Terex South Dakota, Inc. in the USA and many future printings of this and all other manuals. other countries. Printed on recycled paper Contact Us: Printed in U.S.A. http://www.genieindustries.com e-mail: awp.techpub@terex.com Z-30/20N • Z-30/20N RJ • Z-34/22 • Z-34/22N Part No. 139378...
This machine complies with: Z-30/20N RJ Serial label (located under cover) Serial number stamped on chassis Terex South Dakota, Inc. 500 Oak Wood Road PO Box 1150 Watertown, SD 57201 Z-34/22 Z-34/22N Part No. 139378 Z-30/20N • Z-30/20N RJ • Z-34/22 • Z-34/22N...
Safety Rules Danger Failure to obey the instructions and safety rules in this manual and the Genie Z-30/20N Operator’s Manual or the Z-34/22 and Z-34/22N Operator's Manual will result in death or serious injury. Many of the hazards identified in the operator’s manual are also safety hazards...
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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. Z-30/20N • Z-30/20N RJ • Z-34/22 • Z-34/22N Part No. 139378...
18 cm For operational specifications, refer to the Operator's Manual. Continuous improvement of our products is a Genie policy. Product specifications are subject to change without notice. Part No. 139378 Z-30/20N • Z-30/20N RJ • Z-34/22 • Z-34/22N 2 - 1...
13 to 18 seconds Platform level down 13 to 18 seconds Continuous improvement of our products is a Genie policy. Product specifications are subject to change without notice. 2 - 2 Z-30/20N • Z-30/20N RJ • Z-34/22 • Z-34/22N Part No. 139378...
Continuous improvement of our products is a the approved optional fluids. Consult the Genie Genie policy. Product specifications are Industries Service Department before use. subject to change without notice. Part No. 139378 Z-30/20N • Z-30/20N RJ • Z-34/22 • Z-34/22N 2 - 3...
O-rings. or when new hoses or fittings are installed. They are not standard SAE size O-rings. They are available in the O-ring field service kit (Genie part SAE O-ring Boss Port number 49612). (tube fitting - installed into Aluminum) 2 Lubricate the O-ring before installation.
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• Key switch in the off position with the key removed • Wheels chocked • All external AC power supply disconnected from the machine Part No. 139378 Z-30/20N • Z-30/20N RJ • Z-34/22 • Z-34/22N 3 - 1...
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Make copies of the Maintenance Inspection Report to use for each inspection. Maintain completed forms for a minimum of 4 years or in compliance with employer, jobsite and governmental regulations and requirements. 3 - 2 Z-30/20N • Z-30/20N RJ • Z-34/22 • Z-34/22N Part No. 139378...
After repair, place a check in the “R” box. Legend Y = yes, acceptable N = no, remove from service R = repaired Part No. 139378 Z-30/20N • Z-30/20N RJ • Z-34/22 • Z-34/22N 3 - 5...
Result: The operator's manual is not appropriate for the machine or all manuals are not in good condition or are illegible. Remove the machine from service until the manual is replaced. 3 - 6 Z-30/20N • Z-30/20N RJ • Z-34/22 • Z-34/22N Part No. 139378...
Operator's Manual located on your procedures are required. machine. Complete information to perform this procedure is available in the Operator's Manual located on your machine. Part No. 139378 Z-30/20N • Z-30/20N RJ • Z-34/22 • Z-34/22N 3 - 7...
5 Grease each tooth on the outside of the turntable rotation bearing. Grease Specification Chevron Ultra-duty grease, EP NLGI 2 (lithium based) or equivalent 3 - 8 Z-30/20N • Z-30/20N RJ • Z-34/22 • Z-34/22N Part No. 139378...
Refer to Section 2, Specifications. 5 Install the plugs into the drive hub. 6 Repeat this procedure for the other drive hub. Part No. 139378 Z-30/20N • Z-30/20N RJ • Z-34/22 • Z-34/22N 3 - 9...
3 Be sure that the battery retainers and cable connections are tight. 5 Be sure that the battery retainers and cable connections are tight. 3 - 10 Z-30/20N • Z-30/20N RJ • Z-34/22 • Z-34/22N Part No. 139378...
