Terex Z-30/20N Manuals

Maintenance Manual - Booms S® Booms This manual includes detailed procedures for each maintenance inspection. Z® Booms For Repair procedures, Fault Codes, Electrical and Hydraulic Schematics, refer to the appropriate Service and Repair Manual for your machine. Refer to the inside cover for a list of models included in this manual. Part No. 1268489GT Rev J May 2020 Maintenance Manual May 2020 Introduction ii S® Booms • Z® Booms Part No. 1268489GT 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 maintenance procedure. This manual provides detailed scheduled maintenance information for the machine owner and user. 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 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: [email protected] Copyright © 2015 by Terex Corporation 1268489GT Rev J, May 2020 First Edition, Ninth Printing Genie, "S" and "Z" are registered trademarks of Terex South Dakota, Inc. in the U.S.A. and many other countries. "TraX" and "XC" are trademarks of Terex South Dakota, Inc. May 2020 Maintenance Manual Introduction Part No. 1268489GT S® Booms • Z® Booms iii Models included in this manual Use the following chart to identify the specific serial number for models included in this manual. Models Serial number S-40, S-45, S- 40HF, S-45HF, S-40XC, S-45XC from S4015-20505 to S4016H-23499 from S4515-20505 to S4516H-23499 from S40H-23500 from S45H-23500 from S40XCH-101 from S45XCH-101 S-60, S-65, S- 60HF, S-65HF, S-60J, S-60X, S-60XC, S- 65XC from S6013-26296 to S6016-31260 from S6016N-31261 to S6016N-35000 from S6016H-35001 to S6016H-36399 from S6014D-101 to S6016D-639 from S6016M-101 to S6016M-399 from S60X13-26296 to S60X16H-36399 from S60XC13-26296 to S60XC16H-36399 from S60HC13-26296 to S60HC15A- 29544 from S60TX13-26296 to S60TX16H- 36399 from S60TX14D-101 to S60TX16D-639 from S65TX13-26296 to S65TX16H-36399 from S65TX14D-101 to S65TX16D-639 from S60H/S60X/S60TX/S65TXH-36400 from S60XCH-36400 to S60XCH-45000 from S60XCH/S65XCH-45001 from S60/S60TX/S60XD-640 from S60JH-101 from S60M-400 from S65XCM-101 from S65TXM-101 S-80, S-85, S- 80X, S-80XC, S-85XC. S- 80HF, S-85HF from S80/85/80X15-12264 to16H-13999 from S80/85/80X15D-101 to 16D-339 from S80/85/80XH-14000 from S80/85/80XD-340 from S80/85XCH-101 S-100, S-105 from S10015D-1001 to S10016D-1549 from S10515D-983 to S10516D-1549 from S100D-1550 from S105D-1550 S-120, S-125 from S12015D-1012 to S12016D-1549 from S12515D-984 to S12516D-1549 from S120D-1550 from S125D-1550 S-100HD, S-120HD from S100HD14D-200 to S100HD16D-229 from S120HD14D-201 to S120HD16D-229 from S100/S120HDD-230 SX-105 XC from SX105D-101 SX-125 XC from SX125D-101 SX-135 XC from SX135H-101 SX-150 from SX15015-100 to SX15016H-499 from SX150H-500 SX-180 from SX18014-101 to SX18016H-599 from SX180H-600 Maintenance Manual May 2020 Introduction iv S® Booms • Z® Booms Part No. 1268489GT Z-30/20N, Z- 30/20N RJ from Z30N14-15222 to Z30N16F-18899 from Z30N16D-104 to Z30N16D-199 from Z30NF-18900 from Z30ND-200 Z-33/18 from Z331815M-101 to Z331816M-1299 from Z3318M-1300 Z-34/22 DC from Z3414-9686 to Z3416F-11999 from Z34F-12000 Z-34/22 N from Z34N14-10984 to Z34N16F-13999 from Z34N15D-102 to Z34N16D-279 from Z34NF-14000 from Z34ND-280 Z-34/22 IC from Z3406-4800 to Z3413-9460 from Z3413-9461 to Z3415-10688 from Z3416F-10689 to Z3416F-11999 from Z34F-12000 Z-34/22 BE from Z3414-9686 to Z3416F-11999 from Z34F-12000 Z-40/23N