Genie Z 30/20N Aerial Work Platform Service Manual

Service Manual

Refer to inside cover for additional serial number information

Part No. 106373

Rev A2

March 2006

including rotating jib models

(from serial number 5934)

Introduction April 2004 ii

Important

Read, understand and obey the safety rules and operating instructions in the

Genie Z-30/20N

Operator's Manual before attempting any maintenance or repair procedure.

This manual provides detailed scheduled maintenance information for the machine owner and user. It also provides troubleshooting fault codes 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.

Serial Number Information

Genie Industries offers the following Service

Manuals for these models:

Title Part No.

Z-30/20N Service Manual

(before serial number 5934) ................................. 35532

Technical Publications

Genie Industries 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:

http://www.genieindustries.com

e-mail: [email protected]

Copyright © 1996 by Genie Industries

106373 Rev A April 2004

"Genie" and "Z" are registered trademarks of

Genie Industries in the USA and many other countries.

Printed on recycled paper

Printed in U.S.A.

Genie Z-30/20N Part No. 106373

April 2004 Section 1 • Safety Rules

Safety Rules

Danger

Failure to obey the instructions and safety rules in this manual and the Genie Z-30/20N Operator’s

Manual 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.

Part No. 106373 Genie Z-30/20N iii

Section 1 • Safety Rules April 2004

SAFETY RULES

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.

Used to indicate the presence of an imminently hazardous situation which, if not avoided, will result in death or serious injury.

Used to indicate the presence of a potentially hazardous sitiuation which, if not avoided, could result in death or serious injury.

With safety alert symbol—used to indicate the presence of a potentially hazardous situation which, if not avoided, may cause minor or moderate injury.

Without safety alert symbol—used to indicate the presense of a potentially hazardous situation which, if not avoided, may result in property damage.

Indicates special operation or maintenance information.

Be sure to wear protective eye wear and other protective clothing if the situation warrants it.

unsecured components when lifting or placing loads. Always wear approved steel-toed shoes.

Be aware of potential crushing hazards such as moving parts, free swinging or

Workplace Safety

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.

iv


March 2006 Section 1 • Safety Rules

Table of Contents

Introduction

Section 1

Important Information ..................................................................................................

ii

Safety Rules

General Safety Rules .................................................................................................

iii

Section 2 Rev Specifications

C Machine Specifications .......................................................................................... 2 - 1

C Performance Specifications ................................................................................... 2 - 1

B Hydraulic Specifications ........................................................................................ 2 - 2

C Manifold Component Specifications ...................................................................... 2 - 3

C Machine Torque Specifications .............................................................................. 2 - 3

B Hydraulic Hose and Fitting Torque Specifications ................................................. 2 - 4

A SAE and Metric Fasteners Torque Charts ............................................................. 2 - 5

Section 3 Rev Scheduled Maintenance Procedures

Introduction ........................................................................................................... 3 - 1

Pre-Delivery Preparation ....................................................................................... 3 - 3

Maintenance Inspection Report ............................................................................. 3 - 5

B

Checklist A Procedures

A-1 Perform Pre-operation Inspection ................................................................ 3 - 6

A-2 Perform Function Tests ............................................................................... 3 - 6

A-3 Perform 30 Day Service ............................................................................... 3 - 7

A-4 Grease the Turntable Rotation Bearing and Worm Drive Gear .................... 3 - 7 v

Part No. 106373 Genie Z-30/20N

March 2006

TABLE OF CONTENTS

Section 3 Rev

Scheduled Maintenance Procedures, continued

C

Checklist B Procedures

B-1 Check the Batteries ..................................................................................... 3 - 8

B-2 Inspect the Electrical Wiring ......................................................................... 3 - 9

B-3 Test the Key Switch ................................................................................... 3 - 10

B-4 Check the Tires and Wheels (including lug nut torque) .............................. 3 - 10

B-5 Confirm the Proper Brake Configuration .................................................... 3 - 11

B-6 Check the Oil Level in the Drive Hubs ....................................................... 3 - 11

B-7 Test the Ground Control Override .............................................................. 3 - 12

B-8 Test the Platform Self-leveling ................................................................... 3 - 12

B-9 Test the Drive Brakes ................................................................................ 3 - 13

B-10 Test the Drive Speed - Stowed Position .................................................... 3 - 13

B-11 Test the Drive Speed - Raised or Extended Position ................................. 3 - 14

B-12 Test the Alarm Package (if equipped) ........................................................ 3 - 14

B-13 Test the Turntable Rotation Stop ............................................................... 3 - 15

B-14 Check the Electrical Contactors ................................................................. 3 - 16

B-15 Perform Hydraulic Oil Analysis .................................................................. 3 - 16

B

Checklist C Procedures

C-1 Grease the Platform Overload Mechanism (if equipped) ........................... 3 - 17

C-2 Test the Platform Overload System (if equipped) ...................................... 3 - 17 vi


April 2005

TABLE OF CONTENTS

Section 3 Rev

Scheduled Maintenance Procedures, continued

B

Checklist D Procedures

D-1 Check the Primary Boom Wear Pads ........................................................ 3 - 20

D-2 Check the Free-wheel Configuration .......................................................... 3 - 21

D-3 Check the Turntable Rotation Bearing Bolts .............................................. 3 - 22

D-4 Replace the Drive Hub Oil ......................................................................... 3 - 23

D-5 Replace the Hydraulic Tank Return Filter Element .................................... 3 - 23

D-6 Calibrate the Platform Overload System (if equipped) ............................... 3 - 24

B

Checklist E Procedures

E-1 Test or Replace the Hydraulic Oil .............................................................. 3 - 26

E-2 Grease the Steer Axle Wheel Bearings ..................................................... 3 - 28

Section 4 Rev Repair Procedures

Introduction ........................................................................................................... 4 - 1

B

Platform Controls

1-1 Controllers ................................................................................................... 4 - 2

B

Platform Components

2-1 Platform Leveling Slave Cylinder ................................................................. 4 - 4

2-2 Platform Rotator ........................................................................................... 4 - 5

B

Jib Boom Components

3-1 Jib Boom ...................................................................................................... 4 - 7

3-2 Jib Boom Bell Crank (models without rotating jib boom) .............................. 4 - 8

3-3 Jib Boom Rotator (models with rotating jib boom) ........................................ 4 - 8

3-4 Jib Boom Lift Cylinder ................................................................................ 4 - 10

Part No. 106373 Genie Z-30/20N vii

April 2005

TABLE OF CONTENTS

Section 4 Rev

Repair Procedures, continued

B

Primary Boom Components

4-1 Cable Track ............................................................................................... 4 - 11

4-2 Primary Boom ............................................................................................ 4 - 11

4-3 Primary Boom Lift Cylinder ........................................................................ 4 - 15

4-4 Extension Cylinder ..................................................................................... 4 - 17

4-5 Platform Leveling Master Cylinder ............................................................. 4 - 18

B

Secondary Boom Components

5-1 Secondary Boom ....................................................................................... 4 - 21

5-2 Secondary Boom Lift Cylinder ................................................................... 4 - 26

A

Hydraulic Pumps

6-1 Auxiliary and Function Pump ..................................................................... 4 - 28

B

Manifolds

7-1 Function Manifold Components ................................................................. 4 - 30

7-2 Valve Adjustments - Function Manifold ...................................................... 4 - 34

7-3 Jib Boom and Platform / Jib Boom Rotate Manifold Components .............. 4 - 37

7-4 Valve Coils ................................................................................................. 4 - 38

B

Turntable Rotate Components

8-1 Turntable Rotation Hydraulic Motor ........................................................... 4 - 40

A

Steer Axle Components

9-1 Hub and Bearings ...................................................................................... 4 - 41

A

Motor Controller

10-1 Motor Controller ......................................................................................... 4 - 42 viii


March 2006

TABLE OF CONTENTS

Section 5 Rev Fault Codes

Introduction ........................................................................................................... 5 - 1

A Fault Code Chart ................................................................................................... 5 - 3

Section 6 Rev Schematics

Introduction ........................................................................................................... 6 - 1

A Load Sensor Option Diagram (before serial number 6290) ................................... 6 - 2

A Electrical Symbols Legend .................................................................................... 6 - 3

A Hydraulic Symbols Legend .................................................................................... 6 - 4

A Power Cable Diagram (before serial number 6290) ............................................... 6 - 5

B Power Cable Diagram (after serial number 6289) .................................................. 6 - 6

B Electrical Schematic (before serial number 6290) ................................................. 6 - 7

B Electrical Schematic (after serial number 6289) .................................................... 6 - 9

A Ground Control Panel Wiring Diagram (before serial number 6290) .................... 6 - 11

A Ground Control Panel Wiring Diagram (after serial number 6289) ....................... 6 - 12

A Platform Control Box Wiring Diagram (before serial number 6290) ..................... 6 - 13

A Platform Control Box Wiring Diagram (after serial number 6289) ........................ 6 - 14

A Power Panel Wiring Diagram .............................................................................. 6 - 15

A Hydraulic Schematic ............................................................................................ 6 - 16

Part No. 106373 Genie Z-30/20N ix

April 2005

This page intentionally left blank.

x


March 2006 Section 2 • Specifications

Specifications

REV C

Machine Specifications

Tires and wheels

Tire size (solid rubber)

Load range

Tire contact area

Overall tire diameter

Wheel diameter

Wheel width

22 x 7 x 18.4 in

56 x 18 x 47 cm

7600 lbs

3447 kg

35 sq in

226 sq cm

22 in

56 cm

18.4 in

47 cm

7 in

18 cm

Wheel lugs

Front

Rear

Lug nut torque, dry

Lug nut torque, lubricated

8 @

5

/

8

-18

9 @

5

/

8

-18

125 ft-lbs

169.5 Nm

94 ft-lbs

127.4 Nm

Fluid Capacities

Hydraulic tank capacity

Hydraulic system capacity

(including tank)

Drive hubs

61:1

62.5:1

23 ounces

25.6 ounces

4 gallons

15.1 liters

6 gallons

22.7 liters

Drive hub oil type:

SAE 90 multipurpose hypoid gear oil API service classification GL5

0.68 liter

0.76 liter

Continuous improvement of our products is a

Genie policy. Product specifications are subject to change without notice.

Performance Specifications

Drive speed, maximum

Stowed position

Boom raised or extended

3.3 mph

5.3 km/h

40 ft / 8.3 sec

12.2 m / 8.3 sec

0.6 mph

1 km/h

40 ft / 44 sec

12.2 m / 44 sec

Braking distance, maximum

High range on paved surface

Gradeability

2 to 4 ft

0.6 to 1.2m

See Operator's Manual

Boom function speeds, maximum from platform controls (with rated load secured to platform)

Jib boom up 26 to 32 seconds

23 to 29 seconds Jib boom down

Jib boom rotate, 200°

(before serial number 8333) 12 to 18 seconds

Jib boom rotate, 180°

(after serial number 8332)

Primary boom up

Primary boom down

Primary boom extend

(models with rotating jib boom)

(models without rotating jib boom)

12 to 18 seconds

14 to 22 seconds

12 to 20 seconds

Primary boom retract

Secondary boom up

Secondary boom down

Turntable rotate, 355°

Platform rotate, 160°

Platform level up

Platform level down

14 to 24 seconds

9 to 15 seconds

12 to 18 seconds

11 to 18 seconds

7 to 15 seconds

50 to 65 seconds

5 to 11 seconds

14 to 19 seconds

13 to 18 seconds

Part No. 106373 Genie Z-30/20N 2 - 1

Section 2 • Specifications April 2005

SPECIFICATIONS REV B

Hydraulic Specifications

Hydraulic Oil Specifications

Hydraulic oil type

ISO viscosity grade

Viscosity index

Chevron Rykon MV equivalent

Multi-viscosity

200

Cleanliness level, minimum

Water content, maximum

15/13

200 ppm

Chevron Rykon MV oil is fully compatible and mixable with Shell Donax TG (Dexron III) oils.

Genie specifications require hydraulic oils which are designed to give maximum protection to hydraulic systems, have the ability to perform over a wide temperature range, and have a minimum viscosity index of 150. They should provide excellent antiwear, oxidation, corrosion inhibition, seal conditioning, and foam and aeration suppression properties.

Optional fluids

Biodegradable

Fire resistant

Petro Canada Premium ECO 46

Statoil Hydra Way Bio Pa 32

BP Biohyd SE-S

UCON Hydrolube HP-5046

Quintolubric 822

Mineral based Shell Tellus T32

Shell Tellus T46

Chevron Aviation A

Function pump

Type:

Displacement

Flow rate @

2800 psi / 172 bar

Hydraulic tank return filter

Function manifold

System relief valve pressure

Fixed displacement gear pump

0.183 cu in

3 cc

2.1 gpm

7.9 L/min

10 micron with

25 psi / 1.7 bar bypass

Primary boom down relief pressure

Secondary boom down relief pressure

2800 psi

193 bar

1600 psi

110 bar

1600 psi

110 bar

Primary boom extend relief pressure

Models without rotating jib

Primary boom extend relief pressure

Models with rotating jib

Turntable rotate relief pressure

2800 psi

193 bar

1800 psi

124 bar

1100 psi

76 bar

Auxiliary pump

Type:

Displacement

Fixed displacement gear pump

0.3 gpm

1.14 L/min

Use Chevron Aviation A hydraulic oil when in ambient temperatures consistently below 0°F / -18°C.

Use Shell Tellus T46 hydraulic oil when oil temperatures consistently exceed 205°F / 96°C.

Genie specifications require additional equipment and special installation instructions for the approved optional fluids. Consult the Genie Industries Service

Department before use.

2 - 2 Genie Z-30/20N Part No. 106373


REV C SPECIFICATIONS

Manifold Component

Specifications

Plug torque

SAE No. 2

SAE No. 4

SAE No. 6

SAE No. 8

SAE No. 10

SAE No. 12

36 in-lbs / 4 Nm

10 ft-lbs / 13 Nm

14 ft-lbs / 19 Nm

38 ft-lbs / 51 Nm

41 ft-lbs / 55 Nm

56 ft-lbs / 76 Nm

Valve Coil Resistance Specification

Description

Solenoid valve, N.C. poppet, 20V DC

(schematic item M)

Specification

Solenoid valve, 3 position 4 way, 20V DC

(schematic items A, J, K, U, V, Y, AA, BB and CC)

22

Ω

Proportional solenoid valve, 24V DC

(schematic item H)

19.5

Ω

23.5

Ω

Solenoid valve, N.O. poppet, 20V DC

(schematic item P)

23.5

Ω

Machine Torque Specifications

Platform rotator and jib boom rotator (Z-30/20NRJ)

1-8 center bolt, GR 8 480 ft-lbs

651 Nm

3

/

8

-16 bolts, GR 8 44 ft-lbs

60 Nm

Turntable rotate bearing

Rotate bearing mounting bolts, lubricated 180 ft-lbs

244 Nm

Drive hubs, brakes and motors

Drive hub mounting bolts, lubricated

Brake mounting bolts, lubricated

Drive motor mounting bolts

180 ft-lbs

244 Nm

93 ft-lbs

126 Nm

31 ft-lbs

42 Nm

Part No. 106373 Genie Z-30/20N 2 - 3

Section 2 • Specifications March 2006

SPECIFICATIONS REV B

Hydraulic Hose and Fitting

Torque Specifications

Your machine is equipped with Parker Seal-Lok

® fittings and hose ends. Genie specifications require that fittings and hose ends be torqued to specification when they are removed and installed or when new hoses or fittings are installed.

SAE O-ring Boss Port

(tube fitting - installed into Aluminum)

SAE Dash size

-4

-6

-8

-10

-12

-16

-20

-24

Torque

11 ft-lbs / 14.9 Nm

23 ft-lbs / 31.2 Nm

40 ft-lbs / 54.2 Nm

69 ft-lbs / 93.6 Nm

93 ft-lbs / 126.1 Nm

139 ft-lbs / 188.5 Nm

172 ft-lbs / 233.2 Nm

208 ft-lbs / 282 Nm

SAE O-ring Boss Port

(tube fitting - installed into Steel)

SAE Dash size

-4

-6

-8

-10

-12

-16

-20

-24

Torque

16 ft-lbs / 21.7 Nm

35 ft-lbs / 47.5 Nm

60 ft-lbs / 81.3 Nm

105 ft-lbs / 142.4 Nm

140 ft-lbs / 190 Nm

210 ft-lbs / 284.7 Nm

260 ft-lbs / 352.5 Nm

315 ft-lbs / 427.1 Nm

Seal-Lok® fittings

1 Replace the O-ring. The O-ring must be replaced anytime the seal has been broken.

The O-ring cannot be re-used if the fitting or hose end has been tightened beyond finger tight.

The O-rings used in the Parker

Seal Lok® fittings and hose ends are custom-size O-rings. They are not standard SAE size O-rings.

They are available in the O-ring field service kit (Genie part number 49612).

2 Lubricate the O-ring before installation.

3 Be sure that the face seal O-ring is seated and retained properly.

4 Position the tube and nut squarely on the face seal end of the fitting and tighten the nut finger tight.

5 Tighten the nut or fitting to the appropriate torque per given size as shown in the table.

6 Operate all machine functions and inspect the hoses and fittings and related components to confirm that there are no leaks.