Do not • Ground control panel overfill. • Function manifold wiring 11 Install the vent caps and neutralize any electrolyte that may have spilled. Part No. 139378 Z-30/20N • Z-30/20N RJ • Z-34/22 • Z-34/22N 3 - 11...
Result: The machine functions should not operate. 6 Turn the key switch to the off position. Result: No function should operate. 3 - 12 Z-30/20N • Z-30/20N RJ • Z-34/22 • Z-34/22N Part No. 139378...
2 Check each wheel for damage, bends and disengaged position cracks. 3 Check each lug nut for proper torque. Refer to Section 2, Specifications. engaged position Part No. 139378 Z-30/20N • Z-30/20N RJ • Z-34/22 • Z-34/22N 3 - 13...
4 Install the plugs into the drive hub. 5 Check the torque of the drive hub bolts. Refer to Section 2, Specifications . 6 Repeat this procedure for each drive hub. 3 - 14 Z-30/20N • Z-30/20N RJ • Z-34/22 • Z-34/22N Part No. 139378...
Refer to Section 2, Specifications. Note: The brakes must be able to hold the machine on any slope it is able to climb. Part No. 139378 Z-30/20N • Z-30/20N RJ • Z-34/22 • Z-34/22N 3 - 15...
6 Continue at full speed and note the time when finish line. Refer to Section 2, Specifications. your machine reference point passes over the finish line. Refer to Section 2, Specifications. 3 - 16 Z-30/20N • Z-30/20N RJ • Z-34/22 • Z-34/22N Part No. 139378...
Move the jib boom switch to the down position, hold for a moment and then release it. Result: The descent alarm should sound when each switch is held down. Part No. 139378 Z-30/20N • Z-30/20N RJ • Z-34/22 • Z-34/22N 3 - 17...
Remove steer tires. all rings, watches and other jewelry. Note: Replace the contactors if any damage is found. 3 - 18 Z-30/20N • Z-30/20N RJ • Z-34/22 • Z-34/22N Part No. 139378...
If the hydraulic oil is not replaced at the two year inspection, test the oil quarterly. Replace the oil when it fails the test. See E-1, Test or Replace the Hydraulic Oil. Part No. 139378 Z-30/20N • Z-30/20N RJ • Z-34/22 • Z-34/22N 3 - 19...
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Calibrate the overload indicator lights flash and the alarm platform overload system. Refer to Repair sounds. Procedure 2-3, How to Calibrate the Platform Overload System (if equipped). Part No. 139378 Z-30/20N • Z-30/20N RJ • Z-34/22 • Z-34/22N 3 - 21...
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Result: All ground control functions should not operate. 11 Using auxiliary power, test all machine functions from the ground controls. Result: All ground control functions should operate. 3 - 22 Z-30/20N • Z-30/20N RJ • Z-34/22 • Z-34/22N Part No. 139378...
(15,000 lbs / 7000 kg) under the drive chassis between the non-steer wheels. 3 Lift the wheels off the ground and then place blocks under the drive chassis for support. 3 - 24 Z-30/20N • Z-30/20N RJ • Z-34/22 • Z-34/22N Part No. 139378...
Genie Service Parts (Genie part no. 36555). 2 Confirm that each turntable mounting bolt is torqued in sequence to specification. Refer to Section 2, Specifications. Bolt torque sequence Part No. 139378 Z-30/20N • Z-30/20N RJ • Z-34/22 • Z-34/22N 3 - 25...
Refer to Section 2, Specifications. 5 Install the plugs into the drive hub. 6 Repeat this procedure for the other drive hub. 3 - 26 Z-30/20N • Z-30/20N RJ • Z-34/22 • Z-34/22N Part No. 139378...
3 Raise the primary and secondary booms to full components to be sure that there are no leaks. height using the ground controls. Do not extend the primary boom. Part No. 139378 Z-30/20N • Z-30/20N RJ • Z-34/22 • Z-34/22N 3 - 27...
