Terex Genie TX-34/20 Manuale utente

Service Manual

TZ-34/20

Part No. 825934

Rev C5

August 2022

Serial Number Range

from TZ3413-596 to TZ3416J-3099

and from TZ34J-3100

GenieTZ-34/20 Part No.825934

August 2022

Introduction

825934 Rev C November 2015

Second Edition, Third Printing

Genie and is a registered trademarks of Terex

South Dakota, Inc. in the USA and many other

countries.

"TZ" is a trademark of Terex South Dakota, Inc.

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: [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 TZ3413-595

Part No.825934 GenieTZ-34/20

August 2022

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 1/2018 3 3-26 updated turntable rotation bearing bolt torque spec's

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

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

Number Legend and front cover

C4 4/2019 5 Electrical Schematics

C5 8/2022 4 6-2

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 #.

iii

GenieTZ-34/20 Part No.825934

August 2022

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 GenieTZ-34/20

August 2022

Serial Number Legend

Introduction

TZ-34 11 - 299

Model

Model year

Sequence

number

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:

Maximum wind speed:

Maximum platform height:

Maximum platform reach:

Gradeability:

Nominal Power:

Country of manufacture:

This machine complies with:

Compliance STD #1

Compliance STD #2

Compliance STD #3

Position 4

Pos 5

Position 6

Position 7

Position 8

Position 9

Position 10

Position 11

Position 14

Position 3

Power supply voltage: Position 12

Control system voltage: Position 13

Nominal battery/design voltage power:

Position 40

Maximum hydraulic pressure: Position 27

99.999 lbs / 99.999 kg

TZ3411-299

2011 03/14/11

PN - 77055

Genie UK LTD

The Maltings

Wharf Road, Grantham, Lin

NG31 6BH United Kingdom

Manufacturer:Manufacturer:

European Representative:

TZ-34

DATE:

GVWR / PNBV:

GAWR / PNBE:

TIRES / PNEU:

RIMS / JANTE:

COLD TIRE INFLATION/

THIS VEHICLE CONFORMS TO ALL APPLICABLE U.S. FEDERAL

MOTOR VEHICLE SAFETY STANDARDS IN EFFECT ON THE DATE

OF MANUFACTURE SHOWN ABOVE.

THIS VEHICLE CONFORMS TO ALL APPLICABLE STANDARDS

PRESCRIBED UNDER THE CANADIAN MOTOR VEHICLE SAFETY

REGULATIONS IN EFFECT ON THE DATE OF MANUFACTURE/

CE VEHICULE EST CONFORME A TOUTES LES NORMES QUI

LUI SONT APPLICABLES EN VERTU DU REGLAMENT SUR LA

SECURITE DES VEHICULES AUTOMOBILES DU CANADA EN

VIGUER A LA DATE DE SA FABRICATION

V.I.N/N.I.V.:

TYPE OF VEHICLE/TYPE DE VEHICULE:TRAILER/REMORQUE

MODEL:

SERIAL NUMBER:

ELECTRICAL SCHEMATIC:

MODEL YEAR:

Position 25

Position 24

Position 26

ES0441

Position 40

99.999 lbs/ 99.99 kg

PRESS.DE GONFL. A FROID ‘SINGLE’

TZ3411-299

2011

NOMINAL

POWER:

PN - 77172

TZ-34

Terex USA, LLC.

590 Huey Road

Rock Hill, SC 29732

USA

Serial number

(stamped on chassis)

Serial label

GenieTZ-34/20 Part No.825934

August 2022

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 modify or alter a MEWP without prior written

permission from the manufacture.

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 GenieTZ-34/20

August 2022

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.

GenieTZ-34/20 Part No.825934

August 2022

Table of Contents

viii

Introduction

Important Information ......................................................................................................

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

Revision History .............................................................................................................

iii

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

Section 1 Safety Rules

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

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 GenieTZ-34/20

August 2022

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

GenieTZ-34/20 Part No.825934

August 2022

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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