Terex Genie Z-34 IC Installations- und Betriebsanleitung

Service and Repair Manual

Serial Number Range

Z®-34/22 IC

from Z3413-9461

Z3415-

10688

This manual includes:

Repair procedures

Fault Codes

Electrical and

Hydraulic

Schematics

from Z3416F-10689 to

Z3416F-

11999

from Z34F-12000 to

Z34F-

13999

from Z3415D-102 to

Z3416D-

279

from Z34D-280 to

Z34D-

1899

For detailed maintenance

procedures, refer to the

appropriate Maintenance

Manual for your machine.

Part No. 1274592

Rev

December 2022

Service and Repair Manual December 2022

Introduction

ii Z®-34/22 IC Part No. 1274592GT

Intr od ucti o n Intr od ucti o n

Important

Read, understand and obey the safety rules and

operating instructions in the appropriate Operator's

Manual on your machine before attempting any

procedure.

This manual provides troubleshooting and repair

procedures for qualified service professionals.

Basic mechanical, hydraulic and electrical skills are

required to perform most procedures. However,

several procedures require specialized skills, tools,

lifting equipment and a suitable workshop. In these

instances, we strongly recommend that

maintenance and repair be performed at an

authorized Genie dealer service center.

Compliance

Machine Classification

Group B/Type 3 as defined by ISO 16368

Machine Design Life

Unrestricted with proper operation, inspection and

scheduled maintenance.

Technical Publications

Genie has endeavored to deliver the highest

degree of accuracy possible. However, continuous

improvement of our products is a Genie policy.

Therefore, product specifications are subject to

change without notice.

Readers are encouraged to notify Genie of errors

and send in suggestions for improvement. All

communications will be carefully considered for

future printings of this and all other manuals.

Internet: www.genielift.com

E-mail: awp.techpub@terex.com

Find a Manual for this Model

Go to http://www.genielift.com

Use the links to locate Service Manuals,

Maintenance Manuals, Service and Repair

Manuals, Parts Manuals and Operator's Manuals.

1274592GT Rev B, July 2021

First Edition, Second Printing

Genie is a registered trademark of Terex South Dakota, Inc. in

the U.S.A. and many other countries.

“Z” is a trademark of Terex South Dakota, Inc.

December 2022 Service and Repair Manual

Introduction

Part No. 1274592GT Z®-34/22 IC iii

Revision History

Revision Date Section Procedure / Page / Description

A 9/2016

Initial Release

7/2021

Front cover Add ending serial break

12/2022

Front cover Add facility code and serial break

Reference Examples:

Electronic Version

Click on any content or procedure in the Table of Contents to view

the update.

Section – Repair Procedure, 4-2

Section – Fault Codes, All charts

Section – Schematics, Legends and schematics

Service and Repair Manual December 2022

Introduction

iv Z®-34/22 IC Part No. 1274592GT

Serial Number Legend

To August 31, 2016

1 Model

2 Model year

3 Facility code

4 Sequence number

5 Serial number (stamped on chassis)

6 Serial label (located under cover)

From September 1, 2016

1 Model

2 Facility code

3 Sequence number

4 Serial number (stamped on chassis)

5 Serial label (located under cover)

December 2022 Service and Repair Manual

Safety Rules

Part No. 1274592GT Z®-34/22 IC v

Section 1 Safet y R ul es

Danger

Failure to obey the instructions and safety rules in

this manual and the appropriate Operator's Manual

on your machine will result in death or serious

injury.

Many of the hazards identified in the operator's

manual are also safety hazards when maintenance

and repair procedures are performed.

Do Not Perform Maintenance

Unless:

You are trained and qualified to perform

maintenance on this machine.

You read, understand and obey:

•manufacturer's instructions and safety rules

•employer's safety rules and worksite

regulations

•applicable governmental regulations

You have the appropriate tools, lifting

equipment and a suitable workshop.

Service and Repair Manual December 2022

Safety Rules

vi Z®-34/22 IC Part No. 1274592GT

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 proce

dure thoroughly. This

manual and the decals on the machine,

use signal words to identify the following:

Safety alert symbol

—

used to alert

personnel to potential personal

injury hazards. Obey all safety

messages that follow this symbol

to avoid possible

injury or death.

Indicates a imminently hazardous

situation which, if not avoided, will

result in death or serious injury.

Indicates a 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 pro

tective clothing if the situation

warrants it.

Be aware of potential crushing hazards

such as moving parts, free swinging or

unsecured components when lifting or

placing loads. Always wear approved

steel

-toed shoes.

Workplace Safety

Any person working on or around a machine must

be aware of all known safety hazards. Personal

safety and the continued safe operation of the

machine should be your top priority.

Be sure to keep sparks, flames and

lighted tobacco away from flammable and

combustible

materials like battery gases

and engine fuels. Always have an

approved fire extinguisher within easy

reach.

Be sure that all tools and working areas

are properly maintained and ready for

use. Keep work surfaces clean and free of

debris that could get in

to 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.