RJ from Z40N13-1902 to Z40N16N-4499 from Z40NN-4500 Z-45/25 DC, Z- 45/25J DC from Z452513A-48153 to Z452516N-57199 from Z452513B-3078 to Z452516M-6699 from Z452513D-101 to Z452516D-939 from Z4525D-940 from Z4525M-6700 from Z4525N-57200 to Z4525N-58604 from Z4525F-58605 Z-45/25 IC, Z- 45/25J IC, Z- 45HF, Z-45XC from Z452513A-47001 to Z452516N-57199 from Z452514B-3301 to Z452516M-6699 from Z452513D-101 to Z452516D-939 from Z4525D-940 from Z4525M-6700 from Z4525N-57200 to Z4525N-58604 from Z4525F-58605 from Z4525XCF-101 from Z4525XCM-101 Z-45/25(J) BE from Z452513A-48153 to Z452516N-57199 from Z4525N-57200 to Z4525N-58604 from Z4525F-58605 from Z4525M-6700 Z-45 DC, Z-45 FE from Z45EM-101 Z-51/30J from Z513014B-1201 to Z5130M-2000 from Z5130M-2000 Z-60/37 DC, Z-60/37 FE from Z6016N-101 to Z6016N-599 from Z60N-600 to Z60N-700 from Z60H-701 Z-62/40 from Z6215A-101 to Z6216N-2999 from Z6216D-101 to Z6216D-149 from Z6216M-101 to Z6216M-399 from Z62D-150 from Z62H-3000 from Z62M-400 Z-80/60 from Z8013-4592 to Z8016H-6399 from Z80H-6400 Z-135/70 from Z13505-101 to Z13513-2000 ZX-135/70 from ZX13514-2533 to ZX13516H-3199 (includes 2463, 2469, 2531) from ZX135H-3200

Maintenance Manual - Booms S® Booms This manual includes detailed procedures for each maintenance inspection. Z® Booms For Repair procedures, Fault Codes, Electrical and Hydraulic Schematics, refer to the appropriate Service and Repair Manual for your machine. Refer to the inside cover for a list of models included in this manual. Part No. 1268489GT Rev J1 March 2022 Maintenance Manual March 2022 Introduction ii S® Booms • Z® Booms Part No. 1268489GT 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 maintenance procedure. This manual provides detailed scheduled maintenance information for the machine owner and user. 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 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: [email protected] Copyright © 2015 by Terex Corporation 1268489GT Rev J, May 2020 First Edition, Ninth Printing Genie, "S" and "Z" are registered trademarks of Terex South Dakota, Inc. in the U.S.A. and many other countries. "TraX" and "XC" are trademarks of Terex South Dakota, Inc. March 2022 Maintenance Manual Introduction Part No. 1268489GT S® Booms • Z® Booms iii Models included in this manual Use the following chart to identify the specific serial number for models included in this manual. Models Serial number S-40, S-45, S- 40HF, S-45HF, S-40XC, S-45XC from S4015-20505 to S4016H-23499 from S4515-20505 to S4516H-23499 from S40H-23500 from S45H-23500 from S40XCH-101 from S45XCH-101 S-60, S-65, S- 60HF, S-65HF, S-60J, S-60X, S-60XC, S- 65XC from S6013-26296 to S6016-31260 from S6016N-31261 to S6016N-35000 from S6016H-35001 to S6016H-36399 from S6014D-101 to S6016D-639 from S6016M-101 to S6016M-399 from S60X13-26296 to S60X16H-36399 from S60XC13-26296 to S60XC16H-36399 from S60HC13-26296 to S60HC15A- 29544 from S60TX13-26296 to S60TX16H- 36399 from S60TX14D-101 to S60TX16D-639 from S65TX13-26296 to S65TX16H-36399 from S65TX14D-101 to S65TX16D-639 from S60H/S60X/S60TX/S65TXH-36400 from S60XCH-36400 to S60XCH-45000 from S60XCH/S65XCH-45001 from S60/S60TX/S60XD-640 from S60JH-101 from S60M-400 from S65XCM-101 from S65TXM-101 S-80, S-85, S- 80X, S-80XC, S-85XC, S- 80HF, S-85HF, S-80J from S80/85/80X15-12264 to16H-13999 from S80/85/80X15D-101 to 16D-339 from S80/85/80XH-14000 from S80/85/80XD-340 