Service Manual - Genie

1 Service ManualPart No. 43037 Rev BJanuary 2007(from serial number 100 to 1186) Genie Z-34/22 ICPart No. 43037 Service Manual - First EditioniiIntroductionGenie North AmericaTelephone (206) 881-1800 Toll Free 800 536-1800 in Free 800 426-8089 in CanadaFax (206) 883-3475E-mail: EuropeTelephone (44) 0636-813943 Fax (44) 0636-815270 , understand and obey the safety rules andoperating instructions in the appropriateGenie Z-34/22 IC Operator s Manual beforeattempting any maintenance or repair Manual provides detailed scheduledmaintenance information for the machine ownerand user. It also provides troubleshooting andrepair procedures for qualified mechanical, hydraulic and electricalskills are required to perform most , several procedures require specializedskills, tools, lifting equipment and a suitableworkshop.

2 In these instances, we stronglyrecommend that maintenance and repair beperformed at an authorized Genie dealerservice Industries has endeavored to deliver thehighest degree of accuracy possible. However,continuous improvement of our products is a Geniepolicy. Therefore product specificationsare subject to change without are encouraged to notify Genie of errorsand send in suggestions for improvement. Allcommunications will be carefully considered forfuture printings of this and other manuals. Pleasewrite to the technical publications team in care ofGenie Industries, PO Box 97030, Redmond WA98073-9730 you have any questions, please call GenieIndustries.

3 Copyright 1997 by Genie Industries43037 Rev B January 2007 First Printing, Second PrintingGenie is a registered trademarkof Genie Industries. Registered 2009987 Printed on recycled paperPrinted in No. 43037 Genie Z-34/22 ICService Manual - First EditioniiiDangerFailure to obey the instructions and safety rulesin this Manual and the appropriateGenie Z-34/22 IC Operator s Manual will result indeath or serious of the hazards identified in theoperator s Manual are also safety hazardswhen maintenance and repair proceduresare Not Perform MaintenanceUnless:You are trained and qualified to performmaintenance on this read, understand and obey.

4 - manufacturer s instructions and safety rules- employer s safety rules and worksiteregulations- applicable governmental regulationsYou have the appropriate tools, liftingequipment and a suitable RulesGenie Z-34/22 ICPart No. 43037 Service Manual - First EditionSAFETY RULESW orkplace SafetyBe sure to keep sparks, flames andlighted tobacco away from flammable andcombustible materials like battery gasesand engine fuels. Always have an approved fireextinguisher within easy sure that all tools and working areasare properly maintained and ready foruse. Keep work surfaces clean and free ofdebris that could get into machine components andcause sure that your workshop or work areais properly ventilated and well sure any forklift, overhead crane orother lifting or supporting device is fullycapable of supporting and stabilizing theweight to be lifted.

5 Use only chains or straps thatare in good condition and of ample sure that fasteners intended for onetime use ( , cotter pins and self-lockingnuts) are not reused. These componentsmay fail if they are used a second sure to properly dispose of old oil orother fluids. Use an approved be environmentally safe .Personal SafetyAny person working on or around a machine mustbe aware of all known safety hazards. Personalsafety and the continued safe operation of themachine should be your top each procedure thoroughly. Thismanual and the decals on the machine,use signal words to identify the following:Indicates the presence of a hazardthat will cause death or the presence of a hazardthat may cause death or the presence of a hazardthat will or may cause seriousinjury or damage to the special operation ormaintenance sure to wear protective eye wear andother protective clothing if the situationwarrants aware of potential crushing hazardssuch as moving parts, free swinging orunsecured components when lifting orplacing loads.