December 2022

Table of Contents

Part No. 1274592GT Z®-34/22 IC vii

Introduction Introduction...........................................................................................................ii

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

Find a Manual for this Model .................................................................................. ii

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

Serial Number Legend .......................................................................................... iv

Section 1 Safety Rules ..........................................................................................................v

General Safety Rules ............................................................................................. v

Section 2Specifications .......................................................................................................1

Machine Specifications...........................................................................................1

Machine Component Weights ................................................................................2

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

Hydraulic Specification ...........................................................................................3

Hydraulic Component Specifications......................................................................5

Machine Torque Specifications ..............................................................................6

Kubota WG-972 Engine Specifications ..................................................................7

GM .998L Engine Specifications ............................................................................8

Kubota D1105 Engine Specifications .....................................................................9

Perkins 403D-11 Engine Specifications ...............................................................10

Perkins 403F-11 Engine Specifications ...............................................................11

Hydraulic Hose and Fitting Torque Specifications ...............................................12

Torque Procedure ................................................................................................13

SAE and Metric Fasteners Torque Charts ...........................................................15

December 2022

Table of Contents

viii Z®-34/22 IC Part No. 1274592GT

Section 3 Repair Procedures ............................................................................................. 16

Introduction .......................................................................................................... 16

Platform Controls............................................................................................... 18

1-1 Drive Joystick................................................................................................. 18

How to Adjust the Drive Joystick .................................................................... 18

1-2 Boom Function Speed Controller Adjustments.............................................. 20

Boom Function Speed Controller Adjustments............................................... 20

Platform Components ....................................................................................... 22

2-1 Platform Leveling Slave Cylinder................................................................... 22

How to Remove the Platform Leveling Slave Cylinder ................................... 22

How to Bleed the Leveling Slave Cylinder...................................................... 22

2-2 Platform Rotator............................................................................................. 23

How to Remove the Platform Rotator ............................................................. 23

How to Bleed the Platform Rotator ................................................................. 24

2-3 Platform Overload System............................................................................. 25

How to Calibrate the Platform Overload System (if equipped) ....................... 25

Jib Boom Components...................................................................................... 26

3-1 Jib Boom ........................................................................................................ 26

How to Remove the Jib Boom ........................................................................ 26

3-2 Jib Boom Bell Crank ...................................................................................... 27

How to Remove the Jib Boom Bell Crank ...................................................... 27

3-3 Jib Boom Lift Cylinder .................................................................................... 27

How to Remove the Jib Boom Lift Cylinder .................................................... 27

December 2022

Table of Contents

Part No. 1274592GT Z®-34/22 IC ix

Primary Boom Components..............................................................................29

4-1 Cable Track ....................................................................................................29

How to Repair the Primary Boom Cable Track ...............................................29

4-2 Primary Boom.................................................................................................29

How to Shim the Primary Boom ......................................................................29

How to Remove the Primary Boom.................................................................30

How to Disassemble the Primary Boom .........................................................32

4-3 Primary Boom Lift Cylinder ............................................................................33

How to Remove the Primary Boom Lift Cylinder.............................................33

4-4 Primary Boom Extension Cylinder .................................................................34

How to Remove the Primary Boom Extension Cylinder..................................34

4-5 Platform Leveling Master Cylinder .................................................................36

How to Remove the Platform Leveling Master Cylinder .................................36

Secondary Boom Components.........................................................................38

5-1 Secondary Boom............................................................................................39

How to Disassemble the Secondary Boom.....................................................39

5-2 Secondary Boom Lift Cylinders......................................................................42

How to Remove the Secondary Boom Lift Cylinders ......................................42

December 2022

Table of Contents

x Z®-34/22 IC Part No. 1274592GT

Engines ............................................................................................................... 44

6-1 Kubota Diesel Models.................................................................................... 44

Timing Adjustment .......................................................................................... 44

How to Check the Glow Plugs ........................................................................ 44

RPM Adjustment ............................................................................................. 44

How to Remove the Flex Plate ....................................................................... 45

How to Install the Flex Plate ........................................................................... 45

Coolant Temperature and Oil Pressure Switches .......................................... 45

6-2 Kubota Gasoline / LPG Models ..................................................................... 46

Choke Adjustment .......................................................................................... 46

Timing Adjustment .......................................................................................... 46

Carburetor Adjustment.................................................................................... 46

RPM Adjustment ............................................................................................. 46

How to Remove the Flex Plate ....................................................................... 47

How to Install the Flex Plate ........................................................................... 47

Coolant Temperature and Oil Pressure Switches .......................................... 47

6-3 Perkins Diesel Models ................................................................................... 48

Timing Adjustment .......................................................................................... 48

RPM Adjustment ............................................................................................. 48

How to Remove the Flex Plate ....................................................................... 49

How to Install the Flex Plate ........................................................................... 49

Coolant Temperature and Oil Pressure Switches .......................................... 49

6-4 GM .998L Models .......................................................................................... 50

Timing Adjustment .......................................................................................... 50

How to Remove the Flex Plate ....................................................................... 51

How to Install the Flex Plate ........................................................................... 51

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