Seal-Lok

®

Fittings

(hose end)

SAE Dash size

-4

-6

-8

-10

-12

-16

-20

-24

Torque

18 ft-lbs / 25 Nm

30 ft-lbs / 40 Nm

40 ft-lbs / 55 Nm

60 ft-lbs / 80 Nm

85 ft-lbs / 115 Nm

110 ft-lbs / 150 Nm

140 ft-lbs / 190 Nm

180 ft-lbs / 245 Nm

2 - 4 Genie Z-30/20N Part No. 106373


REV A SPECIFICATIONS

1/4

20

28

SAE FASTENER TORQUE CHART

• This chart is to be used as a guide only unless noted elsewhere in this manual •

SIZE THREAD

Grade 5

LUBED in- lbs

100

90

N m

11.3

10.1

in- lbs

80

120

DRY

N m

9

13.5

Grade 8

LUBED in- lbs

140

120

N m

15.8

13.5

in- lbs

110

160

DRY

N m

12.4

18

A574 High Strength

Black Oxide Bolts

LUBED in- lbs

130

140

N m

14.7

15.8

5/16

3/8

7/16

1/2

9/16

5/8

3/4

7/8

1

1 1/8

1 1/4

1 1/2

18

10

16

9

14

13

20

12

18

11

18

24

16

24

14

20

7

12

6

12

8

12

7

12

LUBED f t - lbs

64

80

90

110

130

200

220

320

13

14

23

26

37

41

57

350

480

530

590

670

840

930

1460

1640

N m

86.7

108.4

122

149

176

271

298

433

17.6

19

31.2

35.2

50.1

55.5

77.3

474

650

718

800

908

1138

1260

1979

2223

DRY

N m

115

149

162

203

230

366

406

583

23

25.7

42

47.4

66.4

74.5

101.6

637

867

962

1071

1206

1518

1681

2643

2969

f t - lbs

85

110

120

150

170

270

300

430

17

19

31

35

49

55

75

470

640

710

790

890

1120

1240

1950

2190

LUBED f t - lbs

90

120

130

160

180

280

310

450

18

20

33

37

50

60

80

500

680

750

970

1080

1360

1510

2370

2670

N m

122

162

176

217

244

379

420

610

24

27.1

44.7

50.1

67.8

81.3

108.4

678

922

1016

1315

1464

1844

2047

3213

3620

DRY

N m

162

203

230

284

325

515

569

827

33.9

36.6

59.6

66.4

94.7

108.4

149

908

1233

1342

1749

1952

2467

2725

4284

4826

f t - lbs

120

150

170

210

240

380

420

610

25

27

44

49

70

80

110

670

910

990

1290

1440

1820

2010

3160

3560

f t - lbs

105

130

140

180

200

320

350

510

21

24

38

43

61

68

93

560

770

840

1090

1220

1530

1700

2670

3000

LUBED

N m

142

176

189

244

271

433

474

691

28.4

32.5

51.5

58.3

82.7

92.1

126

759

1044

1139

1477

1654

2074

2304

3620

4067

METRIC FASTENER TORQUE CHART

• This chart is to be used as a guide only unless noted elsewhere in this manual •

Size

Class 4.6

4.6

Class 8.8

8.8

Class 10.9

10.9

Class 12.9

12.9

(m m )

5

6

7

LUBED DRY LUBED DRY LUBED DRY LUBED DRY in- lbs

16

N m in- lbs

1.8

19 3.05

45 5.12

21

36

N m in- lbs

2.4

4.07

41

69

N m in- lbs

4.63

54

7.87

93

N m in- lbs

6.18

58

N m in- lbs

6.63

78

10.5

100 11.3

132

N m in- lbs

8.84

15

68

N m in- lbs

7.75

91

N m

10.3

116 13.2

155 17.6

60 6.83

116 13.2

155 17.6

167 18.9

223 25.2

1.95

22.1

260 29.4

LUBED DRY LUBED DRY LUBED DRY LUBED DRY f t - lbs N m f t - lbs N m f t - lbs N m f t - lbs N m f t - lbs N m f t - lbs N m f t - lbs N m f t - lbs N m

8

5.4

7.41

7.2

9.88

14 19.1

18.8

25.5

20.1

27.3

26.9

36.5

23.6

32 31.4

42.6

10

10.8

14.7

14.4

19.6

27.9

37.8

37.2

50.5

39.9

54.1

53.2

72.2

46.7

63.3

62.3

84.4

12

18.9

25.6

25.1

34.1

48.6

66 64.9

88 69.7

94.5

92.2

125 81 110 108 147

14

30.1

40.8

40 54.3

77.4

105 103 140 110 150 147 200 129 175 172 234

16

46.9

63.6

62.5

84.8

125 170 166 226 173 235 230 313 202 274 269 365

18

64.5

87.5

86.2

117 171 233 229 311 238 323 317 430 278 377 371 503

20

91 124 121 165 243 330 325 441 337 458 450 610 394 535 525 713

22

124 169 166 225 331 450 442 600 458 622 612 830 536 727 715 970

24

157 214 210 285 420 570 562 762 583 791 778 1055 682 925 909 1233

Part No. 106373 Genie Z-30/20N 2 - 5

Section 2 • Specifications March 2006


2 - 6 Genie Z-30/20N Part No. 106373

April 2005 Section 3 • Scheduled Maintenance Procedures

Scheduled Maintenance Procedures

Observe and Obey:

Maintenance inspections shall be completed by a person trained and qualified on the maintenance of this machine.

Scheduled maintenance inspections shall be completed daily, quarterly, six months, annually and every 2 years as specified on the

Maintenance Inspection Report.

Failure to properly complete each inspection when required could result in death, serious injury or substantial machine damage.

Immediately tag and remove from service a damaged or malfunctioning machine.

Repair any machine damage or malfunction before operating machine.

Keep records on all inspections for three years.

Unless otherwise specified, perform each procedure with the machine in the following configuration:

· Machine parked on a firm, level surface

· Boom in the stowed position

· Turntable rotated with the boom between the non-steer wheels

· Key switch in the off position with the key removed

· Wheels chocked

· All external AC power supply disconnected from the machine

About This Section

This section contains detailed procedures for each scheduled maintenance inspection.

Each procedure includes a description, safety warnings and step-by-step instructions.

Symbols Legend

CAUTION



Used to indicate the presence of a potentially hazardous situation which, if not avoided, could result in death or serious injury.


Without safety alert symbol—used to indicate the presence of a potentially hazardous situation which, if not avoided, may result in property damage.

Used to indicate operation or maintenance information.

Indicates that a specific result is expected after performing a series of steps.

Indicates that an incorrect result has occurred after performing a series of steps.

Part No. 106373 Genie Z-30/20N 3 - 1

Section 3 • Scheduled Maintenance Procedures April 2005

SCHEDULED MAINTENANCE PROCEDURES

Maintenance Symbols Legend

The following symbols have been used in this manual to help communicate the intent of the instructions. When one or more of the symbols appear at the beginning of a maintenance procedure, it conveys the meaning below.

Maintenance Schedule

There are five types of maintenance inspections that must be performed according to a schedule— daily, quarterly, six months, annual, and two year.

The Scheduled Maintenance Procedures Section and the Maintenance Inspection Report have been divided into five subsections—A, B, C, D and E.

Use the following chart to determine which group(s) of procedures are required to perform a scheduled inspection.

Indicates that tools will be required to perform this procedure.

Indicates that new parts will be required to perform this procedure.

Indicates that a cold motor or pump will be required to perform this procedure.

Inspection

Daily or every 8 hours

Quarterly or every 250 hours

Six months or every 500 hours

Annual or every 1000 hours

Two year or every 2000 hours

Checklist

A

A + B

A + B + C

A + B + C + D

A + B + C + D + E

Indicates that dealer service will be required to perform this procedure.

Maintenance Inspection Report

The maintenance inspection report contains checklists for each type of scheduled inspection.

Make copies of the Maintenance Inspection Report to use for each inspection. Store completed forms for three years.

3 - 2 Genie Z-30/20N Part No. 106373

Pre-Delivery Preparation

April 2004

Fundamentals

It is the responsibility of the dealer to perform the

Pre-delivery Preparation.

The Pre-delivery Preparation is performed prior to each delivery. The inspection is designed to discover if anything is apparently wrong with a machine before it is put into service.

A damaged or modified machine must never be used. If damage or any variation from factory delivered condition is discovered, the machine must be tagged and removed from service.

Repairs to the machine may only be made by a qualified service technician, according to the manufacturer's specifications.

Scheduled maintenance inspections shall be performed by qualified service technicians, according to the manufacturer's specifications and the requirements listed in the responsibilities manual.

Section 3 • Scheduled Maintenance Procedures

Instructions

Use the operator’s manual on your machine.

The Pre-delivery Preparation consists of completing the

Pre-operation Inspection, the Maintenance items and the

Function Tests.

Use this form to record the results. Place a check in the appropriate box after each part is completed. Follow the instructions in the operator’s manual.

If any inspection receives an N, remove the machine from service, repair and re-inspect it. After repair, place a check in the R box.

Legend

Y = yes, completed

N = no, unable to complete

R = repaired

Comments

Pre-Delivery Preparation

Pre-operation inspection completed

Maintenance items completed

Function tests completed

Y N R

Model

Serial number

Date

Machine owner

Inspected by (print)

Inspector signature

Inspector title

Inspector company

Genie Industries USA

18340 NE 76th Street

PO Box 97030

Redmond, WA 98073-9730

Genie UK

The Maltings, Wharf Road

Grantham, Lincolnshire

NG31- 6BH England

(425) 881-1800

Part No. 106373

(44) 1476-584333

Genie Z-30/20N

Copyright © 2002 by Genie Industries. Genie® is a registered trademark of Genie Industries.

Rev A

3 - 3



3 - 4 Genie Z-30/20N Part No. 106373

March 2006 Section 3 • Scheduled Maintenance Procedures

Maintenance Inspection Report

Model

Serial number

Date

Hour meter

Machine owner

Inspected by (print)

Inspector signature

Inspector title

Inspector company

Instructions

· Make copies of this page to use for each inspection.

· Select the appropriate checklist(s) for the type of inspection to be performed.

Daily or 8 hour

Inspection:

Quarterly or 250 hour

Inspection:

A

A+B

Six Month or 500 hour

Inspection: A+B+C

Annual or 1000 hours

Inspection: A+B+C+D

2 Year or 2000 hour

Inspection: A+B+C+D+E

· Place a check in the appropriate box after each inspection procedure is completed.

· If any inspection receives an “N”, tag and remove the machine from service, repair and re-inspect it. After repair, place a check in the “R” box.

Legend

Y = yes, acceptable

N = no, remove from service

R = repaired

Comments

Checklist A - Rev B

A-1 Pre-operation inspection

A-2 Function tests

Perform after 40 hours:

A-3 30 Day Service

Perform every 100 hours:

A-4 Grease rotation bearing

Y N R

Checklist B - Rev C

B-1 Batteries

B-2 Electrical wiring

B-3 Key switch

B-4 Tires and Wheels

B-5 Brake configuration

B-6 Drive hub oil level

B-7 Ground control override

B-8 Platform leveling

B-9 Drive brakes

B-10 Drive speed-stowed

B-11 Drive speed-raised

B-12 Alarm package

(if equipped)

B-13 Turntable rotation stop

B-14 Electrical contactors

B-15 Hydraulic oil analysis

Y N R

Checklist C - Rev B

C-1 Grease platform overload (if equipped)

C-2 Test platform overload (if equipped)

Y N R

Checklist D - Rev B

D-1 Boom wear pads

D-2 Free-wheel configuration

D-3 Turntable bearing bolts

D-4 Drive hub oil

D-5 Hydraulic return filter

D-6 Calibrate platform overload system

(if equipped)

Y N R

Checklist E - Rev B

E-1 Hydraulic oil

E-2 Wheel bearings

Y N R

Part No. 106373 Genie Z-30/20N 3 - 5


Checklist A Procedures

April 2005

REV B

A-1

Perform Pre-operation Inspection

Completing a pre-operation inspection is essential to safe machine operation. The pre-operation inspection is a visual inspection performed by the operator prior to each work shift. The inspection is designed to discover if anything is apparently wrong with a machine before the operator performs the function tests. The pre-operation inspection also serves to determine if routine maintenance procedures are required.

Complete information to perform this procedure is available in the Genie Z-30/20N Operator's Manual on your machine.

A-2

Perform Function Tests

Completing the function tests is essential to safe machine operation. Function tests are designed to discover any malfunctions before the machine is put into service. A malfunctioning machine must never be used. If malfunctions are discovered, the machine must be tagged and removed from service.

Complete information to perform this procedure is available in the Genie Z-30/20N Operator's

Manual. Refer to the Operator's Manual on your machine.

3 - 6 Genie Z-30/20N Part No. 106373


REV B CHECKLIST A PROCEDURES

A-3

Perform 30 Day Service

The 30 day maintenance procedure is a one-time sequence of procedures to be performed after the first 30 days or 50 hours of usage. After this interval, refer to the maintenance checklists for continued scheduled maintenance.

1 Perform the following maintenance procedures:

· A-4

· B-4

· D-3

· D-5

Grease the Turntable Rotation

Bearing and Worm Drive Gear

Check the Lug Nut Torque

(including the tires and wheels)

Check the Turnable Rotation

Bearing Bolts

Replace the Hydraulic Tank

Return Filter Element

A-4

Grease the Turntable Rotation

Bearing and Worm Drive Gear

Genie specifications require that this procedure be performed every

100 hours.

Frequent application of lubrication to the turntable bearing and worm drive gear is essential to good machine performance and service life. Continued use of an insufficently greased gear will result in component damage.

1 Locate the grease fitting on the tank side turntable cover bulkhead.

2 Pump grease into the turntable rotation bearing.

Rotate the turntable in increments of 4 to 5 inches / 10 to 13 cm at a time and repeat this step until the entire bearing has been greased.

3 Locate the 2 grease fittings on top of the worm drive housing.

a

Part No. 106373 a grease fittings

4 Pump grease into the gear until you see it coming out of the side of the gear housing.

5 Grease each tooth on the outside of the turntable rotation bearing.

Grease type

Multipurpose grease

Genie Z-30/20N 3 - 7


Checklist B Procedures

March 2006

REV C

B-1

Check the Batteries

Proper battery condition is essential to good machine performance and operational safety.

Improper fluid levels or damaged cables and connections can result in engine component damage and hazardous conditions.

Bodily injury hazard. Batteries contain acid. Avoid spilling or contacting battery acid. Neutralize battery acid spills with baking soda and water.

Electrocution hazard. Contact with hot or live circuits could result in death or serious injury. Remove all rings, watches and other jewelry.

Perform this test after fully charging the batteries.

For a more accurate determination of the battery condition, fully charge the battery(s) and allow the battery(s) to rest 24 hours before performing this procedure to allow the battery cells to equalize.

1 Put on protective clothing and eye wear.

2 Disconnect the battery pack from the machine.

3 Open the latch on the battery packs. Swing open the battery packs.

4 Remove the battery box cover retaining fasteners. Remove the battery box cover.

5 Be sure that the battery cable connections are free of corrosion.

6 Be sure that the battery retainer and cable connections are tight.

7 Remove the battery vent caps and check the specific gravity of each battery cell with a hydrometer.

Result: If any battery cell displays a specific gravity of less than 1.026, the battery must be replaced.

8 Check the battery acid level of the battery. If needed, replenish with distilled water to the bottom of the battery fill tube. Do not overfill.

9 Install the battery vent caps.

10 Check each battery pack and verify that the batteries are wired correctly. Refer to the

Battery Connection Diagram decal on the machine.

11 Install the battery box cover and tighten the retaining fasteners.

12 Close and latch the battery packs.

13 Connect the battery packs to the machine.

3 - 8 Genie Z-30/20N Part No. 106373


REV C CHECKLIST B PROCEDURES

B-2

Inspect the Electrical Wiring

Maintaining electrical wiring in good condition is essential to safe operation and good machine performance. Failure to find and replace burnt, chafed, corroded or pinched wires could result in unsafe operating conditions and may cause component damage.

1 Remove the drive chassis cover from the non-steer end of the machine.

2 Inspect the following areas for burnt, chafed, corroded and loose wires:

· Electrical power panel

· Electrical relay panel

· Ground control panel

· Function manifold wiring


3 Turn the key switch to ground controls and pull out the red Emergency Stop button to the on position at both the ground and platform controls.

4 Raise the secondary boom until the lower mid-pivot is 10 feet / 3 m off the ground.

5 Inspect the turntable center area for burnt, chafed and pinched cables.

6 Lower the boom to the stowed position and turn the machine off.

7 Inspect the following areas for burnt, chafed, corroded, pinched and loose wires:

· Cable track on the primary boom

· Primary boom to platform cable harness

· Inside of the platform control box

Part No. 106373 Genie Z-30/20N 3 - 9

Section 3 • Scheduled Maintenance Procedures March 2006

CHECKLIST B PROCEDURES REV C

B-3

Test the Key Switch

Proper key switch action and response is essential to safe machine operation. The machine can be operated from the ground or platform controls and the activation of one or the other is accomplished with the key switch. Failure of the key switch to activate the appropriate control panel could cause a hazardous operating situation.

1 Pull out the red Emergency Stop button to the on position at both the ground and platform controls.

2 Turn the key switch to platform controls.

3 Check the machine functions from the ground

controls.

Result: The machine functions should not operate.

4 Turn the key switch to ground controls.

5 Check the machine functions from the platform

controls.

Result: The machine functions should not operate.

6 Turn the key switch to the off position.

Result: No function should operate.

B-4

Check the Tires and Wheels

(including lug nut torque)

Maintaining the tires and wheels, including proper wheel fastener torque, is essential to safe operation and good performance. Tire and/or wheel failure could result in a machine tip-over.

Component damage may also result if problems are not discovered and repaired in a timely fashion.

1 Check the tire surface and sidewalls for cuts, cracks and unusual wear.

2 Check each wheel for damage, bends and cracks.

3 Check each lug nut for proper torque. Refer to

Section 2, Specifications.

4 Check the torque of the drive hub mounting bolts. Refer to Section 2, Specifications.

3 - 10 Genie Z-30/20N Part No. 106373



B-5

Confirm the Proper

Brake Configuration

Proper brake configuration is essential to safe operation and good machine performance.

Hydraulically-released, spring-applied individual wheel brakes can appear to operate normally when they are actually not fully operational.

1 Check each drive hub disconnect cap to be sure it is in the engaged position.

disengaged position

B-6

Check the Oil Level in the Drive Hubs

Failure to maintain proper drive hub oil levels may cause the machine to perform poorly and continued use may cause component damage.

1 Drive the machine to rotate the hub until one of the plugs is located on top and the other is at

90 degrees.

a

engaged position a drive hub plugs

2 Remove the plug located at 90 degrees and check the oil level.

Result: The oil level should be even with the bottom of the side plug hole.

3 If necessary, remove the top plug and add oil until the oil level is even with the bottom of the side plug hole. Refer to Section 2,

Specifications.

4 Install the plugs into the drive hub.

5 Repeat this procedure for each drive hub.

Part No. 106373 Genie Z-30/20N 3 - 11



B-7

Test the Ground Control Override

A properly functioning ground control override is essential to safe machine operation. The ground control override function is intended to allow ground personnel to operate the machine from the ground controls whether the red Emergency Stop button on the platform controls is in the on or off position. This function is particularly useful if the operator at the platform controls cannot return the boom to the stowed position.

1 Push in the red Emergency Stop button at the platform controls to the off position.

2 Turn the key switch to ground controls and pull out the red Emergency Stop button to the on position.

3 Operate each boom function through a partial cycle at the ground controls.

Result: All boom functions should operate.

B-8

Test the Platform Self-leveling

Automatic platform self-leveling throughout the full cycle of boom raising and lowering is essential for safe machine operation. The platform is maintained level by the platform leveling slave cylinder which is controlled by the platform leveling master cylinder located at the base of the primary boom. A platform self-leveling failure creates an unsafe working condition for platform and ground personnel.

