Terex Genie Z-30N Installation and operating manual

Service and Repair Manual
Serial Number Range
Z®-30/20N
Z
®
-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
to
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
B
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.
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
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
A3 3/2018 Specifications
Performance Specifications
B 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