Terex Genie TX-34/20 User manual

Service Manual
TZ-34/20
TM
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
ii
Introduction
Copyright © 2011 Terex Corporation
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.
Contact Us:
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.
iv

Part No.825934 GenieTZ-34/20
August 2022
Serial Number Legend
Introduction
v
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
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
vi
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 ...................................................................................................... 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 GenieTZ-34/20
August 2022
TABLE OF CONTENTS
ix
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
x
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