1 Turn the key switch to ground controls and pull out the red Emergency Stop button to the on position at both the ground and platform controls.

2 Lower the boom to the stowed position.

3 Adjust the platform to a level position using the platform leveling toggle switch.

4 Raise and lower the primary boom through a full cycle.

Result: The platform should remain level at all times to within ±5 degrees.

3 - 12 Genie Z-30/20N Part No. 106373



B-9

Test the Drive Brakes

B-10

Test the Drive Speed -

Stowed Position

Proper brake action is essential to safe machine operation. The drive brake function should operate smoothly, free of hesitation, jerking and unusual noise. Hydraulically-released individual wheel brakes can appear to operate normally when they are actually not fully operational.

Collision hazard. Be sure that the machine is not in free-wheel or partial free-wheel configuration.

Refer to B-5, Confirm the Proper

Brake Configuration.

Select a test area that is firm, level and free of obstructions.

1 Mark a test line on the ground for reference.

2 Lower the boom to the stowed position.

3 Turn the key switch to platform controls.

4 Choose a reference point on the machine; i.e., contact patch of a tire, as a visual reference for use when crossing the test line.

5 Bring the machine to top drive speed before reaching the test line. Release the drive joystick when your reference point on the machine crosses the test line.

6 Measure the distance between the test line and your machine reference point. Refer to


The brakes must be able to hold the machine on any slope it is able to climb.

Proper drive function movement is essential to safe machine operation. The drive function should respond quickly and smoothly to operator control.

Drive performance should also be free of hesitation, jerking and unusual noise over the entire proportionally controlled speed range.


1 Create start and finish lines by marking two lines on the ground 40 feet / 12.2 m apart.

2 Turn the key switch to platform control and pull out the red Emergency Stop button to the on position at both the ground and platform controls.

3 Choose a reference point on the machine; i.e., contact patch of a tire, as a visual reference for use when crossing the start and finish lines.

4 Bring the machine to maximum drive speed before reaching the start line. Begin timing when your reference point on the machine crosses the start line.

5 Continue at full speed and note the time when your machine reference point passes over the finish line. Refer to Section 2,

Specifications.

Part No. 106373 Genie Z-30/20N 3 - 13



B-11

Test the Drive Speed -

Raised or Extended Position

Proper drive function movement is essential to safe machine operation. The drive function should respond quickly and smoothly to operator control.

Drive performance should also be free of hesitation, jerking and unusual noise over the entire proportionally controlled speed range.


1 Create start and finish lines by marking two lines on the ground 40 feet / 12.2 m apart.

2 Turn the key switch to platform control and pull out the red Emergency Stop button to the on position at both the ground and platform controls.

3 Raise the primary boom more than

5 feet / 1.5 m.

4 Choose a reference point on the machine; i.e., contact patch of a tire, as a visual reference for use when crossing the start and finish lines.

5 Bring the machine to maximum drive speed before reaching the start line. Begin timing when your reference point on the machine crosses the start line.

6 Continue at full speed and note the time when your machine reference point passes over the finish line. Refer to Section 2, Specifications.

B-12

Test the Alarm Package

(if equipped)

The alarm package includes:

· Travel alarm

· Descent alarm

· Flashing beacon

Alarms and a beacon are installed to alert operators and ground personnel of machine proximity and motion. The alarm package is installed on the ground controls side turntable cover.

1 Turn the key switch to ground controls and pull out the red Emergency Stop buttons to the on position at both ground and platform controls.

Result: The flashing beacon should be on and flashing.

2 Hold the function enable toggle switch to either side, then move the primary boom toggle switch to the down position, hold for a moment then release it.

3 Hold the function enable toggle switch to either side, then move the secondary boom toggle switch to the down position, hold for a moment then release it.

4 Hold the function enable toggle switch to either side, then move the jib boom toggle switch to the down position, hold for a moment then release it.

Result: The descent alarm should sound when each control toggle switch is held down.

3 - 14 Genie Z-30/20N Part No. 106373



5 Turn the key switch to platform controls.

Result: The flashing beacon should be on and flashing.

6 Press down the foot switch.

7 Move the primary boom toggle switch to the down position, hold for a moment then release it.

8 Move the secondary boom toggle switch to the down position, hold for a moment then release it.

9 Move the jib boom toggle switch to the down position, hold for a moment then release it.

Result: The descent alarm should sound when each control toggle switch is held down.

10 Move the drive joystick off center, hold for a moment then release it. Move the drive joystick off center in the opposite direction, hold for a moment then release it.

Result: The travel alarm should sound when the drive joystick is moved off center in either direction.

B-13

Test the Turntable Rotation Stop

The turntable is capable of rotating the boom 359 degrees and is stopped midpoint between the steer wheels by the rotation stop. Detecting a rotation stop malfunction is essential to safe operation and good machine performance. If the turntable rotates past the rotation stop, component damage may result.

1 Turn the key switch to platform controls and pull out the red Emergency Stop buttons to the on position at both ground and platform controls.

2 Rotate the turntable to the left as far as it will go.

Result: Movement should stop when the primary boom reaches midpoint between the steer tires.

3 Rotate the turntable to the right as far as it will go.

Result: Movement should stop when the primary boom reaches mid-point between the steer tires.

Part No. 106373 Genie Z-30/20N 3 - 15



B-14

Check the Electrical Contactors

Maintaining the electrical contactors in good condition is essential to safe machine operation.

Failure to locate a worn or damaged contactor could result in an unsafe working condition and component damage.

1 Remove the drive chassis cover from the nonsteer end of the machine and locate the electrical contactors mounted on the electrical component mounting panel.

2 Visually inspect the contact points of each contactor for the following items:

· Excessive burns

· Excessive pitting


Replace the contactors if any damage is found.

B-15

Perform Hydraulic Oil Analysis

Replacement or testing of the hydraulic oil is essential for good machine performance and service life. Dirty oil and suction strainers may cause the machine to perform poorly and continued use may cause component damage.

Extremely dirty conditions may require oil changes to be performed more often.

Before replacing the hydraulic oil, the oil may be tested by an oil distributor for specific levels of contamination to verify that changing the oil is necessary. 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.

3 - 16 Genie Z-30/20N Part No. 106373


Checklist C Procedures

REV B

C-1

Grease the Platform Overload

Mechanism (if equipped)

Genie specifications require that this procedure be performed every 500 hours or 6 months, whichever comes first. Perform this procedure more often if dusty conditions exist.

Application of lubrication to the platform overload mechanism is essential to safe machine operation.

Continued use of an improperly greased platform overload mechanism could result in the system not sensing an overloaded platform condition and will result in component damage.

1 Locate the grease fittings on each pivot pin of the platform overload assembly.

2 Thoroughly pump grease into each grease fitting using a multi-purpose grease.

C-2

Test the Platform Overload

System (if equipped)


500 hours or six months.

Testing the platform overload system regularly is essential to safe machine operation. Continued use of an improperly operating platform overload system could result in the system not sensing an overloaded platform condition. Machine stablity could be compromised resulting in the machine tipping over.

Perform this procedure with the machine on a firm, level surface.

1 Turn the key switch to platform control.

2 Level the platform from the platform controls.

3 Determine the maximum platform capacity.

Refer to the machine serial plate.

Part No. 106373 Genie Z-30/20N 3 - 17


CHECKLIST C PROCEDURES REV B

4 Using a suitable lifting device, place an appropriate test weight equal to that of the maximum platform capacity in one of the locations shown.

Result: The platform overload indicator light should be off at both the ground and platform controls.

5 Carefully move the test weight to each remaining location.

Result: The platform overload indicator light should be off at both the ground and platform controls.

6 Add an additional 10 lbs / 4.5 kg of weight to overload the platform.

Result: The alarm should be sounding.

The platform overload indicator light should be flashing at both the ground and platform controls.

Result: If the alarm does not sound and the platform overload indicator light does not come on with the test weights in any of the platform locations, the platform overload system needs to be calibrated. See D-6, Calibrate the

Platform Overload System.

There may be an approximate 2 second delay before the overload indicator light turns on and the alarm sounds.

7 Carefully move the test weights to each remaining location in the platform.



Result: If the alarm does not sound and the platform overload indicator light does not come on with the test weights in any of the platform locations, the platform overload system needs to be calibrated. See D-6, Calibrate the

Platform Overload System.


8 Test all machine functions from the platform controls.

Result: All platform control functions should not operate.

9 Turn the key switch to ground control.

10 Test all machine functions from the ground controls.

Result: All ground control functions should not operate.

Machine functions should still operate with auxiliary power at the ground controls.

3 - 18 Genie Z-30/20N Part No. 106373

April 2005

REV B

11 Lift the test weights off the platform floor using a suitable lifting device.

Result: The platform overload indicator light and alarm should turn off at both the ground and platform controls.

There may be an approximate 2 second delay before the overload indicator light and alarm turn off.


Result: All ground control functions should operate normally.



Result: All platform control functions should operate.

If the platform overload system is not operating properly, see D-6,

Calibrate the Platform Overload

System.


CHECKLIST C PROCEDURES

Part No. 106373 Genie Z-30/20N 3 - 19


Checklist D Procedures

April 2005

REV B

D-1

Check the Primary Boom

Wear Pads

Maintaining the primary boom wear pads in good condition is essential to safe machine operation.

Wear pads are placed on boom tube surfaces to provide a low friction, replaceable wear pad between moving parts. Improperly shimmed wear pads or continued use of worn out wear pads may result in component damage and unsafe operating conditions.

1 Measure each wear pad. Replace the wear pad once it reaches the minimum allowable thickness. If the wear pad is still within specifications, shim as necessary to obtain minimum clearance with zero binding.

2 Extend and retract the primary boom through the entire range of motion to check for tight spots that could cause binding or scraping.

Always maintain squareness between the primary boom outer and inner tubes.

Models without rotating jib boom:

Primary boom wear pad specifications

Top and side wear pads

(extension end of boom)

Bottom wear pads

(extension end of boom)

Bottom and side wear pads

(pivot end of boom)

Top wear pads

(pivot end of boom)

New

3

/

4

inch

19 mm

3

/

4

inch

19 mm

3

/

4

inch

19 mm

1

/

2

inch

12.7 mm

Minimum

5

/

8

inch

15.9 mm

5

/

8

inch

15.9 mm

5

/

8

inch

15.9 mm

3

/

8

inch

9.5 mm

Models with rotating jib boom:

Primary boom wear pad specifications

All wear pads

New

1

/

2

inch

12.7 mm

Minimum

3

/

8

inch

9.5 mm

3 - 20 Genie Z-30/20N Part No. 106373


REV B CHECKLIST D PROCEDURES

D-2

Check the Free-wheel

Configuration

Proper use of the free-wheel configuration is essential to safe machine operation. The free-wheel configuration is used primarily for towing. A machine configured to free-wheel without operator knowledge may cause death or serious injury and property damage.

Collision hazard. Select a work site that is firm and level.

Component damage hazard. If the machine must be towed, do not exceed 2 mph / 3.2 km/h.

1 Chock the steer wheels to prevent the machine from rolling.

2 Center a lifting jack of ample capacity

(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.

4 Disengage the drive hubs by turning over the drive hub disconnect caps on each non-steer wheel hub.

disengaged position

5 Manually rotate each non-steer wheel.

Result: Each non-steer wheel should rotate with minimum effort.

6 Engage the drive hubs by turning over the drive hub disconnect caps.

7 Carefully remove the blocks, lower the machine and remove the jack.

Collision hazard. Failure to engage the drive hubs could result in death or serious injury and property damage.

engaged position

Part No. 106373 Genie Z-30/20N 3 - 21


CHECKLIST D PROCEDURES REV B

D-3

Check the Turntable Rotation

Bearing Bolts

Maintaining proper torque on the turntable bearing bolts is essential to safe machine operation.

Improper bolt torque could result in an unsafe operating condition and component damage.

1 Raise the secondary boom and place a safety chock on the secondary boom lift cylinder.

Carefully lower the secondary boom onto the lift cylinder safety chock.

Crushing hazard. Keep hands away from the cylinder and all moving parts when lowering the secondary boom.

A lift cylinder safety chock is available through Genie Service

Parts (Genie part no. 36555).

2 Confirm that each turntable mounting bolt is torqued in sequence to specification. Refer to


9

1

4

7

11

5

2

12

6

8

10

3

Bolt torque sequence

3 Raise the secondary boom and remove the safety chock. Lower the secondary boom to the stowed position.

4 Open the latch on the battery packs and swing them out to expose the turntable bearing bolt access hole.

5 Confirm that each turntable bearing mounting bolt is torqued in sequence to specification.

Refer to Section 2,

Specifications.

1

4

7

6

2

8

Bolt torque sequence

5

3

3 - 22 Genie Z-30/20N Part No. 106373



D-4

Replace the Drive Hub Oil

Replacing the drive hub oil is essential for good machine performance and service life. Failure to replace the drive hub oil at yearly intervals may cause the machine to perform poorly and continued use may cause component damage.

1 Select the drive hub to be serviced. Drive the machine until one of the two plugs is at the lowest point.

2 Remove both plugs and drain the oil into a suitable container.

3 Drive the machine until one plug is at the top and the other is at 90 degrees.

a a drive hub plugs

4 Fill the hub with oil from the top hole until the oil level is even with the bottom of the side plug hole. Refer to Section 2, Specifications.

5 Install the plugs into the drive hub.

6 Repeat this procedure for the other drive hub.

D-5

Replace the Hydraulic Tank

Return Filter Element

Genie requires that this procedure be performed every 1000 hours or operation or yearly, whichever comes first. Perform this procedure more often if dusty conditions exist.

Replacement of the hydraulic return filter element is essential for good machine performance and service life. A dirty or clogged filter element may cause the machine to perform poorly and continued use may cause component damage.

Extremely dirty conditions may require that the filter element be replaced more often.

Bodily injury hazard. Beware of hot oil. Contact with hot oil may cause severe burns.

1 Locate the hydraulic return filter housing on top of the hydraulic tank.

2 Clean the area around the oil filter housing cap located on top of the reservoir.

3 Remove the cap from the housing.

4 Lift the handle on the filter element and rotate the element counterclockwise to release the element from the housing.

5 Remove the filter element from the filter housing.

Part No. 106373 Genie Z-30/20N 3 - 23


CHECKLIST D PROCEDURES REV B

6 Install the new oil filter element into the filter housing.

7 Push the filter element down to be sure the oring on the element is fully seated into the housing.

8 Rotate the filter element clockwise to lock it in place.

9 Install the filter housing cap.

10 Clean up any oil that may have spilled during the replacement procedure.

11 Use a permanent ink marker to write the date and number of hours from the hour meter on the oil filter housing.

12 Turn the key switch to ground controls and pull out the red Emergency Stop button to the on position.

13 Move and hold the function enable toggle switch to either side and move and hold the primary boom toggle switch in the up direction.

14 Inspect the filter housing and related components to be sure that there are no leaks.

D-6

Calibrate the Platform Overload

System (if equipped)


1000 hours of operation or yearly.

Yearly calibration of the platform overload system is essential to safe machine operation. Continued use of an improperly calibrated platform overload system could result in the system failing to sense an overloaded platform. The stability of the machine is compromised and it could tip over.

Perform this procedure with the machine on a firm, level surface.

1 Level the platform.

2 Determine the maximum platform capacity.

Refer to the machine serial plate.

3 Using a suitable lifting device, place an appropriate test weight equal to that of the maximum platform capacity at the center of the platform floor.

3 - 24 Genie Z-30/20N Part No. 106373



Determine the limit switch trigger point:

4 Gently move the platform up and down by hand, so it bounces approximately 2.5 to 5 cm. Allow the platform to settle.

Result: The overload indicator light and the

alarm are on. Slowly tighten the load spring adjustment nut by turning it clockwise just until the overload indicator light and alarm turns off.

The platform will need to be moved up and down and allowed to settle in between adjustments.


Result: The overload indicator light and

alarm are off. Slowly loosen the load spring adjustment nut by turning it counterclockwise just until the overload indicator light and alarm turn on. Then slowly tighten the load spring adjustment nut by turning it clockwise just until the overload indicator light and alarm turn off.


The platform will need to be moved up and down and allowed to settle in between adjustments.

Confirm the setting:


6 Lift the test weight off the platform floor using a suitable lifting device.

7 Place the test weight back onto the center of the platform floor using a suitable lifting device.

Result: The alarm should be off. The platform overload indicator light should be off at both the ground and platform controls.

There may be an approximate 2 second delay before the overload indicator light and alarm turn off.

8 Add an additional 10 lb / 4.5 kg test weight to the original test weight to overload the platform.





Result: All platform control functions should not operate.

10 Turn the key switch to ground control.


Result: All ground control functions should not operate.

If the platform overload system is not operating properly, repeat steps 1 through 4.

Part No. 106373 Genie Z-30/20N 3 - 25


Checklist E Procedures

April 2005

REV B

E-1

Test or Replace the Hydraulic Oil

Replacement or testing of the hydraulic oil is essential for good machine performance and service life. Dirty oil and suction strainers may cause the machine to perform poorly and continued use may cause component damage.

Extremely dirty conditions may require that the oil be changed more often.

Before replacing the hydraulic oil, the oil may be tested by an oil distributor for specific levels of contamination to verify that changing the oil is necessary. If

the hydraulic oil is not replaced at the two year inspection, test the oil quarterly.

Replace the oil when it fails the test.

When removing a hose assembly or fitting, the O-ring on the fitting and/or hose end must be replaced and then torqued to specification during installation. Refer to

Section 2,

Hydraulic Hose and

Fitting Torque Specifications.

Perform this procedure with the boom in the stowed position.

1 Close the hydraulic shutoff valve located at the hydraulic tank.

Component damage hazard. The machine must not be operated with the hydraulic tank shutoff valve in the closed position or component damage will occur. If the tank valve is closed, remove the key from the key switch and tag the machine to inform personnel of the condition.

2 Place a suitable container under the hydraulic tank.

3 Tag, disconnect and plug the hydraulic hose from the hydraulic tank shutoff valve.

Bodily injury hazard. Spraying hydraulic oil can penetrate and burn skin. Loosen hydraulic connections very slowly to allow the oil pressure to dissipate gradually. Do not allow oil to squirt or spray.

4 Open the valve on the hydraulic tank and completely drain the oil into a suitable container.


3 - 26 Genie Z-30/20N Part No. 106373


REV B CHECKLIST E PROCEDURES

5 Tag, disconnect and plug the hydraulic hoses from the hydraulic tank return filter housing.

Cap the fittings on the filter housing.



