70 Bedienungsanleitung

Oshkosh Corporation

Oshkosh Corporation JLG H800AJ Gebrauchs- und Pflegehandbuch

Oshkosh

Oshkosh JLG 1500SJ Installations- und Benutzerhandbuch

Skyjack

Skyjack SJ30AJE Bedienungsanleitung

Oshkosh

Oshkosh JLG 800A Installations- und Benutzerhandbuch

Skyjack

Skyjack SJ 46AJ Bedienungsanleitung

Molift

Molift Quick Raiser 205 Bedienungsanleitung

Snorkel

Snorkel SL26RTE Kurzanleitung

Oshkosh Corporation

Oshkosh Corporation JLG E300A Bedienungsanleitung

Skyjack

Skyjack SJ45 T+ Bedienungsanleitung

Genie

Genie S-105 Bedienungsanleitung

nifty

nifty 170SD series Montageanleitung

JLG

JLG 15MVL Series Bedienungsanleitung

Genie

Genie Z-45 XC Bedienungsanleitung