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5 Adjust the dial indicator to "0". 6 Lower the secondary boom to the stowed position and lower the primary boom to a horizontal position. Fully extend the primary boom. 3 - 28 Z-30/20N • Z-30/20N RJ • Z-34/22 • Z-34/22N Part No. 139378...
Bodily injury hazard. Beware of Fitting Torque Specifications. hot oil. Contact with hot oil may cause severe burns. Note: Perform this procedure with the boom in the stowed position. Part No. 139378 Z-30/20N • Z-30/20N RJ • Z-34/22 • Z-34/22N 3 - 29...
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8 ft-lbs / 10.8 Nm. Component damage hazard. The hydraulic tank is plastic and may become damaged if the tank mounting fasteners are over tightened. 3 - 30 Z-30/20N • Z-30/20N RJ • Z-34/22 • Z-34/22N Part No. 139378...
Result: There should be no side to side or up and down movement. Chevron Ultra-duty grease, EP NLGI 2 (lithium based) Skip to step 10 if there is no movement. or equivalent Part No. 139378 Z-30/20N • Z-30/20N RJ • Z-34/22 • Z-34/22N 3 - 31...
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23 Install the dust cap, then the tire and wheel assembly. Torque the wheel lug nuts to specification. Refer to Section 2, Specifications. 3 - 32 Z-30/20N • Z-30/20N RJ • Z-34/22 • Z-34/22N Part No. 139378...
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• Key switch in the off position with the after performing a series of steps. key removed • Wheels chocked • All external AC power supply disconnected from the machine Part No. 139378 Z-30/20N • Z-30/20N RJ • Z-34/22 • Z-34/22N 4 - 1...
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9 Start a timer and simultaneously press down the foot switch and move the primary boom toggle switch in the down direction. Note how long it takes to reach 0.65A. Part No. 139378 Z-30/20N • Z-30/20N RJ • Z-34/22 • Z-34/22N 4 - 3...
1 Raise the jib boom to a horizontal position. 2 Move the platform level toggle switch up and down through two platform leveling cycles to remove any air that might be in the system. 4 - 4 Z-30/20N • Z-30/20N RJ • Z-34/22 • Z-34/22N Part No. 139378...
5 Support the platform rotator with a suitable lifting device. Do not apply any lifting pressure. Part No. 139378 Z-30/20N • Z-30/20N RJ • Z-34/22 • Z-34/22N 4 - 5...
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Continue holding the toggle switch until air stops coming out of the bleed valve. Close the bleed valve. Crushing hazard. Keep clear of the platform during rotation. 4 - 6 Z-30/20N • Z-30/20N RJ • Z-34/22 • Z-34/22N Part No. 139378...
Note: The platform will need to be moved up and down and allowed to settle between each adjustment. Note: There may be a 2 second delay before the platform overload indicator lights and alarm responds. Part No. 139378 Z-30/20N • Z-30/20N RJ • Z-34/22 • Z-34/22N 4 - 7...
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Note: There may be a 2 second delay before the platform overload indicator light and alarm responds. 9 Test all machine functions from the platform controls. Result: All platform control functions should not operate. 4 - 8 Z-30/20N • Z-30/20N RJ • Z-34/22 • Z-34/22N Part No. 139378...
Component damage hazard. Hoses and cables can be damaged if they are kinked or pinched. Part No. 139378 Z-30/20N • Z-30/20N RJ • Z-34/22 • Z-34/22N 4 - 9...
Crushing hazard. The jib boom bell crank could become unbalanced and fall when the pins are removed if not properly supported and secured to the lifting device. 4 - 10 Z-30/20N • Z-30/20N RJ • Z-34/22 • Z-34/22N Part No. 139378...
5 Support and secure the jib boom bell crank to an appropriate lifting device. 6 Remove the pin retaining fasteners from the slave cylinder rod-end pivot pin. Do not remove the pin. Part No. 139378 Z-30/20N • Z-30/20N RJ • Z-34/22 • Z-34/22N 4 - 11...
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5 seconds, then release it. Repeat three times. Crushing hazard. Keep hands and head clear of the platform pivot weldment during rotation. 4 - 12 Z-30/20N • Z-30/20N RJ • Z-34/22 • Z-34/22N Part No. 139378...