6 Remove the hydraulic tank mounting fasteners.

Remove the hydraulic tank from the machine.

7 Remove the tank lid retaining fasteners and remove the lid and return filter assembly from the tank.

8 Remove the suction strainer from the hydraulic tank and clean it using a mild solvent.

9 Rinse out the inside of the tank with a mild solvent.

10 Install the suction strainer into the tank.

11 Install the lid and return filer assembly onto the hydraulic tank.

12 Install the hydraulic tank on the machine. Install the hydraulic tank mounting fasteners and torque them to 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.

13 Install the hydraulic hoses.

14 Fill the tank with hydraulic oil until the fluid is within the

FULL

and

ADD

marks on the hydraulic tank. Do not overfill. Refer to Section 2,

Specifications.

15 Clean up any oil that may have spilled. Properly discard of used oil.

16 Open the hydraulic tank shutoff valve.

Component damage hazard. Be sure to open the hydraulic tank shutoff valve after installing the hydraulic tank.

Part No. 106373 Genie Z-30/20N 3 - 27


CHECKLIST E PROCEDURES REV B

E-2

Grease the Steer Axle Wheel

Bearings

Maintaining the steer axle wheel bearings is essential for safe machine operation and service life. Operating the machine with loose or worn wheel bearings may cause an unsafe operating condition and continued use may result in component damage. Extremely wet or dirty conditions or regular steam cleaning and pressure washing of the machine may require that this procedure be performed more often.

1 Loosen the wheel lug nuts. Do not remove them.

2 Block the non-steer wheels, then center a lifting jack under the steer axle.

3 Raise the machine 6 inches / 15 cm and place blocks under the drive chassis for support.

4 Remove the lug nuts. Remove the tire and wheel assembly.

5 Check for wheel bearing wear by attempting to move the wheel hub side to side, then up and down.

Result: There should be no side to side or up and down movement.

Skip to step 10 if there is no movement.

6 Remove the dust cap from the hub. Remove the cotter pin from the castle nut.

7 Tighten the castle nut to 35 ft-lbs / 47 Nm to seat the bearings.

8 Loosen the castle nut and re-tighten to

8 ft-lbs / 11 Nm.

9 Check for wheel bearing wear by attempting to move the wheel hub side to side, then up and down.

Result: If there is no side to side or up and down movement, continue with step 11 and grease the wheel bearings.

Result: If there is side to side or up and down movement, continue to step 11 and replace the wheel bearings with new ones.

When replacing a wheel bearing, both the inner and outer bearings, including the pressed-in races, must be replaced.

10 Remove the dust cap from the hub. Remove the cotter pin from the castle nut.

11 Remove the castle nut.

12 Pull the hub off of the spindle. The washer and outer bearing should fall loose from the hub.

13 Place the hub on a flat surface and gently pry the bearing seal out of the hub. Remove the rear bearing.

14 Pack both bearings with clean, fresh grease.

15 Place the large inner bearing into the rear of the hub.

3 - 28 Genie Z-30/20N Part No. 106373

April 2005

REV B

16 Install a new bearing grease seal into the hub by pressing it evenly into the hub until it is flush.

17 Slide the hub onto the yoke spindle.

Component damage hazard. Do not apply excessive force or damage to the lip of the seal may occur.

18 Place the outer bearing into the hub.

19 Install the washer and castle nut.


21 Loosen the castle nut and re-tighten to

8 ft-lbs / 11 Nm.

22 Install a new cotter pin. Bend the cotter pin to lock it in.

Always use a new cotter pin when installing a castle nut.

23 Install the dust cap, then the tire and wheel assembly. Torque the wheel lug nuts to specification. Refer to Section 2, Specifications.

24 Raise the machine and remove the blocks.

Lower the machine to the ground.


CHECKLIST E PROCEDURES

Part No. 106373 Genie Z-30/20N 3 - 29



3 - 30 Genie Z-30/20N Part No. 106373

April 2005 Section 4 • Repair Procedures

Repair Procedures


Repair procedures shall be completed by a person trained and qualified on the repair of this machine.


Repair any machine damage or malfunction before operating the machine.

Before Repairs Start:

Read, understand and obey the safety rules and operating instructions in the

Genie Z-30/20N Operator’s Manual on your machine.

Be sure that all necessary tools and parts are available and ready for use.

Read each procedure completely and adhere to the instructions. Attempting shortcuts may produce hazardous conditions.

Unless otherwise specified, perform each repair procedure with the machine in the following configuration:


· Boom in stowed position

· Turntable rotated with the boom between the non-steer wheels

· Key switch in the off position with the key removed

· Wheels chocked



Most of the procedures in this section should only be performed by a trained service professional in a suitably equipped workshop. Select the appropriate repair procedure after troubleshooting the problem.

Perform disassembly procedures to the point where repairs can be completed. Then to reassemble, perform the disassembly steps in reverse order.

Symbols Legend



Used to indicate the presence of a potentially hazardous situation which, if not avoided, could result in death or serious injury.


Without safety alert symbol—used to indicate the presence of a potentially hazardous situation which, if not avoided, may result in property damage.

Used to indicate operation or maintenance information.

Indicates that a specific result is expected after performing a series of steps.

Indicates that an incorrect result has occurred after performing a series of steps.

Part No. 106373 Genie Z-30/20N 4 - 1

Section 4 • Repair Procedures

Platform Controls

April 2005

REV B

1-1

Controllers

The drive joystick is connected to the drive motor controller, located under the drive chassis cover at the non-steer end of the machine. Maintaining the boom function speed controller at the proper settings is essential to safe machine operation.

The boom function speed controller should operate smoothly and provide proportional speed control through its entire range of motion. For further information or assistance, contact the Genie

Industries Service Department.

Boom Function Speed Controller

Adjustments

Electrocution hazard. Contact with electrically charged circuits could result in death or serious injury.

Remove all rings, watches and other jewelry.

Do not adjust the boom function speed controller unless the static battery supply voltage is above

24V DC.

1 Turn the key switch to platform controls and pull out the red Emergency Stop button to the on position at both the ground and platform controls.

2 Open the platform control box lid and locate the boom function speed controller.

f g a b c a d b e c a boom function speed controller b drive and brake printed circuit board c drive joystick a black/red wire b diode c white/red wire d boom function speed controller f e ramp rate trimpot threshold trimpot g max out trimpot

4 - 2 Genie Z-30/20N Part No. 106373


REV B PLATFORM CONTROLS

3 Locate the diode between the black/red wire from the boom function speed controller and the white/red wire. Disconnect the white/red wire from the diode on the black/red wire.

4 Connect the negative lead from a multi-meter set to measure amperage to the wire connector of the white/red wire. Connect the positive lead of the multi-meter to the diode on the black/red wire.

5 Turn the boom function speed controller to the

CREEP

position.

6 Set the threshold: Press down the foot switch and move the primary boom toggle switch to the up position. Adjust the amperage to 0.28A.

Turn the threshold trimpot adjustment screw clockwise to increase the amperage or counterclockwise to decrease the amperage.

7 Turn the boom function speed controller to the 9 position.

8 Set the max out: Press down the foot switch and move the primary boom toggle switch to the down position. Adjust the amperage to 0.65A. Turn the max out trimpot adjustment screw clockwise to increase the amperage or counterclockwise to decrease the amperage.

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.

10 Set the ramp rate: Turn the ramp rate trimpot to obtain a 2 second delay from 0 to 0.65A. Turn the trimpot clockwise to increase the time or counterclockwise to decrease the time.

11 Disconnect the leads from the multi-meter and connect the white/red wire to the diode on the black/red wire.

Boom function speed controller specifications

Threshold

(controller turned to

CREEP

)

Max out

(controller turned to 9)

Ramp rate

0.28A

0.65A

2 seconds

Part No. 106373 Genie Z-30/20N 4 - 3


Platform Components

April 2005

REV B

2-1

Platform Leveling Slave Cylinder

The slave cylinder and the rotator pivot are the two primary supports for the platform. The slave cylinder keeps the platform level through the entire range of primary boom motion. It operates in a closed loop hydraulic circuit with the master cylinder. The slave cylinder is equipped with counterbalance valves to prevent platform movement in the event of a hydraulic line failure.

How to Remove the Slave

Cylinder

Before cylinder removal is considered, bleed the slave cylinder to be sure there is no air in the closed loop hydraulic circuit.


Section 2, Hydraulic Hose and


1 Extend the boom until the slave cylinder barrel-end pivot pin is accessible.

2 Raise the boom slightly and place blocks under the platform for support. Lower the boom until the platform is resting on the blocks.

3 Tag and disconnect the hydraulic hoses to the slave cylinder at the union and connect them together with a connector. Cap the fittings on the cylinder hoses.


4 Remove the external snap rings from the rod-end pivot pin. Do not remove the pin.

5 Remove the external snap rings from the barrel-end pivot pin.

6 Place a block of wood under the barrel of the slave cylinder for support.

7 Use a soft metal drift to remove the rod-end pivot pin.

Crushing hazard. The platform could fall if not properly supported.

8 Use a soft metal drift to remove the barrel-end pivot pin.

9 Carefully pull the cylinder with hydraulic hoses out of the boom.

Crushing hazard. The slave cylinder could fall if not properly supported.

How to Bleed the Slave Cylinder

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 Genie Z-30/20N Part No. 106373


REV B PLATFORM COMPONENTS

2-2

Platform Rotator

The platform rotator is a hydraulically activated helical gear assembly used to rotate the platform

180 degrees.

How to Remove the

Platform Rotator




1 Remove the platform.

2 Tag, disconnect and plug the hydraulic hoses from the platform rotate manifold.


3 Support the platform mounting weldment. Do not apply any lifting pressure.

4 Remove the six mounting bolts from the platform mounting weldment. Remove the center bolt and slide the platform mounting weldment off of the platform rotator.

5 Support the platform rotator with a suitable lifting device. Do not apply any lifting pressure.

6 Remove the pin retaining fasteners from the jib boom and leveling links to platform rotator pivot pins. Do not remove the pins.

7 Support the jib boom, jib boom cylinder and leveling links with an overhead crane.

8 Use a soft metal drift to drive both pins out, then remove the platform rotator from the machine.

Crushing hazard. The platform rotator will fall when the pins are removed if not properly supported.

When installing the platform rotator, be sure to torque the fasteners to specification. Refer to


How to Bleed the Platform

Rotator

This procedure will require two people.

1 Move the function enable toggle switch to either side and activate the platform rotate toggle switch to the right and then to the left through two platform rotation cycles. Then hold the switch to the right position until the platform is fully rotated to the right.

Part No. 106373 Genie Z-30/20N 4 - 5

Section 4 • Repair Procedures April 2005

PLATFORM COMPONENTS REV B

2 Connect a clear hose to the top bleed valve.

Place the other end of the hose in a container to collect any drainage. Secure the container to the boom.

3 Open the top bleed valve on the rotator, but do not remove it.

a b c d

5 Connect the clear hose to the bottom bleed valve and open the valve. Do not remove the bleed valve.

6 Move the function enable toggle switch to either side and hold the platform rotate toggle switch to the right position until the platform is fully rotated to the right. 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.

7 Remove the hose from the bleed valve and clean up any hydraulic oil that may have spilled.

8 Rotate the platform fully in both directions and inspect the bleed valves for leaks.

a clear hose b top bleed valve c bottom bleed valve d container

4 Move the function enable toggle switch to either side and hold the platform rotate toggle switch to the left position until the platform is fully rotated to the left. 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 Genie Z-30/20N Part No. 106373


Jib Boom Components

REV B

3-1

Jib Boom

How to Remove the Jib Boom






2 Remove the platform mounting weldment and the platform rotator. See 2-2, How to

Remove the Platform Rotator.

3 Tag, disconnect and plug the jib boom lift cylinder hydraulic hoses. Cap the fittings on the jib boom lift cylinder.


4 Remove the cable cover from the side of the jib boom.

5 Remove the mounting fasteners from the jib boom/platform rotate manifold and lay the manifold to the side. Do not remove the hoses or disconnect the wiring.

Component damage hazard.

Hoses and cables can be damaged if they are kinked or pinched.

6 Models with rotating jib boom: Tag, disconnect and plug the hydraulic hoses from the jib boom rotator. Cap the fittings on the rotator manifold.


7 Attach a lifting strap from an overhead crane to the jib boom.

8 Models without rotating jib boom: Remove the pin retaining fastener from the jib boom pivot pin at the jib boom bellcrank. Use a soft metal drift to remove the pin, then remove the jib boom from the jib boom bellcrank.

Crushing hazard. The jib boom could fall when the pin is removed if not properly supported by the overhead crane.

Models with rotating jib boom: Remove the pin retaining fastener from the jib boom pivot pin at the jib boom rotator. Use a soft metal drift to remove the pin, then remove the jib boom from the jib boom rotator.

Crushing hazard. The jib boom could fall when the pin is removed if not properly supported by the overhead crane.

Part No. 106373 Genie Z-30/20N 4 - 7


JIB BOOM COMPONENTS REV B

9 Remove the pin retaining fasteners from the jib boom lift cylinder rod-end pivot pin. Do not remove the pin.

10 Models without rotating jib boom: Remove both of the jib boom leveling links from the bell crank.

Models with rotating jib boom: Remove both of the jib boom leveling links from the jib boom rotator.

11 Attach a lifting strap from an overhead crane to the rod-end of the jib boom lift cylinder.

12 Models without rotating jib boom: Use a soft metal drift to remove the jib boom lift cylinder rod-end pivot pin. Remove the jib boom lift cylinder from the bell crank.

Models with rotating jib boom: Use a soft metal drift to remove the jib boom lift cylinder rod-end pivot pin. Remove the jib boom lift cylinder from the jib boom rotator.

Crushing hazard. The jib boom lift cylinder could fall when the pin is removed if not properly supported by the overhead crane.

3-2

Jib Boom Bell Crank

(models without rotating jib boom)


Bell Crank



Section 2,

Hydraulic Hose and


1 Remove the Jib Boom, See 3-1, How to

Remove the Jib Boom.

2 Support and secure the jib boom bell crank to an appropriate lifting device.

3 Remove the pin retaining fasteners from the slave cylinder rod-end pivot pin. Do not remove the pin.

4 Place a block of wood under the platform leveling slave cylinder for support. Protect the cylinder rod from damage.

5 Remove the pin retaining fasteners from the jib boom bell crank at the extension boom. Use a soft metal drift to remove the pin.

6 Use a soft metal drift to remove the slave cylinder rod-end pivot pin.

7 Remove the jib boom bell crank from the extension boom.

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 - 8 Genie Z-30/20N Part No. 106373


REV B JIB BOOM COMPONENTS

3-3

Jib Boom Rotator

(models with rotating jib boom)

The platform rotator is a hydraulically activated helical gear assembly used to rotate the jib boom

160 degrees.


Rotator





1 Remove the jib boom, See 3-1, How to Remove the Jib Boom.

2 Support and secure the jib boom rotator to an appropriate lifting device.

3 Remove the eight mounting bolts from the jib boom rotator mount.

4 Remove the center bolt. Carefully remove the jib boom rotator from the machine.

Crushing hazard. The jib boom rotator could become unbalanced and fall when removed from the machine if not properly supported and secured to the lifting device.

When installing the jib boom rotator, be sure to torque the fasteners to specification. Refer to


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.

7 Place a block of wood under the platform leveling slave cylinder for support. Protect the cylinder rod from damage.

8 Remove the pin retaining fasteners from the jib boom bell crank at the extension boom. Use a soft metal drift to remove the pin.

9 Use a soft metal drift to remove the slave cylinder rod-end pivot pin.

10 Remove the jib boom bell crank from the extension boom.

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.

Part No. 106373 Genie Z-30/20N 4 - 9


JIB BOOM COMPONENTS REV B

How to Bleed the Jib Boom

Rotator

This procedure will require two people.

1 Turn the key switch to ground controls and pull out the red Emergency Stop buttons to the on position at both the ground and platform controls.

2 Connect a clear hose to the top bleed valve.

Place the other end of the hose in a container to collect any drainage. Open the top bleed valve, but do not remove it.

a b c d a top bleed valve b clear hose c container d bottom bleed valve

3 Move and hold the function enable toggle switch to either side and move and hold the jib boom rotate toggle switch to the right for approximately 5 seconds, then release it.

Repeat three times.

Crushing hazard. Keep hands and head clear of the platform pivot weldment during rotation.

4 Move and hold the function enable switch to either side and move and hold the jib boom rotate toggle switch to the left for approximately

5 seconds, then release it. Repeat three times.

5 Fully rotate the jib boom to the left and continue holding the jib boom rotate toggle switch until air stops coming out of the bleed valve.

Immediately release the platform rotate toggle switch and close the bleed valve.


6 Rotate the jib boom to the right until the jib boom is centered.

7 Connect the clear hose to the bottom bleed valve and open the valve.

8 Rotate the jib boom to the right and continue holding the platform rotate toggle switch until air stops coming out of the bleed valve.

Crushing hazard. Keep hands and head clear of the jib boom during rotation.

9 Close the bleed valve and remove the hose.

10 Rotate the jib boom full left and right and inspect the bleed valves for leaks.


11 Turn the key switch to the off position and clean up any hydraulic oil that may have spilled.

4 - 10 Genie Z-30/20N Part No. 106373


REV B JIB BOOM COMPONENTS

3-4

Jib Boom Lift Cylinder


Lift Cylinder





1 Raise the jib boom slightly and place blocks under the platform mounting weldment for support. Lower the jib boom until the platform is resting on the blocks.

2 Tag, disconnect and plug the jib boom lift cylinder hydraulic hoses. Cap the fittings on the cylinder.


3 Remove the pin retaining fasteners from the jib boom lift cylinder rod-end pivot pin. Do not remove the pin.

4 Use a soft metal drift to tap the rod-end pivot pin half way out and lower one of the leveling links to the ground. Tap the pin the other direction and lower the opposite leveling link.

Do not remove the pin.

5 Attach a lifting strap from an overhead crane to the rod end of the jib boom lift cylinder.

6 Remove the pin retaining fasteners from the jib boom lift cylinder barrel-end pivot pin. Use a soft metal drift to remove the barrel-end pivot pin.

7 Use a soft metal drift to remove the jib boom lift cylinder rod-end pivot pin. Remove the jib boom lift cylinder from the machine.

Crushing hazard. The jib boom lift cylinder could fall when the pins are removed if not properly supported by the overhead crane.