from S80/85XCH-101 from S80JH-101 S-100, S-105 from S10015D-1001 to S10016D-1549 from S10515D-983 to S10516D-1549 from S100D-1550 from S105D-1550 S-120, S-125 from S12015D-1012 to S12016D-1549 from S12515D-984 to S12516D-1549 from S120D-1550 from S125D-1550 S-100HD, S-120HD from S100HD14D-200 to S100HD16D-229 from S120HD14D-201 to S120HD16D-229 from S100/S120HDD-230 SX-105 XC from SX105D-101 SX-125 XC from SX125D-101 SX-135 XC from SX135H-101 SX-150 from SX15015-100 to SX15016H-499 from SX150H-500 SX-180 from SX18014-101 to SX18016H-599 from SX180H-600 Maintenance Manual March 2022 Introduction iv S® Booms • Z® Booms Part No. 1268489GT Z-30/20N, Z- 30/20N RJ from Z30N14-15222 to Z30N16F-18899 from Z30N16D-104 to Z30N16D-199 from Z30NF-18900 from Z30ND-200 Z-33/18 from Z331815M-101 to Z331816M-1299 from Z3318M-1300 Z-34/22 DC from Z3414-9686 to Z3416F-11999 from Z34F-12000 Z-34/22 N from Z34N14-10984 to Z34N16F-13999 from Z34N15D-102 to Z34N16D-279 from Z34NF-14000 from Z34ND-280 Z-34/22 IC from Z3406-4800 to Z3413-9460 from Z3413-9461 to Z3415-10688 from Z3416F-10689 to Z3416F-11999 from Z34F-12000 Z-34/22 BE from Z3414-9686 to Z3416F-11999 from Z34F-12000 Z-40/23N RJ from Z40N13-1902 to Z40N16N-4499 from Z40NN-4500 Z-45/25 DC, Z- 45/25J DC from Z452513A-48153 to Z452516N-57199 from Z452513B-3078 to Z452516M-6699 from Z452513D-101 to Z452516D-939 from Z4525D-940 from Z4525M-6700 from Z4525N-57200 to Z4525N-58604 from Z4525F-58605 Z-45/25 IC, Z- 45/25J IC, Z- 45HF, Z-45XC from Z452513A-47001 to Z452516N-57199 from Z452514B-3301 to Z452516M-6699 from Z452513D-101 to Z452516D-939 from Z4525D-940 from Z4525M-6700 from Z4525N-57200 to Z4525N-58604 from Z4525F-58605 from Z4525XCF-101 from Z4525XCM-101 Z-45/25(J) BE from Z452513A-48153 to Z452516N-57199 from Z4525N-57200 to Z4525N-58604 from Z4525F-58605 from Z4525M-6700 Z-45 DC, Z-45 FE from Z45EM-101 Z-51/30J from Z513014B-1201 to Z5130M-2000 from Z5130M-2000 Z-60/37 DC, Z-60/37 FE from Z6016N-101 to Z6016N-599 from Z60N-600 to Z60N-700 from Z60H-701 Z-62/40 from Z6215A-101 to Z6216N-2999 from Z6216D-101 to Z6216D-149 from Z6216M-101 to Z6216M-399 from Z62D-150 from Z62H-3000 from Z62M-400 Z-80/60 from Z8013-4592 to Z8016H-6399 from Z80H-6400 Z-135/70 from Z13505-101 to Z13513-2000 ZX-135/70 from ZX13514-2533 to ZX13516H-3199 (includes 2463, 2469, 2531) from ZX135H-3200

Operator's Manual Serial Number Range Z®-30/20N from Z30NF-22000 ANSI/CSA North America South America Asia Z®-30/20N RJ from Z30ND-1400 with Maintenance Information Original Instructions Seventh Edition First Printing Part No. 1297932GT Operator's Manual Seventh Edition • First Printing Z ®-30/20N • Z ®-30/20N RJ Part No. 1297932GT Front Matter Contents Introduction ........................................................... 1 Symbol and Hazard Pictorials Definitions ............. 6 General Safety ...................................................... 8 Personal Safety ................................................... 12 Work Area Safety ................................................ 13 Legend ................................................................ 21 Controls ............................................................... 22 Inspections .......................................................... 24 Operating Instructions ......................................... 39 Transport and Lifting Instructions ....................... 