Do not allow oil to squirt or spray. 3 Remove the pin retaining fasteners from the jib boom lift cylinder rod-end pivot pin. Do not remove the pin. Part No. 139378 Z-30/20N • Z-30/20N RJ • Z-34/22 • Z-34/22N 4 - 13...
2 Repeat step 1 for each link. 3 To remove a single link, open the lower clip. Use a screwdriver to pry the link to the side. 4 - 14 Z-30/20N • Z-30/20N RJ • Z-34/22 • Z-34/22N Part No. 139378...
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See 3-3, How to Remove the end of the primary boom. Jib Boom Rotator . Part No. 139378 Z-30/20N • Z-30/20N RJ • Z-34/22 • Z-34/22N 4 - 15...
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Crushing hazard. The primary boom assembly could become unbalanced and fall when removed from the machine if not properly supported by the overhead crane. 4 - 16 Z-30/20N • Z-30/20N RJ • Z-34/22 • Z-34/22N Part No. 139378...
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6 Support and slide the extension tube out of the primary boom tube. Place the extension tube on blocks for support. Part No. 139378 Z-30/20N • Z-30/20N RJ • Z-34/22 • Z-34/22N 4 - 17...
10 Place a rod through the upper secondary leveling link pivot pin at the upper pivot and twist to remove the pin. 4 - 18 Z-30/20N • Z-30/20N RJ • Z-34/22 • Z-34/22N Part No. 139378...
3 Remove the counterweight cover fasteners. removed from the machine. Remove the counterweight cover from the machine. 4 Raise the secondary boom until the master cylinder rod-end pivot pin is accessible. Part No. 139378 Z-30/20N • Z-30/20N RJ • Z-34/22 • Z-34/22N 4 - 19...
3 to 4 feet / 1 m. Note: During removal, the overhead crane strap will need to be carefully adjusted for proper balancing. 4 - 20 Z-30/20N • Z-30/20N RJ • Z-34/22 • Z-34/22N Part No. 139378...
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8 Remove the pin retaining fastener from the master cylinder rod-end pivot pin. Use a soft metal drift to remove the pin. Part No. 139378 Z-30/20N • Z-30/20N RJ • Z-34/22 • Z-34/22N 4 - 21...
14 Remove the primary boom extend drive speed limit switch (LS1) mounted on the side of the primary boom at the pivot end. Do not disconnect the wiring. Part No. 139378 Z-30/20N • Z-30/20N RJ • Z-34/22 • Z-34/22N 4 - 23...
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2 feet / 60 cm from the platform Do not remove the pins. end of the primary boom. Measure from the platform end of the primary boom tube. 4 - 24 Z-30/20N • Z-30/20N RJ • Z-34/22 • Z-34/22N Part No. 139378...
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39 Remove the pin retaining fastener from the lower pivot pin on the compression link. Use a soft metal drift to remove the pin. Part No. 139378 Z-30/20N • Z-30/20N RJ • Z-34/22 • Z-34/22N 4 - 25...
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Crushing hazard. The secondary boom lift cylinder could become unbalanced and fall when removed from the machine if not properly supported by the overhead crane. 4 - 26 Z-30/20N • Z-30/20N RJ • Z-34/22 • Z-34/22N Part No. 139378...
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Crushing hazard. The lower secondary compression arm could become unbalanced and fall when removed from the machine if not properly supported by the overhead crane. Part No. 139378 Z-30/20N • Z-30/20N RJ • Z-34/22 • Z-34/22N 4 - 27...
Do not allow oil to squirt 4 Disconnect the battery packs from the machine. or spray. Bodily injury hazard. Beware of hot oil. Contact with hot oil may cause severe burns. 4 - 28 Z-30/20N • Z-30/20N RJ • Z-34/22 • Z-34/22N Part No. 139378...
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20 Remove the pin retaining fastener from the unbalanced and fall when secondary boom lift cylinder rod-end pivot pin. removed from the machine if not properly supported by the overhead crane. Part No. 139378 Z-30/20N • Z-30/20N RJ • Z-34/22 • Z-34/22N 4 - 29...