Part No. 106373 Genie Z-30/20N 4 - 11


Primary Boom Components

April 2005

REV B

4-1

Cable Track

The primary boom cable track guides the cables and hoses running up the boom. It can be repaired link by link without removing the cables and hoses that run through it. Removing the entire primary boom cable track is only necessary when performing major repairs that involve removing the primary boom.

How to Repair the Plastic Cable

Track

Component damage hazard. The primary boom cable track can be damaged if it is twisted.

A 7-link repair section of cable track is available through the Genie Industries Service Parts

(Genie part no. 58919).

4-2

Primary Boom

How to Shim the Primary Boom

1 Extend the boom until the wear pads are accessible.

2 Loosen the wear pad mounting fasteners.

3 Install the new shims under the wear pad to obtain zero clearance and zero drag.

4 Tighten the mounting fasteners.

5 Extend and retract the boom through an entire cycle. Check for tight spots that could cause scraping or binding.

Always maintain squareness between the outer and inner boom tubes.

a b a link separation point b lower clip

1 Use a slotted screwdriver to pry down on the lower clip.

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 - 12 Genie Z-30/20N Part No. 106373


REV B PRIMARY BOOM COMPONENTS


Primary Boom

Bodily injury hazard. This procedure requires specific repair skills, lifting equipment and a suitable workshop. Attempting this procedure without these skills and tools could result in death or serious injury and significant component damage. Dealer service is strongly recommended.






2 Remove the platform rotator. See 2-3, How to

Remove the Platform Rotator.

3 Remove the jib boom. See 3-1,

How to Remove the Jib Boom.

4 Models without rotating jib boom: Remove the jib boom bellcrank. See 3-2, How to

Remove the Jib Boom Bellcrank.

Models with rotating jib boom: Remove the jib boom rotator. See 3-3,

How to Remove the

Jib Boom Rotator.

5 Tag, disconnect and cap the slave cylinder hydraulic hoses at the union. Plug the hoses from the slave cylinder.


6 Remove the upper cable track mounting fasteners from the platform end of the boom.

7 Remove the cable track mounting fasteners, then remove the cable track from the boom and lay it flat on the ground.

Component damage hazard. The cable track can be damaged if it is twisted.


Cables and hoses can be damaged if they are kinked or pinched.

8 Raise the secondary boom until the primary boom lift cylinder rod-end pivot pin is accessible above the mid-pivot weldment. Turn the machine off.

9 Disconnect the battery packes from the machine.

10 Remove all the hose and cable clamps from the underside of the primary boom and at the pivot end of the primary boom.

Part No. 106373 Genie Z-30/20N 4 - 13


PRIMARY BOOM COMPONENTS REV B

11 Attach a lifting strap of ample capacity from an overhead 5 ton / 5000 kg crane to the primary boom for support.

12 Locate the cables from the primary boom cable track to the platform control box. Number each cable and its entry location at the platform control box.

13 Open the platform conrol box.

14 Tag and disconnect each wire from the cables in the platform control box.

15 Pull all the cables out of the platform control box.

16 Remove the front counterweight cover.

17 Remove the extension boom drive limit switch from the side of the primary boom at the pivot end. Do not disconnect the wiring.

18 Tag, disconnect and plug the hydraulic hoses from the jib boom/platform rotate manifold.

19 Pull all the electrical cables and hydraulic hoses out of the plastic cable track. Then pull all the electrical cables and hydraulic hoses out through the boom rest pad.



20 Remove the pin retaining fastener from the master cylinder rod-end pivot pin. Use a soft metal drift to remove the pivot pin. Pull the cylinder back and secure it from moving.

21 Tag, disconnect and plug the extension cylinder hydraulic hoses. Cap the fittings on the cylinder.


22 Attach a lifting strap from an overhead crane to the primary boom lift cylinder.

23 Place 2 x 4 x 18 inch / 5 x 10 x 46 cm support blocks under the cylinder, across the secondary boom.

24 Remove the pin retaining fastener from the primary boom lift cylinder rod-end pivot pin. Use a soft metal drift to remove the pin.

Crushing hazard. The primary boom lift cylinder could fall when it is removed from the machine if not properly supported.

25 Lower the rod end of the primary boom lift cylinder onto support blocks. Protect the cylinder rod from damage.

26 Remove the pin retaining fastener from the primary boom pivot pin.

27 Remove the primary boom pivot pin with a soft metal drift. Carefully remove the primary boom assembly from the machine.

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 - 14 Genie Z-30/20N Part No. 106373



How to Disassemble the Primary Boom

Complete disassembly of the boom is only necessary if the outer or inner boom tubes must be replaced. The extension cylinder can be removed without completely disassembling the boom. See 4-4, How to Remove the Extension Cylinder.

1 Remove the primary boom. See 4-2,

How to Remove the Primary Boom.

2 Place blocks under the extension cylinder for support.

3 Remove the retaining fasteners from the extension cylinder barrel-end pivot pin. Use a soft metal drift to remove the pin.

4 Remove and label the location of the wear pads from the top side of the boom tube at the platform end of the boom.

Pay careful attention to the location and amount of shims used with each wear pad.

5 Support the extension tube with an overhead crane at the platform end of the boom.

Crushing hazard. The boom extension tube could fall when removed from the boom if not properly supported.

6 Support and slide the extension tube out of the primary boom tube. Place the extension tube on blocks for support.

During removal, the overhead crane strap will need to be carefully adjusted for proper balancing.

7 Remove the external snap rings from the slave cylinder barrel-end pivot pin.

8 Use a soft metal drift and drive the slave cylinder barrel-end pivot pin out.

9 Remove the slave cylinder from the primary extension boom tube.

10 Remove the external snap rings from the extension cylinder rod-end pivot pins at the platform end of the extension tube. Use a soft metal drift to remove the pins.

11 Support and slide the extension cylinder out of the pivot end of the boom extension tube. Place the extension cylinder on blocks for support.


Part No. 106373 Genie Z-30/20N 4 - 15



4-3

Primary Boom Lift Cylinder

The primary boom lift cylinder raises and lowers the primary boom. The primary boom lift cylinder is equipped with counterbalance valves to prevent movement in the event of a hydraulic line failure.

How to Remove the Primary

Boom Lift Cylinder





1 Raise the secondary boom enough to access the primary boom lift cylinder barrel-end pivot pin.

2 Raise the primary boom enough to access the primary boom lift cylinder rod-end pivot pin.

3 Support the primary boom lift cylinder with a suitable lifting device. Place a block of wood across the upper secondary boom to support the cylinder when the rod-end pin is removed.

4 Attach an overhead crane to the primary boom at the platform end for support. Raise the primary boom using the overhead crane just enough to relieve the pressure on the primary boom lift cylinder rod-end pivot pin.

5 Remove the counterweight cover fasteners.

Remove the counterweight cover from the machine.

6 Place a block of wood between the counterweight plate on the leveling link and the cross member of the upper secondary boom.

Carefully lower the secondary boom onto the block.

Crushing hazard. Keep hands away from the block and all moving parts when lowering the secondary boom onto the block.

7 Remove the pin retaining fasteners from the primary boom lift cylinder rod-end pivot pin. Use a soft metal drift to remove the pin.

Crushing hazard. The primary boom lift cylinder may fall if not properly supported when the rod-end pivot pin is removed.

8 Lower the rod end of the cylinder onto the blocks that were placed on the upper secondary boom.

9 Remove the pin retaining fastener from the ground control side upper secondary leveling link pivot pin at the upper pivot (same side of machine as the primary boom lift cylinder barrel-end pivot pin retainer).

10 Place a rod through the upper secondary leveling link pivot pin at the upper pivot and twist to remove the pin.

4 - 16 Genie Z-30/20N Part No. 106373



11 Swing the leveling link up out of the way and secure it from moving.

12 Tag, disconnect and plug the primary boom lift cylinder hydraulic hoses. Cap the fittings on the cylinder.


13 Support the barrel end of the primary boom lift cylinder with straps or ropes to restrict it from swinging freely.

14 Remove the pin retaining fastener from the primary boom lift cylinder barrel-end pivot pin.

Do not remove the pivot pin.

15 Place a rod through the barrel-end pivot pin and twist to remove the pin.

Crushing hazard. When the barrelend pivot pin is removed, the primary boom lift cylinder may fall if not properly supported.

16 Attach an overhead crane or similar lifting device to the lug on the rod-end of the primary boom lift cylinder. Carefully loosen the straps and allow the primary boom lift cylinder to slowly swing down.

17 Carefully remove the cylinder from the machine.

Crushing hazard. The primary boom lift cylinder will fall if not properly supported when it is removed from the machine.

4-4

Extension Cylinder

The extension cylinder extends and retracts the primary boom extension tube. The extension cylinder is equipped with counterbalance valves to prevent movement in the event of a hydraulic line failure.


Extension Cylinder





1 Raise the primary boom to the horizontal position. Extend the boom 3 to 4 feet / 1 m until the extension cylinder rod-end pivot pins are accessible.

2 Remove the external snap rings from the extension cylinder rod-end pivot pins. Use a soft metal drift to remove the pins.

3 Remove the counterweight cover fasteners.

Remove the counterweight cover from the machine.

4 Raise the secondary boom until the master cylinder rod-end pivot pin is accessible.

Part No. 106373 Genie Z-30/20N 4 - 17



5 Remove the primary boom extend drive limit switch from the pivot end of the primary boom.

Do not disconnect the wiring.

6 Remove the retaining fastener from the master cylinder rod-end pivot pin. Use a soft metal drift to remove the pin.

7 Manually retract the master cylinder and push it toward the platform end of the boom to obtain enough clearance for extension cylinder removal.

8 Tag, disconnect and plug the extension cylinder hydraulic hoses. Cap the fittings on the cylinder.


9 Remove the retaining fastener from the extension cylinder barrel-end pivot pin. Use a soft metal drift to remove the pin.

10 Carefully pull out and properly support the extension cylinder from the primary boom with a lifting strap from an overhead crane.

Crushing hazard. The cylinder could fall if not properly supported when it is pulled out of the extension tube.

To make installation of the extension cylinder easier, be sure that the cylinder rod is extended

3 to 4 feet / 1 m.


4-5

Platform Leveling Master

Cylinder

The platform leveling master cylinder acts as a pump for the slave cylinder. It is part of the closedloop hydraulic circuit that keeps the platform level through the entire range of primary boom motion.

The platform leveling master cylinder is located inside the upper mid-pivot at the pivot end of the primary boom.

How to Remove the Platform

Leveling Master Cylinder





Before cylinder removal is considered, bleed the cylinder to be sure that there is no air in the closed loop. See 2-2, How to

Bleed the Slave Cylinder.

1 Remove the counterweight cover.

2 Raise the secondary boom until the master cylinder barrel-end pivot pin is above the turntable counterweights.

4 - 18 Genie Z-30/20N Part No. 106373

April 2005

REV B

3 Raise the primary boom until the master cylinder rod-end pivot pin is accessible.

4 Attach an overhead crane to the pivot end of the primary boom for support. Do not lift it.

5 Secure the upper secondary boom to the pivot end of the primary boom with a strap (this will prevent the upper secondary boom from falling when the master cylinder barrel-end pivot pin is removed from the cylinder).

6 Tag, disconnect and plug the master cylinder hydraulic hoses. Cap the fittings on the cylinder.


7 Attach a lifting strap from an overhead crane to the lug on the rod end of the master cylinder, then secure the strap to the primary boom (use this strap to lower the master cylinder out of the upper pivot).

8 Remove the pin retaining fastener from the master cylinder rod-end pivot pin. Use a soft metal drift to remove the pin.

9 Remove the pin retaining fastener from the master cylinder barrel-end pivot pin. Use a soft metal drift to remove the pin from the cylinder.

Do not remove the pin from the upper pivot.

Push the pin to one side, only far enough to remove the cylinder. The pin should remain in one side of the upper secondary boom and upper pivot.

Crushing hazard. The upper secondary boom and the upper pivot could fall if the pivot pin is completely removed.

10 Use the strap around the rod-end lug to lower the cylinder out of the machine.



PRIMARY BOOM COMPONENTS

4 - 19

b h f f g


Secondary Boom Components

April 2005

REV B a b c d e

4 - 20 Genie Z-30/20N

Secondary Boom a upper pivot b upper compression arm c mid-pivot d compression link f e lower secondary boom lower compression arm g turntable pivot h upper secondary boom

Part No. 106373


REV B SECONDARY BOOM COMPONENTS

5-1

Secondary Boom

How to Disassemble the

Secondary Boom

Bodily injury hazard. The procedures in this section require specific repair skills, lifting equipment and a suitable workshop. Attempting this procedure without these skills and tools could result in death or serious injury and significant component damage. Dealer service is required.




1 Remove the counterweight cover.

2 Place a suitable lifting device under the platform for support.

3 Disconnect the battery packs from the machine.

4 Remove the cable cover from the side of the jib boom.

5 Remove the wire loom from the cables at the platform control box.

6 Locate the cables from the primary boom cable track to the platform control box. Number each cable and its entry location at the platform control box.

7 Open the platform control box.

8 Tag and disconnect each wire from the cables in the platform control box.



9 Pull the cables out of the platform control box.

10 Pull all of the electrical cables out of the plastic cable track. Do not pull out the hydraulic hoses.

11 Remove the hose clamps from the bottom side of the primary boom.

12 Before serial number 5945: Tag, disconnect and plug the platform rotator hydraulic hoses at the union located on the bottom side of the primary boom. Cap the fittings on the union.

After serial number 5944: Tag, disconnect and plug the hydraulic hoses from the "P" and "T" ports at the jib boom/rotate manifold. Cap the fittings on the manifold.


Part No. 106373 Genie Z-30/20N 4 - 21


SECONDARY BOOM COMPONENTS REV B

13 Remove the hose clamp from the side of the primary boom at the pivot end.

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.

15 Attach a lifting strap from an overhead crane to the pivot end of the primary boom.

16 Carefully lift the secondary and primary boom assembly with the overhead crane until the master cylinder and primary boom lift cylinder hydraulic hoses are accessible.

17 Remove the cable covers from the top of the upper secondary boom.

18 Tag, disconnect and plug the primary boom lift cylinder and master cylinder hydraulic hoses.

Cap the fittings on the cylinders.


19 Lower the secondary boom to the fully stowed position.

20 Pull all the cables and hoses through the upper pivot.



21 Position a lifting strap from the overhead crane approximately 2 feet / 60 cm from the platform end of the primary boom. Measure from the platform end of the primary boom tube.

22 Remove the pin retaining fasteners from the upper pivot to upper secondary compression arm pivot pins. Use a soft metal drift to remove the pins.

23 Swing the compression arms down and out of the way. Secure them from moving.

24 Remove the pin retaining fasteners from the upper pivot to the upper secondary boom pivot pin. Use a soft metal drift to remove the pin.

25 Carefully remove the entire primary boom assembly from the machine (primary boom assembly, jib boom assembly, platform, master cylinder, primary lift cylinder and upper pivot).

Crushing hazard. The primary boom assembly could become unbalanced and fall when removed from the machine if not properly supported by the overhead crane. Do not remove the assembly from the machine until it is properly balanced.


26 Place the entire assembly onto a structure capable of supporting it.

4 - 22 Genie Z-30/20N Part No. 106373



27 Remove the pin retaining fasteners from the upper secondary compression arm pivot pins.

Do not remove the pins.

28 Position a lifting strap from an overhead crane at the center of the control box side upper secondary compression arm.

29 Use a soft metal drift to remove the upper secondary boom compression arm pivot pins and remove the compression arm from the machine. Repeat this step for the hydraulic tank side upper secondary compression arm.

Crushing hazard. The upper secondary compression arm could become unbalanced and fall when removed from the machine if not properly supported by the overhead crane.

30 Close the hydraulic tank shutoff valve. Tag, disconnect and plug the hydraulic hose from the hydraulic tank shutoff valve.


31 Open the valve on the hydraulic tank and drain the oil into a container of suitable capacity.

Refer to Section 2, Specifications.


32 Tag, disconnect and plug the hydraulic hose from the hydraulic tank return filter housing.

Cap the fitting on the filter housing.





34 Open the ground controls side turntable cover.

35 Remove the terminal strip cover retaining fasteners. Remove the cover.

36 Remove the terminal strip retaining fasteners.


37 Remove the plastic plug in the bulkhead to access the secondary boom lift cylinder rod-end pivot pin.

38 Remove the pin retaining fastener from the rod end of the secondary boom lift cylinder. Use a soft metal drift to remove the pin through the access holes in the bulkheads. Secure the cylinder from moving.

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. 106373 Genie Z-30/20N 4 - 23



40 Attach a lifting strap from an overhead crane to the upper secondary boom.

41 Remove the pin retaining fastener from the mid-pivot to upper secondary boom pivot pin.

Use a soft metal drift to remove the pin.

42 Remove the upper secondary boom with compression link from the machine.

Crushing hazard. The upper secondary boom with compression link could become unbalanced and fall when removed from the machine if not properly supported by the overhead crane.

43 Remove the mounting fasteners from the counterweight attached to the lower leveling link.

44 Attach a lifting strap from an overhead crane to the counterweight. Remove the counterweight from the lower leveling link.

Tip-over hazard. The counterweight is critical to machine stability. If the counterweight is not installed during re-assembly of the machine, the machine will become unstable and tip over.

Crushing hazard. The counterweight could become unbalanced and fall when removed from the machine if not properly supported by the overhead crane.

45 Remove the mounting fasteners from the function manifold and slide the function manifold to the side. This will allow access to the secondary boom lift cylinder barrel-end pivot pin.

46 Remove the mounting fasteners from the auxiliary power unit. Do not disconnect the electrical cables or hydraulic hoses.

47 Slide the auxiliary power unit to the side to access the other secondary boom lift cylinder barrel-end pivot pin.

48 Remove the retaining fasteners from the secondary boom lift cylinder barrel-end pivot pins.

49 Attach a lifting strap from an overhead crane to the lug on the rod end of the secondary boom lift cylinder.

50 Tag, disconnect and plug the hydraulic hoses from the secondary boom lift cylinder. Cap the fittings on the cylinder.


51 Use a slide hammer to remove the barrel-end pivot pins (access the pins from the access holes in the bulkheads, one on each side).

Remove the secondary boom lift cylinder from the machine.

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 - 24 Genie Z-30/20N Part No. 106373



52 Attach a lifting strap from an overhead crane to the mid-pivot for support.

53 Remove the pin retaining fasteners from the mid-pivot to the lower secondary compression arm pivot pins. Use a slide hammer and remove the pins. Lower the compression arms down.

54 Remove the pin retaining fasteners from the mid-pivot to the lower secondary boom pivot pin. Use a soft metal drift to remove the pins.

