Terex Z-30/20N RJ User manual

Service Manual
Serial Number Range
Z-30/20N
from Z30N08-11500 to
Z30N14-
15221
Z-30/20N RJ
from Z34N07-6291 to
Z34N07-
10983
Z-34/22N
from Z3407-5427 to
Z3414-
9685
Z-34/22DC
Part No. 139378
Rev C1
April 2016

Service Manual April 2016
Introduction
ii Z-30/20N • Z-30/20N RJ • Z-34/22 • Z-34/22N Part No. 139378
Intr oduct io n Intr oduct io n
Important
Read, understand and obey the safety rules and
operating instructions in the appropriate Operator's
Manual on your machine before attempting any
maintenance procedure.
This manual provides detailed scheduled
maintenance information for the machine owner
and user. It also 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 © 2011 by Terex Corporation
139378 Rev C1, April 2016
Third Edition, Second Printing
Genie is a registered trademark of Terex South Dakota, Inc. in
the U.S.A. and many other countries.
“Z” is a trademark of Terex South Dakota, Inc.

April 2016 Service Manual
Introduction
Part No. 139378 Z-30/20N • Z-30/20N RJ • Z-34/22 • Z-34/22N iii
Revision History
Revision Date Section Procedure / Page / Description
B2 1/2015 Introduction Added Revision History
Maint. Added B-15, Test the Emergency Power
C
9/2015
Added ending serial breaks.
C1
3/2016
Schematics
Specifications
Added Schematics
Added Commponent Weights
Reference Examples:
Section – Maintenance, B-3
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 Manual April 2016
Introduction
iv Z-30/20N • Z-30/20N RJ • Z-34/22 • Z-34/22N Part No. 139378
Revision History
Revision Date Section Procedure / Page / Description
Reference Examples:
Section – Maintenance, B-3
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

April 2016 Service Manual
Introduction
Part No. 139378 Z-30/20N • Z-30/20N RJ • Z-34/22 • Z-34/22N v
Serial Number Legend
1 Model
2 Model year
3 Sequence number
4 Serial number (stamped on chassis)
5 Serial label (located under cover)

Service Manual April 2016
Safety Rules
vi Z-30/20N • Z-30/20N RJ • Z-34/22 • Z-34/22N Part No. 139378
Section 1 Safet y 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 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.

April 2016 Service Manual
Safety Rules
Part No. 139378 Z-30/20N • Z-30/20N RJ • Z-34/22 • Z-34/22N vii
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 sw
inging 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 ful
ly
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. Thes
e 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.

April 2016
Table of Contents
viii Z-30/20N • Z-30/20N RJ • Z-34/22 • Z-34/22N Part No. 139378
Introduction Introduction .......................................................................................................... ii
Important Information..............................................................................................ii
Find a Manual for this Model...................................................................................ii
Revision History.....................................................................................................iii
Serial Number Legend........................................................................................... v
Section 1 Safety Rules ......................................................................................................... vi
General Safety Rules.............................................................................................vi
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
Section 3 Scheduled Maintenance Procedures ............................................................... 13
Introduction ..........................................................................................................13
Pre-Delivery Preparation Report..........................................................................16
Maintenance Inspection Report...........................................................................18
Checklist A Procedures ..................................................................................... 19
A-1 Inspect the Manuals and Decals...................................................................19
A-2 Perform Pre-operation Inspection .................................................................20
A-3 Perform Function Tests.................................................................................20
A-4 Perform 30 Day Service ................................................................................21
A-5 Grease the Turntable Rotation Bearing and Worm Drive Gear ....................21
A-6 Replace the Drive Hub Oil.............................................................................22

April 2016
Table of Contents
Part No. 139378 Z-30/20N • Z-30/20N RJ • Z-34/22 • Z-34/22N ix
Checklist B Procedures ..................................................................................... 23
B-1 Inspect the Battery.........................................................................................23
B-2 Inspect the Electrical Wiring ..........................................................................24
B-3 Inspect the Tires, Wheels and Lug Nut Torque.............................................25
B-4 Confirm the Proper Brake Configuration .......................................................26
B-5 Check the Drive Hub Oil Level and Fastener Torque....................................26
B-6 Test the Ground Control Override .................................................................27
B-7 Test the Platform Self-leveling.......................................................................27
B-8 Test the Drive Brakes ....................................................................................28
B-9 Test the Drive Speed - Stowed Position........................................................28
B-10 Test the Drive Speed - Raised or Extended Position..................................29
B-11 Test the Alarm Package (if equipped) .........................................................30
B-12 Test the Turntable Rotation Stop.................................................................31
B-13 Check the Electrical Contactors ..................................................................31
B-14 Perform Hydraulic Oil Analysis....................................................................32
B-15 Test the Emergency Power System ............................................................32
Checklist C Procedures ..................................................................................... 34
C-1 Grease the Platform Overload Mechanism (if equipped)..............................34
C-2 Test the Platform Overload System (if equipped) .........................................34
Checklist D Procedures ..................................................................................... 36
D-1 Check the Boom Wear Pads.........................................................................36
D-2 Check the Free-wheel Configuration.............................................................37
D-3 Check the Turntable Rotation Bearing Bolts .................................................38
D-4 Replace the Drive Hub Oil.............................................................................39
D-5 Replace the Hydraulic Tank Return Filter Element.......................................39
D-6 Inspect for Turntable Bearing Wear ..............................................................40
Checklist E Procedures ..................................................................................... 41
E-1 Test or Replace the Hydraulic Oil..................................................................41
E-2 Grease the Steer Axle Wheel Bearings.........................................................43

April 2016
Table of Contents
x Z-30/20N • Z-30/20N RJ • Z-34/22 • Z-34/22N Part No. 139378
Section 4 Repair Procedures ............................................................................................. 45
Introduction ..........................................................................................................45
Platform Controls ............................................................................................... 47
1-1 Controllers......................................................................................................47
Platform Components ....................................................................................... 49
2-1 Platform Leveling Slave Cylinder...................................................................49
2-2 Platform Rotator.............................................................................................50
2-3 Platform Overload System.............................................................................51
Jib Boom Components ...................................................................................... 54
3-1 Platform Overload System.............................................................................54
3-2 Jib Boom Bell Crank (models without rotating jib boom)...............................55
3-3 Jib Boom Bell Crank (models with rotating jib boom)....................................56
3-4 Jib Boom Lift Cylinder....................................................................................58
Primary Boom Components ............................................................................. 59
4-1 Cable Track....................................................................................................59
How to Repair the Primary Boom Cable Track...............................................59
4-2 Primary Boom................................................................................................60
How to Remove the Primary Boom ................................................................60
How to Disassemble the Primary Boom.........................................................62
4-3 Primary Boom Lift Cylinder............................................................................63
4-4 Primary Boom Extension Cylinder.................................................................65
4-5 Platform Leveling Master Cylinder.................................................................67
Secondary Boom Components ........................................................................ 68
5-1 Secondary Boom ...........................................................................................69
5-2 Secondary Boom Lift Cylinders .....................................................................74
Hydraulic Pump .................................................................................................. 77
6-1 Auxiliary and Function Pump.........................................................................77