If the tank valve is closed, remove the key from the key switch and tag the machine to inform personnel of the condition. 4 - 30 Z-30/20N • Z-30/20N RJ • Z-34/22 • Z-34/22N Part No. 139378...
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June 2011 Section 4 • Repair Procedures REV A This page intentionally left blank. Part No. 139378 Z-30/20N • Z-30/20N RJ • Z-34/22 • Z-34/22N 4 - 31...
Tip-over hazard. Do not adjust the relief valve higher than specified. 6 Repeat steps 2 and 3 to confirm the relief valve pressure setting. 4 - 36 Z-30/20N • Z-30/20N RJ • Z-34/22 • Z-34/22N Part No. 139378...
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6 Repeat steps 2 and 3 to confirm the relief valve 6 Repeat steps 2 and 3 to confirm the relief valve pressure setting. pressure setting. Part No. 139378 Z-30/20N • Z-30/20N RJ • Z-34/22 • Z-34/22N 4 - 37...
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Install the relief valve cap. Tip-over hazard. Do not adjust the relief valve higher than specified. 6 Repeat steps 2 and 3 to confirm the relief valve pressure setting. 4 - 38 Z-30/20N • Z-30/20N RJ • Z-34/22 • Z-34/22N Part No. 139378...
Result: The resistance should be within specification, plus or minus 30%. Result: If the resistance is not within specification, plus or minus 30%, replace the coil. Part No. 139378 Z-30/20N • Z-30/20N RJ • Z-34/22 • Z-34/22N 4 - 41...
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0 mA, or if the two current readings do not differ by a minimum of 20%, the coil and/or its internal diode are faulty and the coil should be replaced. 4 - 42 Z-30/20N • Z-30/20N RJ • Z-34/22 • Z-34/22N Part No. 139378...
Do not allow oil to squirt or spray. 2 Remove the turntable rotation motor mounting bolts. Remove the motor from the machine. Part No. 139378 Z-30/20N • Z-30/20N RJ • Z-34/22 • Z-34/22N 4 - 43...
11 Install the dust cap, then the tire and wheel assembly. 12 Lower the machine and remove the blocks. 13 Torque the wheel lug nuts to specification. Refer to Section 2, Specifications. 4 - 44 Z-30/20N • Z-30/20N RJ • Z-34/22 • Z-34/22N Part No. 139378...
Rises to .0L V controller. Rises to .0L V 4 Set an ohmmeter to diode test mode. Rises to .0L V Part No. 139378 Z-30/20N • Z-30/20N RJ • Z-34/22 • Z-34/22N 4 - 45...
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Section 4 • Repair Procedures June 2011 This page intentionally left blank. 4 - 46 Z-30/20N • Z-30/20N RJ • Z-34/22 • Z-34/22N Part No. 139378...
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• Wheels chocked Note: Two persons will be required to safely • All external AC power supply disconnected perform some troubleshooting procedures. from the machine Part No. 139378 Z-30/20N • Z-30/20N RJ • Z-34/22 • Z-34/22N 5 - 1...
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SPEED higher or lower to achieve the maximum raised drive speed of 0.6 mph / 1Km/h or 40 feet / 45 seconds / 12.2 meters / 45 seconds. 5 - 2 Z-30/20N • Z-30/20N RJ • Z-34/22 • Z-34/22N Part No. 139378...
Defective motor Replace the motor ARM SENSOR Machine will not drive. controller. controller. Defective motor Replace the motor FLD SENSOR Machine will not drive. controller. controller. Part No. 139378 Z-30/20N • Z-30/20N RJ • Z-34/22 • Z-34/22N 5 - 3...
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Note: Short can be on OR motor controller is any part of circuit defective. connected to the B+ terminal on the motor controller. 5 - 4 Z-30/20N • Z-30/20N RJ • Z-34/22 • Z-34/22N Part No. 139378...
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OR check for load OR motor mechanical restrictions controller is not being causing excessive load cooled sufficently. on the machine. Part No. 139378 Z-30/20N • Z-30/20N RJ • Z-34/22 • Z-34/22N 5 - 5...
