Terex Genie Z-34/22 Installations- und Betriebsanleitung

Service and Repair Manual

Serial Number Range

Z®-30/20N

from Z30NF-22000

This manual includes:

Repair procedures

Fault Codes

Electrical and

Hydraulic Schematics

Z®-30/20N RJ

Z®-34/22

from Z34F-14000

from Z34NF-17

000

Z®-34/22N

For detailed maintenance

procedures, refer to the

appropriate Maintenance

Manual for your machine.

Part No. 1312293GT

Rev A

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. 1312293GT

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.

1312293GT Rev A, September 2021

Second Edition, First Printing

Genie and "Z" are registered trademarks of Terex South

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

September 2021 Service and Repair Manual

Introduction

Part No. 1312293GT Z®-30/20N • Z®-30/20N RJ • Z®-34/22 • Z®-34/22N iii

Revision History

Revision Date Section Procedure / Page / Description

A 9/2021

Initial Release

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. 1312293GT

Serial Number Legend

1 Model

2 Facility code

3 Sequence number

1 Serial number (stamped on chassis)

2 Serial label (located under cover)

Z-30/20N

Z-30/20N RJ

Z-34/22

Z-34/22N

Model:

Serial number:

Electrical schematic number:

Year of manufacture:

Machine unladen weight:

Rated work load (including occupants):

Maximum number of platform occupants:

Maximum allowable side force:

Maximum allowable inclination of the chassis:

Z30NF-12345

Z30N F - 12345

123

September 2021 Service and Repair Manual

Safety Rules

Part No. 1312293GT Z®-30/20N • Z®-30/20N RJ • Z®-34/22 • Z®-34/22N 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 September 2021

Safety Rules

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

1312293GT

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 eac

h procedure thoroughl

y. 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 po

ssible

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

zardous 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 c

lothing 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.

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. 1312293GT 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 1 Safety Rules......................................................................................................v

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

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

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

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

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

Hydraulic Oil Specifications ................................................................................4

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

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

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

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

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

September 2021

Table of Contents

viii Z®-30/20N • Z®-30/20N RJ • Z®-34/22 • Z®-34/22N Part No. 1312293GT

Section 3 Repair Procedures ......................................................................................... 12

Introduction...................................................................................................... 12

Platform Controls........................................................................................... 14

1-1 Controllers ................................................................................................. 14

Platform Components.................................................................................... 16

2-1 Platform Leveling Slave Cylinder ................................................................ 16

2-2 Platform Rotator......................................................................................... 17

2-3 Platform Overload System.......................................................................... 18

Jib Boom Components.................................................................................. 21

3-1 Platform Overload System.......................................................................... 21

3-2 Jib Boom Bell Crank (models without rotating jib boom).............................. 22

3-3 Jib Boom Bell Crank (models with rotating jib boom) .................................. 23

3-4 Jib Boom Lift Cylinder ................................................................................ 25

Primary Boom Components .......................................................................... 26

4-1 Cable Track ............................................................................................... 26

How to Repair the Primary Boom Cable Track............................................. 26

4-2 Primary Boom ............................................................................................ 27

How to Remove the Primary Boom.............................................................. 27

How to Disassemble the Primary Boom....................................................... 29

4-3 Primary Boom Lift Cylinder......................................................................... 30

4-4 Primary Boom Extension Cylinder .............................................................. 32

4-5 Platform Leveling Master Cylinder.............................................................. 34

Secondary Boom Components ..................................................................... 35

5-1 Secondary Boom ....................................................................................... 36

5-2 Secondary Boom Lift Cylinders .................................................................. 41

September 2021

Table of Contents

Part No. 1312293GT Z®-30/20N • Z®-30/20N RJ • Z®-34/22 • Z®-34/22N ix

Hydraulic Pump ..............................................................................................43

6-1 Auxiliary and Function Pump ......................................................................43

Manifolds ........................................................................................................44

7-1 Function Manifold Components ..................................................................44

7-2 Valve Adjustments - Function Manifold .......................................................48

How to Adjust the System Relief Valve ........................................................48

How to Adjust the Primary Boom Down Relief Valve....................................48

How to Adjust the Secondary Boom Down Relief Valve ...............................49

How to Adjust the Primary Boom Extend Relief Valve ..................................49

How to Adjust the Turntable Rotate Relief Valve..........................................50

7-4 Valve Coils .................................................................................................52

How to Test a Coil Diode .............................................................................53

Turntable Rotation Components ...................................................................54

8-1 Turntable Rotation Hydraulic Motor.............................................................54

Steer Axle Components .................................................................................55

9-1 Hub and Bearings.......................................................................................55

How to Remove the Hub and Bearings ........................................................55

How to Install the Hub and Bearings ............................................................55

Non-steer Axle Components..........................................................................57

10-1 Motor Controller........................................................................................57

September 2021

Table of Contents

x Z®-30/20N • Z®-30/20N RJ • Z®-34/22 • Z®-34/22N Part No. 1312293GT

Section 4 Fault Codes .................................................................................................... 58

Introduction...................................................................................................... 58

Fault Code Charts....................................................................................... 60

Section 5 Schematics..................................................................................................... 63

Introduction...................................................................................................... 63

Electrical Symbol Legend................................................................................. 64

Hydraulic Symbols Legend............................................................................... 65

Limit Switch Location Legend........................................................................... 66

Electrical Schematics – Options ................................................................... 67

Power Cable Wiring Diagram ........................................................................... 68

Drive Contactor Panel Wiring Diagram ............................................................. 69

Manifold and Limit Switch Wiring Diagram........................................................ 72

LVI/BCI Option Wiring Diagram........................................................................ 73

Charger Interlock Option .................................................................................. 76

CTE Option, (CE Models)................................................................................. 77

Contact Alarm Option....................................................................................... 80

Electrical Schematics – ANSI / CSA Models ................................................. 81

Electrical Schematic [ANSI / CSA].................................................................... 82

Electrical Schematic [ANSI / CSA].................................................................... 83

Ground Control Box Terminal Strip Wiring Diagram [ANSI / CSA]..................... 86

Ground Control Box Switch Panel Wiring Diagram [ANSI / CSA] ...................... 87

Platform Control Box Wiring Diagram [ANSI / CSA] .......................................... 90

Electrical Schematics – CE / AS Models ....................................................... 91

Electrical Schematic [CE / AS].......................................................................... 92

Electrical Schematic [CE / AS].......................................................................... 93

Ground Control Box Terminal Strip Wiring Diagram [CE / AS]........................... 96

Ground Control Box Switch Panel Wiring Diagram [CE / AS] ............................ 97

Platform Control Box Wiring Diagram [CE / AS].............................................. 100

Hydraulic Schematics.................................................................................. 101

Hydraulic Schematic ...................................................................................... 102

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