Genie TZ-34/20 Manuale utente

Genie TZ-34/20 Part No. 825934

April 2016

Introduction

825934 Rev DAugust 2016

Third Edition, Third Printing

"Genie" and "TZ" are registered trademarks of

Terex South Dakota, Inc. in the USA and many

other countries.

Printed on recycled paper

Printed in U.S.A.

Important

Read, understand and obey the safety rules and

operating instructions in the appropriate operator's

manual on your machine before attempting any

maintenance or repair procedure.

This manual provides detailed scheduled

maintenance information for the machine owner

and user. It also provides troubleshooting fault

codes 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.

http://www.genielift.com

e-mail: awp[email protected]

Introduction

Serial Number Information

Genie offers the following Service Manual for

these models:

Title Part No.

TZ-34/20 Service Manual ...................................... 84382

From SN TZ3403-001 to TZ3416J-3099

and from SN TZ34J-3100

Part No. 825934 Genie TZ-34/20

April 2016

Revision History

Revision Date Section Procedure / Schematic Page / Description

A 7/2013 New release

B 11/2014 Added rotation brake and EN280 updates

C 11/2015 Update bearing wear tolerance, pg 3-27

C1 1/2016 3 3-26 updated turntable rotation bearing bolt torque spec's

C2 4/2016 5 5-21and 5-25 updated electrical schematics

C3 8/2016 1 Updated front cover, Serial Number Information and

Serial Number Legend and front cover.

REFERENCE EXAMPLES:

Honda Engine_Section 2_Speciﬁcations.

A-6,B-3,C-7_Section 3_Maintenance Procedure.

3-2, 6-4, 9-1_Section 4_Repair Procedure.

5-35, 5-56, 5-104_Section 5_Schematic Page #.

Electronic Version

Click on any procedure or page number

highlighted in blue to view the update.

iii

Genie TZ-34/20 Part No. 825934

April 2016

REVISION HISTORY, CONTINUED

Revision Date Section Procedure / Schematic Page / Description

REFERENCE EXAMPLES:

Honda Engine_Section 2_Speciﬁcations.

A-6,B-3,C-7_Section 3_Maintenance Procedure.

3-2, 6-4, 9-1_Section 4_Repair Procedure.

5-35, 5-56, 5-104_Section 5_Schematic Page #.

Electronic Version

Click on any procedure or page number

highlighted in blue to view the update.

Part No. 825934 Genie TZ-34/20

April 2016

Serial Number Legend

Introduction

Genie TZ-34/20 Part No. 825934

April 2016

Safety Rules

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.

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.

Part No. 825934 Genie TZ-34/20

April 2016

SAFETY RULES

vii

Section 1 • Safety Rules

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.

Genie TZ-34/20 Part No. 825934

April 2016

Table of Contents

viii

Introduction

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

Serial Number Information .............................................................................................. ii

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

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

Section 1 Safety Rules

General Safety Rules ..................................................................................................... iv

Section 2 Speciﬁcations

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

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

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

Manifold Component Speciﬁcations ...........................................................................2 - 3

Hydraulic Hose and Fitting Torque Speciﬁcations ......................................................2 - 4

SAE and Metric Fastener Torque Chart......................................................................2 - 6

Section 3 Scheduled Maintenance Procedures

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

Pre-delivery Preparation Report.................................................................................3 - 3

Maintenance Inspection Report .................................................................................3 - 5

Checklist A Procedures

A-1 Inspect the Manuals and Decals.......................................................................3 - 6

A-2 Perform Pre-operation Inspection.....................................................................3 - 7

A-3 Perform Function Tests .....................................................................................3 - 7

A-4 Torque the Lug Bolts - ANSI/CSA/AS ...............................................................3 - 7

A-5 Torque the Lug Bolts - CE.................................................................................3 - 8

Part No. 825934 Genie TZ-34/20

April 2016

TABLE OF CONTENTS

Section 3 Scheduled Maintenance Procedures, continued

A-6 Perform Hitch Maintenance - ANSI/CSA/AS.....................................................3 - 8

A-7 Perform 30 Day Service....................................................................................3 - 9

A-8 Grease the Turntable Rotation Bearing and Rotate Gear.................................3 - 9

Checklist B Procedures

B-1 Inspect the Batteries.......................................................................................3 - 10

B-2 Inspect the Electrical Wiring ...........................................................................3 - 11

B-3 Inspect the Electrical Contactor......................................................................3 - 11

B-4 Test the Manual Override................................................................................3 - 12

B-5 Test the Platform Rotation (if equipped) .........................................................3 - 13

B-6 Perform Hydraulic Oil Analysis .......................................................................3 - 14

B-7 Perform Axle Maintenance - ANSI/CSA/AS....................................................3 - 14

B-8 Check the Wheel Bearings - CE .....................................................................3 - 15

B-9 Service the Hitch - CE ....................................................................................3 - 15

B-10 Perform Axle Maintenance - CE .....................................................................3 - 16

B-11 Inspect the Parking Brake...............................................................................3 - 17

B-12 Service the Tongue Jack.................................................................................3 - 17

Checklist C Procedures

C-1 Grease the Platform Overload Mechanism (if equipped)................................3 - 18

C-2 Test the Platform Overload System (if equipped) ...........................................3 - 18

C-3 Perform Axle Maintenance - ANSI/CSA/AS....................................................3 - 20

Genie TZ-34/20 Part No. 825934

April 2016

TABLE OF CONTENTS

Section 3 Scheduled Maintenance Procedures, continued

C-4 Replace the Hydraulic Tank Breather Cap

Models with Optional Hydraulic Oil.................................................................3 - 20

C-5 Grease the Axle Wheel Bearings - CE ...........................................................3 - 21

C-6 Adjust the Brakes - CE ...................................................................................3 - 22

Checklist D Procedures

D-1 Perform Axle Maintenance - ANSI/CSA/AS....................................................3 - 23

D-2 Check the Boom Wear Pads...........................................................................3 - 23

D-3 Replace the Hydraulic Tank Return Filter .......................................................3 - 24

D-4 Check the Turntable Rotation Bearing Bolts ...................................................3 - 25

D-5 Inspect for Turntable Bearing Wear.................................................................3 - 26

Checklist E Procedure

E-1 Test or Replace the Hydraulic Oil ...................................................................3 - 28

Section 4 Repair

Introduction.................................................................................................................4 - 1

Platform Components

1-1 Platform ............................................................................................................4 - 2

1-2 Platform Rotator (if equipped)...........................................................................4 - 2

Primary Boom Components

2-1 Cable Track .......................................................................................................4 - 7

2-2 Primary Boom...................................................................................................4 - 9

2-3 Primary Boom Lift Cylinder.............................................................................4 - 13

2-4 Platform Leveling Cylinders ............................................................................4 - 14

Secondary Boom Components

3-1 Secondary Boom............................................................................................4 - 17

3-2 Secondary Boom Lift Cylinder........................................................................4 - 19

Ground Controls

4-1 Level Sensor...................................................................................................4 - 20

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