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

Service and Repair Manual

Serial Number Range

Z-34/22 IC

from Z3406-4800

This manual includes:

Repair procedures

Fault

Codes

Electrical and

Hydraulic Schematics

For detailed maintenance

procedures, refer to the

appropriate Maintenance

Manual for your machine.

Part No. 1268527

Rev A

September 2015

Service and Repair Manual September 2015

Introduction

ii Z-34/22 IC Part No. 1268527

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 Operator's, Parts,

Maintenance, and Service and Repair manuals.

1268527 Rev A, September 2015

First Edition, First Printing

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

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

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

September 2015 Service and Repair Manual

Introduction

Part No. 1268527 Z-34/22 IC iii

Revision History

Revision

Date

Section

Procedure / Page / Description

A 9/2015

Release

Reference Examples:

Electronic Version

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

the update.

Section – Repair Procedure, 4-2

Section – Fault Codes, All charts

Section – Schematics, Legends and schematics

Service and Repair Manual September 2015

Introduction

iv Z-34/22 IC Part No. 1268527

Serial Number Legend

1 Model

2 Model year

3 Sequence number

4 Serial number (stamped on chassis)

5 Serial label

September 2015 Service and Repair Manual

Safety Rules

Part No. 1268527 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 September 2015

Safety Rules

vi Z-34/22 IC Part No. 1268527

Personal Safety

Any person working on or around a machine must

be aware of all known safety hazards. Personal

safety and the continued safe operation of the

machine should be your top priority.

Read each procedure thoroughly. This

manual and the decals on the machine,

use signal words to identify the following:

Safety alert symbol

—used to

alert

personnel to potential

personal injury hazards. Obey all

safety messages that follow this

symbol to avoid possible injury or

death.

Indicates a imminently hazardous

situation which, if not avoided,

will result in death or serious

injury.

Indicates a

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 lif

ting 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 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.

September 2015

Table of Contents

Part No. 1268527 Z-34/22 IC vii

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

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

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

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

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

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

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

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

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

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

Hydraulic Specification ...........................................................................................2

Hydraulic Component Specifications......................................................................4

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

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

Kubota DF-752 Engine Specifications ...................................................................8

Perkins 403C-11 Engine Specifications .................................................................9

Hydraulic Hose and Fitting Torque Specifications ...............................................10

Torque Procedure ................................................................................................11

SAE and Metric Fasteners Torque Charts ...........................................................12

September 2015

Table of Contents

viii Z-34/22 IC Part No. 1268527

Section 3 Repair Procedures ............................................................................................. 13

Introduction .......................................................................................................... 13

Platform Controls............................................................................................... 15

1-1 Drive Joystick................................................................................................. 15

How to Adjust the Drive Joystick .................................................................... 15

1-2 Boom Function Speed Controller Adjustments.............................................. 17

Boom Function Speed Controller Adjustments............................................... 17

Platform Components ....................................................................................... 19

2-1 Platform Leveling Slave Cylinder................................................................... 19

How to Remove the Platform Leveling Slave Cylinder ................................... 19

How to Bleed the Leveling Slave Cylinder...................................................... 19

2-2 Platform Rotator............................................................................................. 20

How to Remove the Platform Rotator ............................................................. 20

How to Bleed the Platform Rotator ................................................................. 21

2-3 Platform Overload System............................................................................. 22

How to Calibrate the Platform Overload System (if equipped) ....................... 22

Jib Boom Components...................................................................................... 24

3-1 Jib Boom ........................................................................................................ 24

How to Remove the Jib Boom ........................................................................ 24

3-2 Jib Boom Bell Crank ...................................................................................... 25

How to Remove the Jib Boom Bell Crank ...................................................... 25

3-3 Jib Boom Lift Cylinder .................................................................................... 25

How to Remove the Jib Boom Lift Cylinder .................................................... 25

September 2015

Table of Contents

Part No. 1268527 Z-34/22 IC ix

Primary Boom Components..............................................................................27

4-1 Cable Track ....................................................................................................27

How to Repair the Primary Boom Cable Track ...............................................27

4-2 Primary Boom.................................................................................................27

How to Shim the Primary Boom ......................................................................27

How to Remove the Primary Boom.................................................................28

How to Disassemble the Primary Boom .........................................................30

4-3 Primary Boom Lift Cylinder ............................................................................31

How to Remove the Primary Boom Lift Cylinder.............................................31

4-4 Primary Boom Extension Cylinder .................................................................32

How to Remove the Primary Boom Extension Cylinder..................................32

4-5 Platform Leveling Master Cylinder .................................................................34

How to Remove the Platform Leveling Master Cylinder .................................34

Secondary Boom Components.........................................................................36

5-1 Secondary Boom............................................................................................37

How to Disassemble the Secondary Boom.....................................................37

5-2 Secondary Boom Lift Cylinders......................................................................40

How to Remove the Secondary Boom Lift Cylinders ......................................40

Engines................................................................................................................42

6-1 Kubota Diesel Models ....................................................................................42

Timing Adjustment ..........................................................................................42

How to Check the Glow Plugs.........................................................................42

RPM Adjustment .............................................................................................42

How to Remove the Flex Plate........................................................................43

How to Install the Flex Plate............................................................................43

Coolant Temperature and Oil Pressure Switches...........................................43

September 2015

Table of Contents

x Z-34/22 IC Part No. 1268527

6-2 Kubota Gasoline / LPG Models ..................................................................... 44

Choke Adjustment .......................................................................................... 44

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

Carburetor Adjustment.................................................................................... 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

6-3 Perkins Diesel Models ................................................................................... 46

Timing 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

Hydraulic Pumps................................................................................................ 49

7-1 Auxiliary Pump ............................................................................................... 49

How to Test the Auxiliary Pump...................................................................... 49

How to Remove the Auxiliary Pump ............................................................... 49

7-2 Function Pump............................................................................................... 50

How to Test the Function Pump ..................................................................... 50

How to Removet the Function Pump .............................................................. 50

7-3 Drive Pump .................................................................................................... 51

How to Remove the Drive Pump .................................................................... 51

How to Prime the Drive Pump ........................................................................ 51

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