55 Remove the mid-pivot from the machine.

Crushing hazard. The mid-pivot could become unbalanced and fall when removed from the machine if not properly supported by the overhead crane.

56 Remove the secondary boom drive speed limit switch (LS4) mounted to the turntable riser on the ground controls side. Do not disconnect the wiring.

57 Attach a lifting strap from an overhead crane to the ground control side lower secondary boom compression arm.

58 Remove the pin retaining fastener from the lower secondary boom compression arm to turntable riser pivot pin.

59 Use a slide hammer and remove the pin.

Remove the compression arm from the machine. Repeat for the hydraulic tank side lower secondary boom compression arm.

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.

60 Attach a lifting strap from an overhead crane to the lower secondary boom.

61 Remove the pin retaining fastener from the lower secondary boom to turntable riser pivot pin. Use a soft metal drift to remove the pin.

62 Remove the lower secondary boom from the machine.

Crushing hazard. The lower secondary boom could become unbalanced and fall when removed from the machine if not properly supported by the overhead crane.

Part No. 106373 Genie Z-30/20N 4 - 25



5-2

Secondary Boom Lift Cylinder

The secondary boom lift cylinder raises and lowers the secondary boom. The secondary boom lift cylinder is equipped with counterbalance valves to prevent movement in the event of a hydraulic line failure.

How to Remove the Secondary

Boom Lift Cylinder





1 Rotate the turntable to either side until the boom is centered between the steer and non-steer tires.

2 Raise the primary boom to full height. Do not extend it.

3 Swing out the battery pack that is directly below the secondary boom lift cylinder.

4 Disconnect the battery packs from the machine.

5 Open the hydraulic tank side turntable cover.

6 Tag and disconnect the power cables on the auxiliary power unit.



7 Close the hydraulic tank shutoff valve. Tag and disconnect and plug the hydraulic hose from the hydraulic tank shutoff valve.


8 Open the valve on the hydraulic tank and drain the oil into a container of suitable capacity.



9 Tag, disconnect and plug the hydraulic hose from the hydraulic tank return filter housing.

Cap the fitting on the filter housing.



4 - 26 Genie Z-30/20N Part No. 106373





11 Open the ground controls side turntable cover.

12 Remove the terminal strip cover retaining fasteners. Remove the cover.

13 Remove the terminal strip retaining fasteners.


14 Remove the plastic plug in the bulkhead to access the secondary boom lift cylinder rod-end pivot pin.

15 Remove the mounting fasteners from the function manifold and slide the manifold to the side This will allow access to the hydraulic tank side barrel-end pivot pin.

16 Attach a lifting strap from an overhead crane to the lug on the rod end of the secondary boom lift cylinder.

17 From the bottom side of the cylinder, remove the retaining fasteners from the secondary boom lift cylinder barrel-end pivot pins.

18 Remove the hose clamp under the lower secondary boom.

19 Use a slide hammer to remove both barrel-end pivot pins (access the pins from the access holes in the bulkheads, one on each side).

20 Remove the pin retaining fastener from the secondary boom lift cylinder rod-end pivot pin.

21 Use a soft metal drift to remove the secondary boom rod-end pivot pin.

Crushing hazard. The secondary boom lift cylinder may fall when the rod-end pivot pin is removed if not properly supported by the overhead crane.

22 Carefully lower the cylinder down through the secondary boom, enough to access the hydraulic hoses. Do not pinch the hoses.


Hoses can be damaged if they are kinked or pinched.

23 Tag, disconnect and plug the hydraulic hoses from the secondary boom lift cylinder. Cap the fittings on the cylinder.


24 Remove the cylinder through the top of the secondary boom.

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.

Part No. 106373 Genie Z-30/20N 4 - 27


Hydraulic Pumps

6-1

Auxiliary and Function Pump

How to Remove the Auxiliary

Pump or Function Pump




1 Close the hydraulic shutoff valve located at the hydraulic tank.

Component damage hazard. The machine must not be operated with the hydraulic tank shutoff valve in the closed position or component damage will occur. If the tank valve is closed, remove the key from the key switch and tag the machine to inform personnel of the condition.

2 Tag, disconnect and plug the hydraulic hoses from the pump. Cap the fittings on the pump.


3 Remove the pump mounting bolts from the pump. Carefully remove the pump from the electric motor.

4 - 28 Genie Z-30/20N

April 2004

REV A

Part No. 106373



Part No. 106373 Genie Z-30/20N 4 - 29


Manifolds

April 2005

REV B

7-1

Function Manifold Components

The function manifold is locate behind the ground controls turntable cover.

8

9

10

5

6

7

11

12

13

14

2

3

4

Index

No.

1

Description

Schematic

Item Function Torque

Solenoid valve, 3 position 4 way ....... A ........... Platform level up/down ..................... 20-25 ft-lbs / 27-34 Nm

Counterbalance valve ........................ B ........... Platform level down ........................... 20-25 ft-lbs / 27-34 Nm

Counterbalance valve ....................... C ........... Platform level up ............................... 20-25 ft-lbs / 27-34 Nm

Relief valve, 1100 psi / 75.8 bar ....... D ........... Turntable rotate left/right ................... 30-35 ft-lbs / 41-47 Nm

Relief valve, 1600 psi / 110 bar ......... E ........... Secondary boom down ..................... 20-25 ft-lbs / 27-34 Nm

Relief valve, 1600 psi / 110 bar ......... F ........... Primary boom down .......................... 20-25 ft-lbs / 27-34 Nm

Relief valve, 1800 psi / 124 bar ........ G ........... Primary boom extend ........................ 20-25 ft-lbs / 27-34 Nm

Proportional solenoid valve .............. H ........... System flow regulating circuit ........... 30-35 ft-lbs / 41-47 Nm

Check valve ....................................... I ............ Brake circuit ...................................... 10-12 ft-lbs / 14-16 Nm

Solenoid valve, 3 position 4 way ....... J ............ Steer left/right .................................... 20-25 ft-lbs / 27-34 Nm

Solenoid valve, 3 position 4 way ....... K ........... Primary boom extend/retract ............. 20-25 ft-lbs / 27-34 Nm

Pressure switch ................................. L ........... Brake circuit

Solenoid valve, N.C. poppet ............. M ........... Brake circuit ...................................... 20-25 ft-lbs / 27-34 Nm

Orifice, 0.045 inch / 1.14 mm ............ N ........... Brake circuit

This list continues. Please turn the page.

4 - 30 Genie Z-30/20N Part No. 106373

April 2005

REV B

1 2 3 4 5

6 7 8

9 10


MANIFOLDS

11

12

13

14

15

16

17

18

19

20

21

25

Part No. 106373

24 23 22

Genie Z-30/20N 4 - 31


MANIFOLDS REV B

Function Manifold Components, continued

The function manifold is locate behind the ground controls turntable cover.

21

22

23

18

19

20

Index

No.

15

16

17

24

25

Description

Schematic

Item Function Torque

Orifice, 0.045 inch / 1.14 mm ............ O ........... Brake and steer circuit

Solenoid valve, N.O. poppet .............. P ........... Brake circuit ...................................... 20-25 ft-lbs / 27-34 Nm

Differential sensing valve ................. Q ........... Differential sensing circuit ................. 30-35 ft-lbs / 41-47 Nm

Relief valve, 2800 psi / 193 bar ........ R ........... System relief ..................................... 20-25 ft-lbs / 27-34 Nm

Orifice, 0.035 inch / 0.89 mm ............. S ........... Tank return circuit

Diagnostic fitting ................................ T ........... Testing

Solenoid valve, 3 position 4 way ...... U ........... Secondary boom up/down ................ 20-25 ft-lbs / 27-34 Nm

Solenoid valve, 3 position 4 way ....... V ........... Primary boom up/down ..................... 20-25 ft-lbs / 27-34 Nm

Flow regulator valve,

1.5 gpm / 5.7 L/min ........................... W ........... Turntable rotate circuit ...................... 20-25 ft-lbs / 27-34 Nm


0.8 gpm / 3 L/min ............................... X ........... Jib boom/platform rotate circuit ......... 20-25 ft-lbs / 27-34 Nm

Solenoid valve, 3 position 4 way ....... Y ........... Turntable rotate left/right ................... 20-25 ft-lbs / 27-34 Nm

4 - 32 Genie Z-30/20N Part No. 106373

April 2005

REV B

1 2 3 4 5

6 7 8

9 10


MANIFOLDS

11

12

13

14

15

16

17

18

19

20

21

25

Part No. 106373

24 23 22

Genie Z-30/20N 4 - 33


MANIFOLDS REV B

7-2

Valve Adjustments -

Function Manifold

How to Adjust the System Relief

Valve


1 Connect a 0 to 5000 psi / 0 to 350 bar pressure gauge to the test port on the function manifold.

2 Turn the key switch to ground control and pull out the red Emergency Stop button to the on position.

3 Move and hold the function enable toggle switch to either side and move and hold the primary boom extend/retract toggle switch in the retract direction with the primary boom fully retracted.

Observe the pressure reading on the pressure gauge. Refer to Section 2, Specifications.

4 Turn the machine off. Hold the system relief valve with a wrench and remove the cap

(item R).

5 Adjust the internal hex socket. Turn it clockwise to increase the pressure or counterclockwise to decrease the pressure. 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.

How to Adjust the Primary Boom

Down Relief Valve




3 Move and hold the function enable toggle switch to either side and move and hold the primary boom up/down toggle switch in the down direction with the primary boom fully lowered.

Observe the pressure reading on the pressure gauge. Refer to Section 2,

Specifications.

4 Turn the machine off. Hold the primary down relief valve with a wrench and remove the cap

(item F).

5 Adjust the internal hex socket. Turn it clockwise to increase the pressure or counterclockwise to decrease the pressure. Then install the relief valve cap.



4 - 34 Genie Z-30/20N Part No. 106373


REV B MANIFOLDS

How to Adjust the Secondary

Boom Down Relief Valve




3 Move and hold the function enable toggle switch to either side and move and hold the secondary boom up/down toggle switch in the down direction with the secondary boom fully lowered. Observe the pressure reading on the pressure gauge. Refer to Section 2,

Specifications.

4 Turn the machine off. Hold the secondary boom down relief valve with a wrench and remove the cap (item E).




How to Adjust the Primary Boom

Extend Relief Valve




3 Move and hold the function enable toggle switch to either side and move and hold the primary boom extend/retract toggle switch in the extend direction with the primary boom fully extended.


Specifications.

4 Turn the machine off. Hold the primary booom extend relief valve with a wrench and remove the cap (item G).


Tip-over hazard. Do not adjust the relief valves higher than specified.


Part No. 106373 Genie Z-30/20N 4 - 35


MANIFOLDS

How to Adjust the Turntable

Rotate Relief Valve




3 Move and hold the function enable toggle switch to either side and move and hold the turntable rotate toggle switch in the right direction (until turntable stops against the rotation stop).


Specifications.

4 Turn the machine off. Hold the turntable relief valve(s) with a wrench and remove the cap

(item D).




April 2005

REV B

4 - 36 Genie Z-30/20N Part No. 106373


REV B MANIFOLDS

7-3

Jib Boom and Platform / Jib Boom Rotate Manifold Components

1

2

3

4

The jib boom/platform rotate manifold is mounted to the jib boom.

Index

No.

Description

Schematic

Item Function

5

Torque

Solenoid valve, 3 position 4 way ..... AA .......... Jib boom up/down ............................. 20-25 ft-lbs / 27-34 Nm

Solenoid valve, 3 position 4 way ..... BB .......... Platform rotate left/right .................... 20-25 ft-lbs / 27-34 Nm

Solenoid valve, 3 position 4 way ..... CC .......... Jib boom rotate left/right ................... 20-25 ft-lbs / 27-34 Nm


0.3 gpm / 1.14 L/min ........................ EE .......... Platform rotate circuit ........................ 20-25 ft-lbs / 27-34 Nm

Orifice plug, 0.025 inch / 0.64 mm ... DD .......... Jib boom rotate circuit

(located under plug)

1 2 3 4

1

2

4

Models with rotating jib boom

Models without rotating jib boom

5

Part No. 106373 Genie Z-30/20N 4 - 37


MANIFOLDS REV B

7-4

Valve Coils

How to Test a Coil

A properly functioning coil provides an electromotive force which operates the solenoid valve. Critical to normal operation is continuity within the coil that provides this force field.



1 Tag and disconnect the wiring from the coil to be tested.

2 Test the coil resistance.

Coils with 2 terminals: Connect the leads from the ohmmeter to the valve coil terminals.

Coils with 1 terminal: Connect the positive lead from the ohmmeter to the valve coil terminal, then connect the negative lead from the ohmmeter to the internal ring of the valve coil.

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.

Valve Coil Resistance Specification

Description

Solenoid valve, N.C. poppet, 20V DC

(schematic item M)

Specification

Solenoid valve, 3 position 4 way, 20V DC

(schematic items A, J, K, U, V, Y, AA, BB and CC)

22

Ω

Proportional solenoid valve, 24V DC

(schematic item H)

19.5

Ω

23.5

Ω

Solenoid valve, N.O. poppet, 20V DC

(schematic item P)

23.5

Ω

How to Test a Coil Diode

Genie incorporates spike suppressing diodes in all of its valve coils. Properly functioning coil diodes protect the electrical circuit by suppressing voltage spikes. Voltage spikes naturally occur within a function circuit following the interruption of electrical current to a coil. Faulty diodes can fail to protect the electrical system, resulting in a tripped circuit breaker or component damage.



1 Test the coil for resistance. See How to Test a

Coil.

2 Connect a 10

W resistor to the negative terminal of a known good 9V DC battery. Connect the other end of the resistor to a terminal on the coil.

The battery should read 9V DC or more when measured across the terminals.

Resistor, 10

W

Genie part number 27287

4 - 38 Genie Z-30/20N Part No. 106373

April 2005

REV B

COIL a d

MULTI

METER c

-

9V

BATTERY b

10

W

RESISTOR c

b a multimeter b 9V DC battery c 10

W resistor d coil

Note: Dotted lines in illustration indicate a reversed connection as specified in step 6

3 Set a multimeter to read DC current.

The multimeter, when set to read

DC current, should be capable of reading up to 800 mA.

4 Connect the negative lead to the other terminal on the coil.

If testing a single-terminal coil, connect the negative lead to the internal metallic ring at either end of the coil.

5 Momentarily connect the positive lead from the multimeter to the positive terminal on the 9V DC battery. Note and record the amperage reading.

6 At the battery or coil terminals, reverse the connections. Note and record the current reading.

Result: Both current readings are greater than

0 mA and are different by a minimum of 20%.

The coil is good.

Result: If one or both of the current readings are

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.



MANIFOLDS

4 - 39


Turntable Rotation Components

8-1

Turntable Rotation Hydraulic

Motor

The turntable rotation hydraulic motor is the only serviceable component of the turntable rotation assembly. The worm gear must not be removed from the housing. In order to remove the housing, the turntable has to be removed.

How to Remove the Turntable

Rotation Motor


Section 2,

Hydraulic Hose and


1 Tag, disconnect and plug the hydraulic hoses from the turntable rotation motor. Cap the fittings on the motor.


2 Remove the turntable rotation motor mounting bolts. Remove the motor from the machine.

April 2005

REV B

4 - 40 Genie Z-30/20N Part No. 106373


Steer Axle Components

REV A

9-1

Hub and Bearings


Hub and Bearings

1 Loosen the wheel lug nuts. Do not remove them.

2 Block the non-steer wheels and place a lifting jack under the steer axle.

3 Raise the machine. Place blocks under the drive chassis for support.

4 Remove the lug nuts. Remove the tire and wheel assembly.

5 Remove the dust cap, cotter pin and castle nut.

Always use a new cotter pin when installing a castle nut.

6 Pull the hub off the yoke spindle. The washer and outer bearing should fall loose from the hub.

7 Place the hub on a flat surface and gently pry the grease seal out of the hub. Remove the inner bearing.

When removing a bearing, always use a new inner bearing seal.

How to Install the Hub and Bearings

When replacing a wheel bearing, both the inner and outer bearings, including the pressed-in races, must be replaced.

1 Be sure that both bearings are packed with grease.

2 Place the large inner bearing into the rear of the hub.

3 Install a new bearing grease seal into the hub by pressing it evenly into the hub until it is flush.

Always replace the bearing grease seal when removing the hub.

4 Slide the hub onto the spindle.

Component damage hazard. Do not apply excessive force or damage to the lip of the seal may occur.

5 Place the outer bearing into the hub.

6 Install the washer and castle nut.


8 Loosen the castle nut, then tighten to

8 ft-lbs / 11 Nm.

9 Install a new cotter pin. Bend the cotter pin to lock it in place.

Always replace the cotter pin with a new one when removing the castle nut or when checking the torque of the castle nut.

10 Install the dust cap.

11 Install the tire and wheel assembly.

12 Lower the machine and remove the blocks.

13 Torque the wheel lug nuts to specification.


Part No. 106373 Genie Z-30/20N 4 - 41



April 2004

REV A

10-1


The drive motor controller is located under the nonsteer end drive chassis cover. The drive motor controller can recognize machine drive malfunctions and display motor controller fault codes by flashing an LED at the ground controls and on the motor controller. See the

Troubleshooting section of this manual for a list of fault codes and additional information. There are no adjustments needed on the drive joystick. For further information or assistance, consult the Genie

Industries Service Department.

How to Test the Motor Controller

Use the following procedure to test the motor controller. If the motor controller is found to be faulty, note which test failed and which fault code (if any) was present at the time of failure.

1 Turn the key switch to the off position.

Disconnect the battery packs from the machine.

2 Remove the drive chassis cover fasteners from the non-steer end of the machine. Remove the drive chassis cover.

3 Discharge the capacitors inside the motor controller by connecting a 10-50

Wresistor or the coil of a 24V DC relay between the B+ and

B- terminals of the motor controller. Hold for approximately 5-10 seconds.



F1 to F2

F1 to B-

F1 to M-

F1 to B+

F2 to B-

F2 to M-

F2 to B+

B- to M-

M- to B+

Pin 17 to B-

Pin 20 to B-

4 Tag and disconnect all power cables from the motor controller.

5 Press the release tab on the motor controller harness connector and remove the motor controller harness connector from the motor controller.

6 Connect the leads from an ohmmeter to test each motor controller terminal combination listed below. Check for resistance.

Result: All desired results must be 500 kilohms or more. If any test has a result of less than

500 kilohms, replace the motor controller.

