Terex Genie Z-34/22 Installation and operating manual

Service and Repair Manual
Serial Number Range
Z®-34/22
from Z3414-9686 to
Z3416F-
11999
from Z34F-12000
This manual includes:
Repair procedures
Fault Codes
Electrical and
Hydraulic Schematics
For detailed maintenance
procedures, refer to the
appropriate Maintenance
Manual for your machine.
Bi-Energy Power
Part No.
1268515GT
Rev B
October 2021

Service and Repair Manual October 2021
Introduction
ii Z®-34/22 Bi-Energy Part No. 1268515GT
Intro ductio n Intro ductio 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.
Contact Us:
Internet: www.genielift.com
E-mail: [e-mail]
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.
Copyright © 2015 by Terex Corporation
1268515GTRev B, October 2021
First Edition, Second Printing
Genie and "Z" are registered trademarks of Terex South
Dakota, Inc. in the U.S.A. and many other countries.

October 2021 Service and Repair Manual
Introduction
Part No. 1268515GT Z®-34/22 Bi-Energy iii
Revision History
Revision Date Section Procedure / Page / Description
A 9/2015 Release
A1
5/2016
Schematics
Update, added Charger interlock option
A2
9/2016
Introduction
Serial Number Legend
B 10/2021 Schematics Electrical, Hydraulic Schematics
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 October 2021
Introduction
iv Z®-34/22 Bi-Energy Part No. 1268515GT
Serial Number Legend
To Augus
t 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 lable (located under cover)

October 2021 Service and Repair Manual
Safety Rules
Part No. 1268515GT Z®-34/22 Bi-Energy v
Sec ti on 1 Safety Rul 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 modify or alter a MEWP without prior
written permission from the manufacturer.
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 October 2021
Safety Rules
vi Z®-34/22 Bi-Energy Part No. 1268515GT
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 fo
llow 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 prote
ctive 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.
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.

October 2021
Table of Contents
Part No. 1268515GT Z®-34/22 Bi-Energy 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
Machine Component Weights.............................................................................1
Performance Specifications ................................................................................2
Hydraulic Oil Specifications ................................................................................2
Hydraulic Component Specifications...................................................................5
Manifold Component Specifications ....................................................................6
Machine Torque Specifications ...........................................................................6
Kubota Z482-E Engine Specifications.................................................................7
Generator Specifications ....................................................................................8
Hydraulic Hose and Fitting Torque Specifications ...............................................9
Torque Procedure ............................................................................................10

October 2021
Table of Contents
viii Z®-34/22 Bi-Energy Part No. 1268515GT
Section 3 Repair Procedures .........................................................................................12
Introduction ......................................................................................................12
Platform Controls...........................................................................................14
1-1 Controllers..................................................................................................14
Boom Function Speed Controller Adjustments.............................................14
1-2 Diodes........................................................................................................16
1-3 Foot Switch ................................................................................................16
1-4 Toggle Switches.........................................................................................17
How to Test a Toggle Switch ....................................................................... 17
Platform Components ....................................................................................18
2-1 Platform Leveling Slave Cylinder ................................................................18
How to Remove the Platform Leveling Slave Cylinder.................................. 18
How to Bleed the Leveling Slave Cylinder....................................................18
2-2 Platform Rotator .........................................................................................19
How to Remove the Platform Rotator...........................................................19
How to Bleed the Platform Rotator...............................................................20
2-3 Platform Overload System..........................................................................21
How to Calibrate the Platform Overload System (if equipped) ......................21
Jib Boom Components ..................................................................................22
3-1 Jib Boom....................................................................................................22
How to Remove the Jib Boom .....................................................................22
3-2 Jib Boom Bell Crank...................................................................................23
How to Remove the Jib Boom Bell Crank .................................................... 23
3-3 Jib Boom Lift Cylinder.................................................................................23
How to Remove the Jib Boom Lift Cylinder ..................................................23

October 2021
Table of Contents
Part No. 1268515GT Z®-34/22 Bi-Energy ix
Primary Boom Components...........................................................................25
4-1 Cable Track................................................................................................25
How to Repair the Primary Boom Cable Track.............................................25
4-2 Primary Boom ............................................................................................25
How to Shim the Primary Boom ...................................................................25
How to Remove the Primary Boom ..............................................................25
How to Disassemble the Primary Boom .......................................................27
4-3 Primary Boom Lift Cylinder .........................................................................28
How to Remove the Primary Boom Lift Cylinder...........................................28
4-4 Primary Boom Extension Cylinder...............................................................30
How to Remove the Primary Boom Extension Cylinder ................................30
4-5 Platform Leveling Master Cylinder ..............................................................31
How to Remove the Platform Leveling Master Cylinder................................31
Secondary Boom Components......................................................................33
5-1 Secondary Boom........................................................................................34
How to Disassemble the Secondary Boom ..................................................34
5-2 Secondary Boom Lift Cylinders...................................................................37
How to Remove the Secondary Boom Lift Cylinders ....................................37
Engines...........................................................................................................39
6-1 Timing Adjustment......................................................................................39
6-2 RPM Adjustment ........................................................................................39
6-3 Engine Drive Pulley ....................................................................................39
How to Remove the Engine Drive Pulley......................................................39
How to Install the Engine Drive Pulley..........................................................40
6-4 Coolant Temperature and Oil Pressure Switches ........................................41

October 2021
Table of Contents
x Z®-34/22 Bi-Energy Part No. 1268515GT
Generator........................................................................................................42
7-1 Generator Pulley ........................................................................................42
How to Remove the Generator Pulley..........................................................42
How to Install the Generator Pulley..............................................................42
7-2 Generator Belts..........................................................................................43
7-3 Generator Voltage Regulator......................................................................44
How to Adjust the Generator Voltage Regulator...........................................44
How to Replace the Voltage Regulator ........................................................45
Hydraulic Pumps............................................................................................47
8-1 Auxiliary Pump ...........................................................................................47
How to Test the Auxiliary Pump...................................................................47
How to Remove the Auxiliary Pump.............................................................47
8-2 Function Pump...........................................................................................48
How to Test the Function Pump...................................................................48
How to Removet the Function Pump............................................................48
Manifolds ........................................................................................................50
9-1 Function Manifold Components ..................................................................50
9-2 Valve Adjustments - Function Manifold ....................................................... 52
How to Adjust the System Relief Valve ........................................................52
How to Adjust the Primary Boom Down Relief Valve....................................52
How to Adjust the Secondary Boom Down Relief Valve ............................... 53
How to Adjust the Turntable Rotate Relief Valve.......................................... 53
9-3 Jib Boom / Platform Rotate Manifold Components. .....................................54
9-4 Valve Coils .................................................................................................55
How to Test a Coil.......................................................................................55
Valve Coil Resistance Specification............................................................. 55
How to Test a Coil Diode.............................................................................56