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Section 5 • Fault Codes June 2011 This page intentionally left blank. 5 - 6 Z-30/20N • Z-30/20N RJ • Z-34/22 • Z-34/22N Part No. 139378...
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Be sure that all necessary tools and test Identify Malfunction Troubleshoot discovered symptoms equipment are available and ready for use. problem still exists Return to Inspect Perform service and test repair problem solved Part No. 139378 Z-30/20N • Z-30/20N RJ • Z-34/22 • Z-34/22N 6 - 1...
SWITCH SHOWN WITH BOOM ROTATED PAST EITHER NON-STEER WHEEL. 4. ALL SOLENOID AND RELAY COILS ARE 24VDC EXCEPT WHERE NOTED. SETUP ENABLE: USE TO SET THE BATTERY INDICATOR PROFILES. 6 - 6 Z-30/20N • Z-30/20N RJ • Z-34/22 • Z-34/22N Part No. 139378...
Section 6 • Schematics June 2011 Electrical Schematic, (CE) (before serial numbers Z30N10-12119, Z34N10-8857 and Z3410-7774) 6 - 15 6 - 16...
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SWITCH SHOWN WITH BOOM ROTATED PAST EITHER NON-STEER WHEEL. 4. ALL SOLENOID AND RELAY COILS ARE 24VDC EXCEPT WHERE NOTED. ADD D40 ONLY IF UNIT HAS L4 AND L48. 6 - 16 Z-30/20N • Z-30/20N RJ • Z-34/22 • Z-34/22N Part No. 139378...
June 2011 Section 6 • Schematics Platform Control Box Wiring Diagram, (CE) before serial numbers Z30N10-12119, Z34N10-8857 and Z3410-7774) 6 - 23 6 - 24...
Section 6 • Schematics June 2011 Electrical Schematic, (ANSI / CSA) (from serial numbers Z30N10-12119, Z34N10-8857 and Z3410-7774) 6 - 25 6 - 26...
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SWITCH SHOWN WITH BOOM ROTATED PAST EITHER NON-STEER WHEEL. 4. ALL SOLENOID AND RELAY COILS ARE 24VDC EXCEPT WHERE NOTED. SETUP ENABLE: USE TO SET THE BATTERY INDICATOR PROFILES. 6 - 26 Z-30/20N • Z-30/20N RJ • Z-34/22 • Z-34/22N Part No. 139378...
June 2011 Section 6 • Schematics Platform Control Box Wiring Diagram, (ANSI / CSA) from serial numbers Z30N10-12119, Z34N10-8857 and Z3410-7774) 6 - 33 6 - 34...
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Section 6 • Schematics June 2011 Electrical Schematic, (AS / CE) (from serial numbers Z30N10-12119, Z34N10-8857 and Z3410-7774) 6 - 35 6 - 36...
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SWITCH SHOWN WITH BOOM ROTATED PAST EITHER NON-STEER WHEEL. 4. ALL SOLENOID AND RELAY COILS ARE 24VDC EXCEPT WHERE NOTED. ADD D40 ONLY IF UNIT HAS L4 AND L48. 6 - 36 Z-30/20N • Z-30/20N RJ • Z-34/22 • Z-34/22N Part No. 139378...
NOTE: WIRE GAUGE NOTED IN PAENTHESES AFTER WIRE COLOR. RD (10) RD (10) BK (2) BK (2) BK (2) ES34DCN RD (10) LEFT SIDE RIGHT SIDE DRIVE MOTOR DRIVE MOTOR Part No. 139378 Z-30/20N • Z-30/20N RJ • Z-34/22 • Z-34/22N 6 - 45...
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June 2011 Section 6 • Schematics Power Cable Wiring Diagram 6 - 45 6 - 46...
207 bar 75.8 bar 0.045 inch 1.14 mm 10 MICRON 0.035 inch 100 MESH 0.89 mm 0.8 gpm 3 L/min L/min HYDRAULIC RESERVOIR FUNCTION MANIFOLD HS0079C Part No. 139378 Z-30/20N • Z-30/20N RJ • Z-34/22 • Z-34/22N 6 - 57...