6 Always wear approved No. 43037 Genie Z-34/22 ICService Manual - First EditionTable of ContentsvIntroductionImportant Information ..iiSection OneSafety RulesGeneral Safety Rules ..iiiSection TwoSpecificationsMachine 2 - 1 Performance 2 - 2 Hydraulic 2 - 2 Bolt Torque Specifications .. 2 - 4 Kubota WG-750 Engine 2 - 5 Kubota D-905 Engine 2 - 7 Section ThreeScheduled Maintenance InspectionsIntroduction .. 3 - 1 Table A ..3 - 2 Table B ..3 - 3 Table 3 - 5 Table 3 - 6 Maintenance Inspection Report .. 3 - 7 Section FourScheduled Maintenance ProceduresIntroduction .. 4 - 1A-1 Inspect the Operator s and Safety 4 - 2A-2 Inspect the Decals and Placards.

7 4 - 2A-3 Inspect for Damage, Loose or Missing Parts ..4 - 3A-4 Check the Engine Oil 4 - 3A-5 Check the Engine Coolant 4 - 4A-6 Check for Fuel Leaks .. 4 - 4A-7 Check the Hydraulic Oil Level ..4 - 5A-8 Check for Hydraulic Leaks .. 4 - 5 Genie Z-34/22 ICPart No. 43037 Service Manual - First EditionTABLE OF CONTENTSviSection FourScheduled Maintenance Procedures, continuedA-9 Check the Tire Pressure ..4 - 6A-10 Test the Platform and Ground Controls .. 4 - 6A-11 Test the Auxiliary Power Operation .. 4 - 7A-12 Test the Tilt Sensor ..4 - 8A-13 Test the Limit Switches .. 4 - 8A-14 Perform 30 Day 4 - 10A-15 Clean the Air Filter Element.

8 4 - 10A-16 Drain the Fuel Filter/Water Separator - Kubota Diesel Models ..4 - 11A-17 Check the Engine 4 - 12A-18 Replace the Engine Oil and Filter .. 4 - 12B-1 Check the Radiator .. 4 - 14B-2 Check the Engine Choke - Kubota Gasoline/LPG Models .. 4 - 14B-3 Check the Exhaust System ..4 - 15B-4 Check the Battery .. 4 - 15B-5 Inspect the Electrical 4 - 16B-6 Inspect the Tires and Wheels (including lug nut torque) .. 4 - 16B-7 Confirm the Proper Brake 4 - 17B-8 Check the Oil Level in the Torque 4 - 17B-9 Check the Glow Plugs - Kubota Diesel 4 - 18B-10 Check and Adjust the Engine RPM ..4 - 18B-11 Test the Key Switch.

9 4 - 20B-12 Test the Emergency Stop Buttons .. 4 - 20B-13 Test the Ground Control Override .. 4 - 21B-14 Test the Platform 4 - 21B-15 Test the Service Horn ..4 - 22B-16 Test the Foot 4 - 22B-17 Test the Engine Idle Select .. 4 - 23B-18 Test the Fuel Select - Kubota Gasoline/LPG 4 - 24B-19 Test the Drive Enable System ..4 - 24B-20 Test the Drive Brakes ..4 - 25B-21 Test the Drive Speed - Stowed 4 - 26 Part No. 43037 Genie Z-34/22 ICService Manual - First EditionTABLE OF CONTENTSviiSection FourScheduled Maintenance Procedures, continuedB-22 Test the Drive Speed - Raised or Extended Position.

10 4 - 26B-23 Test the Alarm Package - Optional 4 - 27B-24 Perform Hydraulic Oil 4 - 28B-25 Replace the Diesel Fuel Filter/Water Separator Element -Kubota Diesel 4 - 29C-1 Check the Primary Boom Wear Pads ..4 - 30C-2 Check the Turntable Rotation Bearing 4 - 30C-3 Check the Free-wheel Configuration .. 4 - 31C-4 Grease the Turntable Rotation Bearing and Worm Drive 4 - 32C-5 Replace the Torque Hub Oil ..4 - 33C-6 Replace the Hydraulic Filters ..4 - 33C-7 Replace the Gasoline Fuel Filter - Kubota Gasoline/LPG 4 - 34C-8 Clean or Replace the Distributor Cap and Rotor -Kubota Gasoline/LPG Models.