47 Maintenance ....................................................... 51 Specifications ...................................................... 53 Copyright © 1995 Terex Corporation Seventh Edition: First Printing, February 2020 Genie and "Z" are registered trademarks of Terex South Dakota, Inc. in the U.S.A. and many other countries. These machines comply with ANSI A92.20 CSA B354.6 Seventh Edition • First Printing Operator's Manual Introduction Part No. 1297932GT Z ®-30/20N • Z ®-30/20N RJ 1 Introduction About this manual Genie appreciates your choice of our machine for your application. Our number one priority is user safety, which is best achieved by our joint efforts. This book is an operation and daily maintenance manual for the user or operator of a Genie machine. This manual should be considered a permanent part of your machine and should remain with the machine at all times. If you have any questions, contact Genie. Product Identification The machine serial number is located on the serial label. Serial number stamped on chassis Serial label (located under cover) Intended Use and Familiarization Guide The intended use of this machine is to lift personnel, including tools, and materials to an aerial work site. Before operating the machine, it’s the operator’s responsibility to read and understand this familiarization guide.  Each person must be trained to operate a Mobile Elevating Work Platform (MEWP).  Familiarization with the MEWP must be given to each person who is authorized, competent and trained.  Only trained and authorized personnel should be permitted to operate the machine.  The operator is responsible to read, understand, and obey the manufacturer’s instructions and safety rules provided in the Operator’s Manual.  The Operator’s Manual is located in the manual storage container, at the platform.  For specific product applications, see Contacting The Manufacturer. Operator's Manual Seventh Edition • First Printing Introduction 2 Z ®-30/20N • Z ®-30/20N RJ Part No. 1297932GT Platform controls symbology and related machine movement: Platform level swtich Platform rotate switch Jib boom up/down Primary boom up/down Turntable rotate Primary boom extend/retract switch Secondary boom up/down Drive forward/reverse Steer right/left Ground controls symbology and related machine movement: Platform level, jib boom up/down, primary boom extend/retract, primary boom up/down, and secondary boom retract/lower. Turntable rotate and platform rotate Sequential functions and movement:  Drive and steer. Interlocked functions:  Elevated drive speed.  Elevated drive in an off-level condition.  Drive enable when the boom is rotated past the non-steer wheels.  All platform and ground controls. Limitations of use:  The intended use of this machine is to lift personnel, including tools, and materials to an aerial work site.  Do not elevate the platform unless the machine is on firm level ground. Stability enhancing means:  Foam filled tires. Restricted operating envelope:  500 lbs/227 kg platform capacity.

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 oducti on Intr oducti on 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: [email protected] 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 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-17000 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: [email protected] 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