Terex Genie Z-34/22 Installation and operating manual

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.
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
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
5
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
4

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
ha
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.
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. 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