Test Desired result

(in kilohms)

500k

W or more

500k

W or more

500k

W or more

500k

W or more

500k

W or more

500k

W or more

500k

W or more

500k

W or more

500k

W or more

500k

W or more

500k

W or more

4 - 42 Genie Z-30/20N Part No. 106373

April 2005 Section 5 • Fault Codes

Fault Codes


Troubleshooting and repair procedures shall be completed by a person trained and qualified on the repair of this machine.



Unless otherwise specified, perform each repair procedure with the machine in the following configuration:


· Boom in stowed position

· Turntable rotated with the boom between

the non-steer wheels

· Key switch in the off position with the

key removed

· Wheels chocked


Before Troubleshooting:

Read, understand and obey the safety rules and operating instructions printed in the

Genie Z-30/20N Operator’s Manual on your machine.

Be sure that all necessary tools and test equipment are available and ready for use.

Be aware of the following hazards and follow generally accepted safe workshop practices.

Crushing hazard. When testing or replacing any hydraulic component, always support the structure and secure it from movement.

Electrocution hazard. Contact with electrically charged circuits could result in death or serious injury. Remove all rings, watches and other jewelry.


Perform all troubleshooting on a firm, level surface.

Two persons will be required to safely perform some troubleshooting procedures.

Part No. 106373 Genie Z-30/20N 5 - 1

Section 5 • Fault Codes April 2004

FAULT CODES REV A

Tip-over hazard. When adjusting the raised drive speed settings, the maximum raised drive speed must not exceed 0.6 mph / 1Km/h or 40 feet/45 seconds /

12.2 meters / 45 seconds. If the machine is allowed to drive faster than specification, the machine could become unstable and will tip over.

Additional troubleshooting of the fault codes may by accomplished by using the hand-held pendant motor controller programmer

(Genie part number 56303).

When using the hand-held pendant motor controller programmer, the M1 MAX SPEED needs to be set to 33. If needed, adjust the M1 MAX 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.

The controller status indicator light will flash a fault code to aid in troubleshooting. This indicator light is mounted on the tilt level sensor mounting bracket, located behind the cover on the ground controls side.

Fault codes are two digits. The controller status indicator light will blink the first digit of a two digit code, pause for 1 second, and then blink the second digit. There will be a 2 second pause between codes.

For example: the indicator light blinks 4 consecutive times, pauses for 1 second, and then blinks 1 time. That would indicate Fault Code 41.

5 - 2 Genie Z-30/20N Part No. 106373


Fault Code Chart

REV A

Fault Code

Programmer

Diagnostic Display

Fault code LED is off or is on, but not blinking

01

12

13

COMMUNICATION

ERROR

HW FAILSAFE 1-2-3

M- SHORTED

FIELD OPEN

ARM SENSOR

FLD SENSOR

Condition Possible Causes Solution

Machine will not drive.

The key switch or

Emergency Stop button(s) was cycled on and off faster than 5 seconds OR controller sensed an internal error during start up.

Push in the ground control red Emergency

Stop button to the off position and wait for 5 seconds. Pull out the ground control red

Emergency Stop button to the on position. If problem persists, replace the motor controller.

Normal operation.






The motor controller failed self test.

The motor controller has a internal short between M- and B- terminals.

Replace the motor controller.

Test the motor controller. See Repair

Section.

Motor wiring is loose

OR motor is defective

OR motor controller has an internal short.

Defective motor controller.

Defective motor controller.

Check for loose or open connections at the drive motors and motor controller OR replace the defective drive motor OR test the motor controller. See Repair

Section.



Part No. 106373 Genie Z-30/20N 5 - 3


FAULT CODE CHART REV A

Fault Code

Programmer


21

31

Condition Possible Causes Solution

THROTTLE FAULT 1

THROTTLE FAULT 2

CONT DRVR OC


Open in wht/red wire

#32 at pin 14 or red/wht wire #29 at pin 16 on the motor controller going from drive joystick to pins 14 and 16 at the motor controller OR pin

14 is internally shorted to power or ground OR the potentiometer on the drive joystick is defective.

Consult Genie

Industries Service

Department.



Pin 14 (wht/red #32) is shorted to power or ground OR the potentiometer on the drive joystick is defective.

Main contactor (PR1) coil defective OR brake release relay CR5 defective.

Consult Genie

Industries Service

Department.

Replace main contactor

PR1 or brake release relay CR5 OR replace the motor controller.

32

MAIN CONT WELDED Machine will not drive.

Main contactor (PR1) contacts stuck closed

OR grn wire at pin 17 on motor controller shorted to ground OR open in motor armature wiring

OR motor controller has an internal short to ground.

Consult Genie

Industries Service

Department.

33

PRECHARGE FAULT Machine will not drive.

External short between

B+ terminal on motor controller and ground

OR motor controller is defective.

Repair short between

B+ terminal on motor controller and ground

OR replace motor controller.

Note: Short can be on any part of circuit connected to the B+ terminal on the motor controller.

5 - 4 Genie Z-30/20N Part No. 106373


REV A FAULT CODE CHART

Fault Code

34

41

42

Programmer


MAIN CONT DNC

LOW BATTERY

VOLTAGE

OVERVOLTAGE

Condition

MISSING CONTACTOR Machine will not drive.




Possible Causes Solution

Motor controller does not detect the main contactor PR1 or brake release relay CR5.

Consult Genie

Industries Service

Department.

Main contactor PR1 or brake release relay CR5 did not close OR open in org/red wire to PR1 and/or CR5 OR main contactor and/or brake release relay is defective.

Consult Genie

Industries Service

Department.

Battery supply voltage to motor controller less than 32V DC.

Completely charge batteries OR check battery cable condition

OR check for corrosion or loose connections at battery terminals and motor controller.

Battery supply voltage to motor controller more than 55V DC OR machine is being operated with the battery charger plugged in.

Be sure the battery charger is disconnected

OR check for loose battery cables or poor connections.

43

THERMAL CUTBACK Machine will not drive.

Machine being operated outside of temperature range of -13°F to

185°F / -25°C to 85°C

OR machine being driven under excessive load OR motor controller is not being cooled sufficently.

Operate machine within specified temperature limits OR check for debris around motor controller preventing proper cooling of the controller OR check for mechanical restrictions causing excessive load on the machine.

Part No. 106373 Genie Z-30/20N 5 - 5



5 - 6 Genie Z-30/20N Part No. 106373

April 2004 Section 6 • Schematics

Schematics


Troubleshooting and repair procedures shall be completed by a person trained and qualified on the repair of this machine.



Before Troubleshooting:

Read, understand and obey the safety rules and operating instructions printed in the

Genie Z-30/20N Operator's Manual on your machine.

Be sure that all necessary tools and test equipment are available and ready for use.


There are two groups of schematics in this section.

An illustration legend precedes each group of drawings.

Electrical Schematics



Hydraulic Schematics


General Repair Process

Malfunction discovered

Identify symptoms

Troubleshoot problem still exists

Return to service problem solved

Inspect and test

Perform repair

Part No. 106373 Genie Z-30/20N 6 - 1

Section 6 • Schematics

Load Sensor Option Diagram

(before serial number 6290)

N

GR WH

1 2

D

R

3

BL

4

LOAD SENSE

OPTION

1 2 3 4 5 6 7 8 9

+ NO NC C

F.S.

JIB

CABLE

#3

CABLE

#2

CABLE

#1

LOAD CELL

April 2004

REV A

WHT-FS

LABEL

P2

P3

DP1

BP1

TS1

TS7

TS8

TS9

TS10

TS11

TS12

TS13

TS15

TS16

L1

L2

DESCRIPTION

EMERGENCY STOP BUTTON

HORN BUTTON

DRIVE CONTROLLER

BOOM FUNCTION SPEED CONTROLLER

AUXILIARY TOGGLE SWITCH

PLATFORM ROTATE TOGGLE SWITCH

JIB BOOM UP/DOWN TOGGLE SWITCH

PLATFORM LEVEL TOGGLE SWITCH

SECONDARY BOOM TOGGLE SWITCH

PRIMARY BOOM TOGGLE SWITCH

TURNTABLE ROTATE TOGGLE SWITCH

BOOM EXTEND TOGGLE SWITCH

DRIVE ENABLE TOGGLE SWITCH

JIB ROTATE TOGGLE SWITCH (OPTION)

DRIVE ENABLE LIGHT

OVERLOAD LIGHT (OPTION)

TS15

L1

TS12

TS10

TS7

TS9

TS11

TS8

BP1

BLK/RED

RED

GRN

TS13

TS16

+

L2

R

L

TS1

NO

P3

NC NC

P2 DP1

6 - 2 Genie Z-30/20N Part No. 106373


Electrical Symbols Legend

REV A

P1

Emergency

Stop button normally closed

TB17

+

TS6

Wire with color cable number

TB20

6V DC

Battery

Toggle switch DPDT

Terminal

AP1

Quick disconnect terminal

BLK #21

TB21

T-circuits connect at terminal

T-circuits connect

Connection no terminal

Circuits crossing no connection

Diode

DE

Light

Ground supression circuit

Circuit breaker

FORWARD REVERSE

PR2

Dual pole relay

FB

Flashing beacon

HM

Hour meter

M-

3 1

B-

B+

A2

A2

Motor controller

S2

Brake release jack

J1

TS3

A1 S1

Drive motor

PUMP

Auxiliary lift pump

Toggle switch SPDT

KS1

PLATFORM

GROUND

Key switch

Tilt sensor

DP1

BRAKE

BOARD

DRIVE

BOARD

X

-

+

A

L

+

R

Drive controller

Joystick

A

-

X

R

RED

GRN

BP1

Boom function speed controller

NC

NO

LS3

Limit switch

PR4

Relay panel contactor

LS1

NOHC

Limit switch normally open held closed

P4

HORN

Horn button normally open

BLK

FS1

Foot switch

PSI

Pressure switch

Horn

Solenoid or relay coil

Relay contact normally open

Relay contact normally closed

Fuse

Part No. 106373 Genie Z-30/20N 6 - 3


Hydraulic Symbols Legend

April 2004

REV A

Hydraulic filter

Check valve

0.045 /

1.14 mm

Orifice with size

Fixed displacement pump

Normally open poppet valve

3000 psi /

207 bar

3:1

Counterbalance valve

1.5 gpm /

5.7 L/min

Flow regulator valve

Solenoid operated dump valve

2800 psi /

193 bar

Relief valve with pressure

Differential sensing valve

Brake

1100 psi /

75.8 bar

Dual relief valve with pressure

Solenoid operated proportional valve

Double acting cylinder

M

Pump prime mover

(motor)

COM

N.O.

N.C.

Pressure switch

6 - 4

25 psi /

1.7 bar

Filter with by-pass

Solenoid operated

2 position, 3 way directional valve

Solenoid operated 3 position,

4 way, directional valve

Normally closed poppet valve



Power Cable Diagram





A B C

1

+

6V DC

-

D

GROUND CONTROLS SIDE

BATTERY PACK

2

_

6V DC

+

3

+

6V DC

-

-

6V DC

+

4

PRIMARY

LIFT PUMP

A1

D1

April 2004

E F G

BLK (10 Ga )

WHT (10 Ga )

-

+

AMMETER

AC

BATTERY

CHARGER

H

BLK (4 Ga )

D1

A2

I

TANK SIDE

BATTERY PACK

J

AUXILIARY

LIFT PUMP

+

6V DC

-

-

6V DC

+

+

6V DC

-

-

6V DC

+

K

5

6

7

8

6 - 5

+

AP2

-

+

-

RED

(2 Ga)

BLK

(2 Ga)

PRIMARY

LIFT PUMP

CONTACTOR (PR2)

F2

100A

F1

500A

BATTERY

CONTROLLER

DRIVE

CONTACTOR

(PR1)

3 DIODES

48V DC

RED (10 Ga )

MOTOR

CONTROLLER

F1

B-

M-

F2

B+

DRIVE MOTOR

Genie Z-30/20N

LEFT SIDE

24V DC

F3

100A

F1

F2 A2

A1

BLK (2 Ga )

BLK (2 Ga )

BLK (2 Ga )

A1

A2

RED (10 Ga )

Part No. 106373

F1

F2

BLK (2 Ga )

RED (2 Ga )

-

+

AUXILIARY

LIFT PUMP

CONTACTOR

(PR3)

RIGHT SIDE

DRIVE MOTOR

AP1

-

+

L M

REV A

N

REV B

N M L

LEFT SIDE

BATTERY PACK

K

-

+

-

+

-

+

-

+

J I

PRIMARY

LIFT PUMP

A1

D1

H G

BLK (10)

WHT (10)

F

-

+

AMMETER

E

AC

BATTERY

CHARGER

BLK (4)

March 2006

D

D1

A2


C


(after serial number 6289)

B A

RIGHT SIDE

BATTERY PACK

1

-

+

2

-

+

-

3

+

-

AUXILIARY

PUMP

+

4

-

+

AP2

-

+

PRIMARY LIFT

PUMP CONTACTOR (PR2)

NOTES:

9. WIRE GAUGE NOTED IN PARENTHESES AFTER

WIRE COLOR.

10

DO NOT ROUTE POWER CABLES ACROSS

FRONT OF MOTOR CONTROLLER. DOING SO

CAN AFFECT INTERNAL CURRENT SENSORS,

CAUSING REDUCED MOTOR PERFORMANCE.

RED (2)

BLK (2)

LEFT SIDE

DRIVE MOTOR

F2

100A

BATTERY

F1

500A

48V DC

CONTROLLER

3 DIODES

DRIVE

CONTACTOR

(PR1)

F2

F1

RED (10)

BLK (2)

A2

A1

BLK (2)

BLK (2)

24V DC

F3

100A

RED (2)

AUXILIARY PUMP

CONTACTOR (PR3)

-

+

AP1

-

+

BLK (2)

MOTOR

CONTROLLER

F1

B-

10

MB+

F2

RED (10)

BLK (2)

A1

A2

F1

RIGHT SIDE

DRIVE MOTOR

F2

RED (10)


5

6

7

8

6 - 6





Electrical Schematic


A B C

1

2

3

4

5

6

7

D

April 2005

E F G H I

10 A

CB1

ORG/RED #CR20

P1

P2

BLK-FS

FS1

WHT-FS

RED/BLK

+

-

C

NC

NO

RED/WHT

WHT

8

OL

LOAD SENSE PCB

LOAD SENSE OPTION

KS1

PLT

GND

RED

WHT #30

WHT/BLK #31

BLK #22

TB31

TB30

WHT-1

WHT/BLK-1

TB22

BLK-2

P3

HORN

LOAD SENSE OPTION (SEE DETAIL )

P2

BLK-FS

FS1

WHT-FS

RED

+

A1

TILT

ALARM

RED/WHT #29

WHT/RED #32

ORG #40

TB40

TB29

TB32

RED/WHT-1

WHT/RED-1

BLK-8

AP2

RED

+48V DC

RED

GROUND

BLK

AP1

BLK

48V DC

BLK

AP2

BLK

RED

AP1

+24V DC

RED

24V DC

F3

100A

BLK

PR3

PUMP

F4

10A

F2

100A

ORG/RED #CR2

PR2

PUMP

22

21

LS4

F1

500A

PR1

PR1

85

86

CR5

TB50

PR1

L3

+

21

22

LS2

TB9

TB49

F1

F2

MOTOR

F1

CURTIS 1244

SEPEX CONTROLLER

M-

A2

A1

A2

A1

B+

MOTOR

F2

B-

F2

F1

17

5

STATUS LED

14

*

Shown with boom

LS1

BOOM

EXTEND/ extended

RETRACT

13

LS2

PRIMARY

BOOM

UP/DOWN

LS4

SECONDARY

BOOM

UP/DOWN

LS1*

30

87

CB2

10A

BRN

TB52

CR4

86

85

FB

TB23

TB28

TB3

86

CR1

85

30

87

30

86

CR2

85

87

BRN

BRN

TB42

8

J K L M

REV B

N

WHT

ORG/RED-1

TS55

FUNCTION

ENABLE

RED

ORG/RED

WHT-1

WHT/BLK-1

RED/WHT-1

WHT/RED-1

BLU/WHT #12

RED

RED

(GND)

(GND)

BRN

BLK (24V DC)

6 - 7 Genie Z-30/20N Part No. 106373

REV B

N M L K J I H G F

April 2005

E D


C



B A

1

WHT

ORG/RED-1

TS12

TURNTABLE

ROTATE

TS10

SECONDARY

BOOM

TS11

PRIMARY

BOOM

TS13

PRIMARY

BOOM

6

4

CR19

5

3

CR19

RED

ORG/RED

WHT-1

WHT/BLK-1

RED/WHT-1

WHT/RED-1

BLU/WHT #12

RED

RED

TS62

L

TURN

ROT

R

TB5

TB4

+

A3

TS60

DN

SEC

BOOM

UP

TB11

TB10

TS61

DN

PRI

BOOM

UP

TB2

TB1

TS9

PLATFORM

LEVEL

TS7 PLATFORM

ROTATE

TS8

JIB

BOOM

TS16

JIB BOOM

ROTATE

4

BCI

5 3

BLK

7

8 7 6 5 4 3 2 1

CR19

BRN

RESET

L.V.I.

