Terex Genie Z-30N Installations- und Betriebsanleitung

Service and Repair Manual

Serial Number Range

Z®-30/20N

-30/20N RJ

from Z3414-

9686 to

from Z30N14-15222 to

Z30N16F-18899

from Z30N16D-104 to

Z30N16D-199

This manual

includes:

Repair procedures

Fault Codes

Electrical and

Hydraulic Schematics

Z®-34/22N

Z3416F-11999

from Z34N14-

10984 to

Z34N16F-13999

Z®-34/22DC

from Z34N15D-102 to

Z34N16D-

279

from Z30NF-18900 to

Z30NF-

21999

from Z34F-12000 to

Z34F-

13999

from Z34NF-14000

Z34NF-16999

For detailed maintenance

procedures, refer to the

appropriate Maintenance

Manual for your machine.

from Z30ND-200

from Z34ND-280

Part No.

1268498GT

Rev

September 2021

Service and Repair Manual September 2021

Introduction

ii Z®-30/20N • Z®-30/20N RJ • Z®-34/22 • Z®-34/22N Part No. 1268498GT

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.

Internet: www.genielift.com

E-mail: awp.techpub@terex.com

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.

1268498GT Rev B, September 2021

First Edition, Second Printing

Genie and”Z” are registered trademark of Terex South Dakota,

Inc. in the U.S.A. and many other countries.

September 2021 Service and Repair Manual

Introduction

Part No. 1268498GT Z®-30/20N • Z®-30/20N RJ • Z®-34/22 • Z®-34/22N iii

Revision History

Revision Date Section Procedure / Page / Description

A 9/2015

New Release

A1 4/2016 Schematics Update

A2 9/2016 Introduction Serial Number Legend

3/2018

Specifications

Performance Specifications

9/2021

Cover

Add ending serial break

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 September 2021

Introduction

iv Z®-30/20N • Z®-30/20N RJ • Z®-34/22 • Z®-34/22N Part No. 1268498GT

Serial Number Legend

To August 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 label (located under cover)

September 2021 Service and Repair Manual

Safety Rules

Part No. 1268498GT Z®-30/20N • Z®-30/20N RJ • Z®-34/22 • Z®-34/22N v

Sec ti on 1 Safety R ul 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 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 September 2021

Safety Rules

vi Z®-30/20N • Z®-30/20N RJ • Z®-34/22 • Z®-34/22N Part No. 1268498GT

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 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 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.

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 main

tained 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.

September 2021

Table of Contents

Part No. 1268498GT Z®-30/20N • Z®-30/20N RJ • Z®-34/22 • Z®-34/22N vii

Introduction Introduction ......................................................................................................ii

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

Find a Manual for this Model............................................................................... ii

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

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

Section 1Safety Rules......................................................................................................v

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

Section 2Specifications...................................................................................................1

Machine Specifications .......................................................................................1

Machine Component Weights .............................................................................2

Performance Specifications ................................................................................3

Hydraulic Specification .......................................................................................4

Hydraulic Component Specifications...................................................................7

Manifold Component Specifications ....................................................................7

Machine Torque Specifications ...........................................................................8

Hydraulic Hose and Fitting Torque Specifications ...............................................9

Torque Procedure ............................................................................................10

SAE and Metric Fasteners Torque Charts.........................................................12

September 2021

Table of Contents

viii Z®-30/20N • Z®-30/20N RJ • Z®-34/22 • Z®-34/22N Part No. 1268498GT

Section 3 Repair Procedures ......................................................................................... 13

Introduction...................................................................................................... 13

Platform Controls........................................................................................... 15

1-1 Controllers ................................................................................................. 15

Platform Components.................................................................................... 17

2-1 Platform Leveling Slave Cylinder ................................................................ 17

2-2 Platform Rotator......................................................................................... 18

2-3 Platform Overload System.......................................................................... 19

Jib Boom Components.................................................................................. 22

3-1 Platform Overload System.......................................................................... 22

3-2 Jib Boom Bell Crank (models without rotating jib boom).............................. 23

3-3 Jib Boom Bell Crank (models with rotating jib boom) .................................. 24

3-4 Jib Boom Lift Cylinder ................................................................................ 26

September 2021

Table of Contents

Part No. 1268498GT Z®-30/20N • Z®-30/20N RJ • Z®-34/22 • Z®-34/22N ix

Primary Boom Components...........................................................................27

4-1 Cable Track................................................................................................27

How to Repair the Primary Boom Cable Track .............................................27

4-2 Primary Boom ............................................................................................28

How to Remove the Primary Boom ..............................................................28

How to Disassemble the Primary Boom .......................................................30

4-3 Primary Boom Lift Cylinder .........................................................................31

4-4 Primary Boom Extension Cylinder...............................................................33

4-5 Platform Leveling Master Cylinder ..............................................................35

Secondary Boom Components......................................................................36

5-1 Secondary Boom........................................................................................37

5-2 Secondary Boom Lift Cylinders...................................................................42

Hydraulic Pump ..............................................................................................45

6-1 Auxiliary and Function Pump ......................................................................45

Manifolds ........................................................................................................46

7-1 Function Manifold Components ..................................................................46

7-2 Valve Adjustments - Function Manifold .......................................................50

How to Adjust the System Relief Valve ........................................................50

How to Adjust the Primary Boom Down Relief Valve....................................50

How to Adjust the Secondary Boom Down Relief Valve ...............................51

How to Adjust the Primary Boom Extend Relief Valve ..................................51

How to Adjust the Turntable Rotate Relief Valve..........................................52

7-4 Valve Coils .................................................................................................54

How to Test a Coil Diode .............................................................................55

September 2021

Table of Contents

x Z®-30/20N • Z®-30/20N RJ • Z®-34/22 • Z®-34/22N Part No. 1268498GT

Turntable Rotation Components................................................................... 57

8-1 Turntable Rotation Hydraulic Motor ............................................................ 57

Steer Axle Components................................................................................. 58

9-1 Hub and Bearings ...................................................................................... 58

How to Remove the Hub and Bearings........................................................ 58

How to Install the Hub and Bearings............................................................ 58

Non-steer Axle Components ......................................................................... 60

10-1 Motor Controller ....................................................................................... 60

Section 4 Fault Codes .................................................................................................... 61

Introduction...................................................................................................... 61

Fault Code Charts....................................................................................... 63

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