DISCHARGE

SET TO "B" SET TO "N"

8

LVI/BCI OPTION

RED

TS1

AUX

ON

DP1

1

2

3

4

5

REV

FWD

LIFT

R L

STEER

DRIVE

6

7

8

9

10

ORG/RED

TS63

RET

PRI

BOOM

EXT

TB8

TB7

JIB

MANIFOLD

GROUND

BLU-JIB

ORG-JIB

BLK-JIB

WHT-JIB

RED-JIB

YEL-JIB

BP1

ROTARY

OEM

FLOW

CONTROL

RED

RED

GRN

BLK/RED

BRN-JIB

BRN

+

F

E

BCI

BCI OPTION

TS59

DN

PLAT

LVL

UP

TS57

L

PLAT

ROT

R

TS58

DN

JIB

BOOM

UP

RED

TB17

TB18

TB15

5

1

6

2

TB14

ORG-6

14

CR10

13

LS2

7

8

TB44

WHT/RED #6

PLATFORM LEVEL

CUTOUT

CE VERSION

ONLY

TB43

TS66

JIB BOOM

ROTATE

GRN/WHT #19

TB47

TB46

JIB BOOM ROTATE OPTION

TB19

TB6

87

30

87A

30

87

CR20

85

86

TS51

AUX

POWER

PLATFORM

CONTROL BOX

GROUND

TB36

TB37

GRN/WHT #19

TB27

86

85

CR3

HM

(GND)

(GND)

FUNCTION

MANIFOLD

GROUND

BRN

BLK (24V DC)

JP1 (REMOVE FOR CE MODELS)

TS15

DRIVE

ENABLE

+

L1

DRIVE

ENABLE

LED

2

3

J1

BRAKE

RELEASE

JACK

87

CR5

30

TB12

TB13

4

5

RED/WHT

TB48

+

A2

TB16

14 LS3

21

13

22

DRIVE

ENABLE

LIMIT

SWITCH*

*

Shown with boom rotated past either non-steer wheel

6

7

TB52

8

Part No. 106373 Genie Z-30/20N 6 - 8







A B

1

2

3

4

5

6

7

C D

April 2005

E F G H I J

RED

AP2

RED

+48V DC

48V DC

F4

10A

F2

100A

CB1

10A

ORG/RED #CR20

ORG/RED #CR2

F1

500A

PR1

P1

KS1

PLT

GND

RED

WHT #30

WHT/BLK #31

BLK #22

TB31

TB30

WHT-1

WHT/BLK-1

RED/WHT #29

WHT/RED #32

ORG #40

TB40

TB29

TB32

RED/WHT-1

WHT/RED-1

BLK-8

22

21

LS4

85

86

CR5

TB50

3

+

21

22

LS2

TB134

TB22

BL/WH-1

4

1

6

U33

3

5

7

12 8

5

A6

5

L45

BLK-2

5

LS18

P3

HORN

BLU/RED-1

P2

BLK-FS

FS1

WHT-FS

RED

L48

D39

+ TILT

ALARM

(A1)

D40

6

5

L4

7

TB23

TB28

AP2

BLK BLK

RED

AP1

+24V DC

RED

24V DC

F3

100A

BLK

PR3

PR2

F1

CURTIS 1244

SEPEX CONTROLLER

MB+

B-

F2

17

5

STATUS LED

TB49

14

LS1

13

2

TB9

A C

TB3

30

CR2

86

87

86

CR1

30

85

85 87

30

87

CR4

86

85

PUMP PUMP

F2 A2 A2 F1

LEFT

MOTOR

F1

A1 A1

F2

RIGHT

MOTOR

FB

B

GROUND

BLK

AP1

BLK

BRN

10 A

CB2

BRN

TB52

8

TB42

K

6 - 9

NOTES:

1. ALL LIMIT SWITCHES WITH BOOM IN STOWED POSITION EXCEPT AS NOTED

2 SWITCH SHOWN WITH BOOM EXTENDED

3 REDUNDANT COIL SUPPRESION DIODE FOR PR1 IS INSIDE CONTROLLER BETWEEN J1-9 AND J1-17.

5

6

7

CE & PLATFORM LOAD SENSE OPTION.

ADD D40 ONLY IF UNIT HAS BOTH L4 & L48.

ANSI/CSA ONLY


L M

REV B

N

WHT

ORG/RED-1

ORG/RED

WHT-1

WHT/BLK-1

RED/WHT-1

WHT/RED-1

BLU/WHT #12

RED

TS55

FUNCTION

ENABLE

RED

(GND)

(GND)

BRN

BLK (24V DC)

REV B

N

WHT

ORG/RED-1

ORG/RED

WHT-1

WHT/BLK-1

RED/WHT-1

WHT/RED-1

TS12

L

TURNTABLE

ROTATE

R

TS10

DN

SECONDARY

BOOM

UP

TS11

DN

PRIMARY

BOOM

UP

6 CR19

4

5 CR19

3

BLU/WHT #12

RED

RED

M

TS62

L

TURN

ROT

R

TB5

TB4

+

A3

L

TS60

DN

SEC

BOOM

UP

TB11

TB10

TS61

DN

PRI

BOOM

UP

TB2

TB1

K

TS13

RET

PRIMARY

BOOM

EXT

J I

TS9

DN

PLATFORM

LEVEL

UP

TS7

L

PLATFORM

ROTATE

R

H

TS8

DN

JIB

BOOM

UP

G

TS16

L

JIB BOOM

ROTATE

R

F

April 2005

E D

4

BCI

5 3

BLK

7

8 7 6 5 4 3 2 1

CR19

BRN

RESET

L.V.I.

DISCHARGE

SET TO "B" SET TO "N"

8

LVI/BCI OPTION

RED

TS1

AUX

ON

DP1

1

2

3

4

5

REV

FWD

LIFT

R L

STEER

DRIVE

6

7

8

9

10

ORG/RED

C



B A

1

JP1 (REMOVE FOR CE VERSION)

TS15

DRIVE

ENABLE


+

DRIVE

ENABLE

LED (L1)

2

3

TS63

RET

PRI

BOOM

EXT

TB8

TB7

JIB

MANIFOLD

GROUND

BLU-JIB

ORG-JIB

BLK-JIB

WHT-JIB

RED-JIB

YEL-JIB

BP1

ROTARY

OEM

FLOW

CONTROL

RED

GRN

BLK/RED

BRN-JIB

RED

BRN

+

F

E

BCI

BCI OPTION

TS59

DN

PLAT

LVL

UP

TS57

L

PLAT

ROT

R

TS58

DN

JIB

BOOM

UP

RED

TB17

TB18

TB15

5

1

6

2

TB14

ORG-6

14

CR10

13

LS2

7

8

TB44

WHT/RED #6

PLATFORM LEVEL

CUTOUT

CE VERSION

ONLY

TB43

TS66

L

JIB

ROT

R

GRN/WHT #19

TB47

TB46

JIB ROTATE OPTION

TB19

TB6

87

30

87A

30

87

CR20

85

86

TS51

AUX

ON

PLATFORM

CONTROL BOX

GROUND

TB36

TB37

GRN/WHT #19

TB27

CR3

86

85

HM

87

CR5

30

RED/WHT

TB48

+

A2

TB16

TB12

TB13

14 LS3

13

21

5

22

DRIVE

ENABLE

LIMIT

SWITCH

4

5

6

(GND)

(GND)

FUNCTION

MANIFOLD

GROUND

7

TB52

BRN

BLK (24V) 8

Part No. 106373

5

NOTES:

SWITCH SHOWN WITH BOOM ROTATED PAST EITHER NON-STEER WHEEL

Genie Z-30/20N 6 - 10




Section 6 • Schematics April 2004

Ground Control Panel Wiring Diagram





A B C

1

2

3

4

5

6

BRN-CB2

BRN-5

WHT-6

BLK-7

WHT/BLK-SP

ORG/RED-CR1

BLK-8

BLU/BLK-19D

BLU-19D

BLU/BLK-1

BLU-1

WHT/RED-1

WHT/BLK-1

WHT-1

RED/WHT-1

RED/BLK-1

RED-1

WHT-TILT

RED-CR3

[OPTION 2]

RED-TILT

WHT-7

TB36/TB37

WHT/BLK-SP

BLK [OPTION 2]

BRN-2

WHT-8

BLK-6

RED/WHT-CR5

ORG/BLK-1

ORG-1

GRN/BLK-1

GRN-1

ORG/RED-1

RED-5

WHT-5

BLK-5

*

*

BLK/RED-CR4

RED/WHT-CR1

WHT-2

BLK-2

GRN/WHT-CR3

GRN/WHT-3

GRN/BLK-3

GRN-3

ORG/RED-3

ORG/BLK-3

ORG-3

BLU/RED-3

BLU/WHT-3

BLU/BLK-3

BLU-3

BLK/RED-3

BLK/WHT-3

BLK-3

WHT/RED-3

WHT/BLK-3

WHT-3

RED/WHT-3

RED/BLK-3

RED-3

22

19

19

18

27

23

23

30

29

28

37

36

32

31

47

46

44

52

52

50

49

48

43

42

40

17

16

15

14

13

12

11

10

9

8

7

6

5

4

3

2

1

BRN-CH

BRN-MH

RED/WHT-MH

ORG/RED-CH

BLK-CR4

ORG/BLK-MH *

ORG-MH *

BLU/BLK-MH

BLU-MH

BLK/WHT-MH

BLK-MH

WHT/RED-MH

WHT/BLK-MH

WHT-MH

RED/BLK-MH

RED-MH

D C B

BRN-CR4

BRN-SP

RED/WHT-SP

ORG/BLK-SP **

ORG-SP **

GRN/BLK-SP

GRN-SP

ORG/RED-L3

ORG-CH

BLU/BLK-MH

BLU-MH

WHT/RED-CH

WHT/BLK-CH

WHT-CH

RED/WHT-CH

RED-SP

WHT-SP

BLK-SP

GRN/WHT-MH

GRN/WHT-SP

GRN/BLK-SP

GRN-SP

ORG/RED-CR5

ORG/BLK-SP

ORG-SP

BLU/WHT-CH

BLU/BLK-SP

BLU-SP

BLK/WHT-SP

BLK-SP

WHT/RED-SP

WHT/BLK-SP

WHT-SP

RED/BLK-SP

RED-SP

A

7

[* SEE OPTIONAL WIRING]

[** JIB BOOM ROTATE OPTION]

8

CONTROL RELAY I.D.

CR1 - SECONDARY 48V DC POWER

CR2 - PRIMARY 48V DC POWER

CR3 - AUXILIARY PUMP

CR4 - HORN

CR5 - BRAKE RELEASE

CR10A - PLATFORM LEVEL CUTOUT (CE ONLY)

CR10B - PLATFORM LEVEL CUTOUT (CE ONLY)

SPARE WIRE LIST

BLK-1

BLK/WHT-1

BLK/RED-1

BLU/WHT-1

BLU/RED-1

GRN/WHT-1

April 2004

D E F G H I J

GROUND

GROUND

LS2-LS4 JUNCTION

LS1-LS2 JUNCTION

BRAKE RELEASE

JIB BOOM ROTATE RIGHT

JIB BOOM ROTATE LEFT

JIB BOOM DOWN

JIB BOOM UP

SWITCHED 48V DC

OFF-LIMIT SPEED

STEER RIGHT

STEER LEFT

JOYSTICK POT. LOW

DRIVE REVERSE

DRIVE FORWARD

2-WIRE POT.

TILT ALARM

AUXILIARY PUMP SELECT

KEY SWITCH POWER

KEY SWITCH POWER

+24V DC TO PLATFORM

LIFT PUMP

LIFT PUMP

PLATFORM ROTATE RIGHT

PLATFORM ROTATE LEFT

DRIVE ENABLE

PLATFORM LEVEL DOWN

RED/WHT-TB3D

ORG/RED-42D

RED/WHT-48C

RED/BLK-CH

ORG/RED-16A

ORG-6

PLATFORM LEVEL UP

DRIVE ENABLE LIGHT

FOOTSWITCH

SECONDARY BOOM DOWN

SECONDARY BOOM UP

HORN

BOOM RETRACT

BOOM EXTEND

BOOM FUNCTION FLOW CONTROL

TURNTABLE ROTATE RIGHT

TURNTABLE ROTATE LEFT

48V DC RELAY COIL POWER

PRIMARY BOOM DOWN

PRIMARY BOOM UP

OPTION NUMBERS

1 - PLATFORM LEVEL CUTOUT

2 - FLASHING BEACON

3 - DESCENT ALARM

1

5

CB2

ORG/RED-CH

2

10A

ORG-14B

ORG/BLK-3

ORG-3

PLATFORM LEVEL CUTOUT (CE VERSION ONLY)

TILT SENSOR

BRN-52D

BRN-CH

RED-27D

ORG-MH

15

14

ORG/BLK-15B

ORG/BLK-CR10B

ORG-CR10A

L3

3

10B

GRN/WHT-19C

GRN/WHT-CH

RED-CH

ORG/BLK-MH

BLK

BLK-CH

ORG/RED-42A

RED-6

WHT-28D

BRN-CB2

LABEL DESCRIPTION

P1

KS1

TS51

TS55


KEY SWITCH


FUNCTION ENABLE TOGGLE SWITCH

TS57 PLATFORM ROTATE TOGGLE SWITCH

TS58 JIB BOOM UP/DOWN TOGGLE SWITCH

TS59 PLATFORM LEVEL TOGGLE SWITCH

TS60 SECONDARY BOOM UP/DOWN TOGGLE SWITCH

TS61

TS62

TS63

PRIMARY BOOM UP/DOWN TOGGLE SWITCH


BOOM EXTEND/RETRACT TOGGLE SWITCH

TS66 JIB BOOM ROTATE TOGGLE SWITCH (OPTION)

CB1

CB2

CIRCUIT BREAKER, CONTROLS, 10A

CIRCUIT BREAKER, CONTROLS RETURN, 10A

J1

HM

CH

MH

BRAKE RELEASE JACK

HOURMETER

CHASSIS HARNESS

MANIFOLD HARNESS

SP SWITCH PANEL

CR_ CONTROL RELAY

A2

A3

L3

BRAKE RELEASE/TRAVEL ALARM

DESCENT ALARM (OPTION)

CONTROLLER STATUS LED

4

RED-23D

BLK-22B

BLK/RED-9D

ORG/BLK-SP

ORG-SP

BRN-52A

BLK/RED-HORN

PLAT. LEVEL DOWN

PLAT. LEVEL UP

JIB ROTATE

(OPTION)

WHT/BLK-19D/48D

BRN-52A

RED-CH

RED/WHT-48A

WHT-23A

BLK-22A

RED-27A

ORG/BLK-15A

BLK-7A

BLK/WHT-8A

WHT/RED-6A

ORG/BLK-47A

ORG-46A

ORG-14A

GRN/BLK-18A

GRN/WHT-19A

GRN/BLK-44A

GRN-43A

RED/BLK-2A

RED-1A

GRN-17A

WHT/BLK-5A

WHT-4A

BLU/BLK-11A

BLU-10A

6 - 11 Genie Z-30/20N Part No. 106373

K L M

REV A

N

RED/WHT

A2

SWITCH PANEL

BRN

HM

CB1

P1

NC

NC

J1

KS1

NO NO

RED

TS51

RED

TS66 L R

TS58

TS55

D

U

TS63

R E

TS59

D

U

TS61

D

U

TS57

L R

D

U

TS60

L

TS62

R

REV A

N

A3

M

BRN

A2

BRN

L

HM

CB1

P1

NC

NC

J1

KS1

NO NO

TS51

TS66

ORG

ORG

TS58

ORG

TS55

TS63

TS59

TS61

TS60

TS57

TS62

DESCENT ALARM WIRING (OPTION)

CONTROL RELAY I.D.

CR1 - SECONDARY 48V DC POWER

CR2 - PRIMARY 48V DC POWER

CR3 - AUXILIARY PUMP

CR4 - HORN

CR5 - BRAKE RELEASE

CR10A - PLATFORM LEVEL CUTOUT (CE ONLY)

CR10B - PLATFORM LEVEL CUTOUT (CE ONLY)

OPTION NUMBERS

1 - PLATFORM LEVEL CUTOUT

2 - FLASHING BEACON

3 - DESCENT ALARM

SPARE WIRE LIST

BLK-1

BLK/WHT-1

BLK/RED-1

GRN/WHT-1


K J I H

[OPTION 2]

RED/WHT-TILT

BRN-CB2

BRN-5

WHT-6

BLK-7

WHT/BLK-SP

WHT-2

BLK [OPTION 2]

BRN-2

WHT-8

BLK-6

RED/WHT-CR5

ORG/BLK-1

ORG-1

GRN/BLK-1

GRN-1

ORG/RED-1 ORG/RED-CR1

BLK-8

BLU/BLK-19D

BLU-19D

RED/BLK-TILT

RED-CR3

BLU/BLK-1

BLU-1

WHT/RED-1

WHT/BLK-1

WHT-1

RED/WHT-1

RED/BLK-1

RED-1

WHT-7

TB36/TB37

WHT/BLK-SP

RED-5

*

*

WHT-5

BLK-5

BLK/RED-CR4

RED/WHT-CR1

D

BLK-C23-4

GRN/WHT-CR3

GRN/WHT-3

GRN/BLK-3

GRN-3

ORG/RED-3

ORG/BLK-3

ORG-3

BLU/RED-3

BLU/WHT-3

BLU/BLK-3

BLU-3

BLK/RED-3

BLK/WHT-3

BLK-3

WHT/RED-3

WHT/BLK-3

WHT-3

RED/WHT-3

RED/BLK-3

RED-3

C

14

13

12

11

10

9

8

7

4

3

2

6

5

1

27

26

25

32

31

30

29

28

24

23

22

19

19

18

17

16

15

48

47

46

44

43

42

40

37

36

134A

134

52

52

50

49

RED-A6

BRN-CH

BRN-MH

RED/WHT-MH

ORG/RED-CH

BLK-CR4

ORG/BLK-MH *

ORG-MH *

BLU/BLK-MH

BLU-MH

BLK/WHT-MH

BLK-MH

WHT/RED-MH

WHT/BLK-MH

WHT-MH

RED/BLK-MH

RED-MH

B

RED-KSI

BRN-CR4

BRN-SP

RED/WHT-SP

ORG/BLK-SP **

ORG-SP **

GRN/BLK-SP

GRN-SP

ORG/RED-L3

ORG-CH

BLU/BLK-MH

BLU-MH

WHT/RED-CH

WHT/BLK-CH

WHT-CH

RED/WHT-CH

RED-SP

KEYSWITCH POWER

KEYSWITCH POWER

GROUND

GROUND

LS2-LS4 JUNCTION

LS1-LS2 JUNCTION

BRAKE RELEASE

JIB RIGHT

JIB LEFT

JIB DOWN

JIB UP

SWITCHED 48V

OFF-LIMIT SPEED

STEER RIGHT

STEER LEFT

JOYSTICK POT. LOW

REVERSE

FORWARD

2-WIRE POT.

TILT ALARM

AUXILIARY PUMP SELECT

LIFT LOCKOUT

BATTERY LIGHT

TRACTION CONTROL

BLK-SP

GRN/WHT-MH

GRN/WHT-SP

GRN/BLK-SP

GRN-SP

ORG/RED-CR5

ORG/BLK-SP

ORG-SP

BLU/WHT-CH

BLU/BLK-SP

BLU-SP

BLK/WHT-SP

BLK-SP

WHT/RED-SP

WHT/BLK-SP

WHT-SP

+24V TO PLATFORM

LIFT PUMP

LIFT PUMP

PLAT. ROTATE RIGHT

PLAT. ROTATE LEFT

DRIVE ENABLE

PLAT. LEVEL DOWN

PLAT. LEVEL UP

DRIVE ENABLE LIGHT

FOOTSWITCH

SEC. BOOM DOWN

SEC. BOOM UP

HORN

BOOM RETRACT

BOOM EXTEND

BOOM FUNCTION F.C.

TURN. ROTATE RIGHT

TURN. ROTATE LEFT

48V RELAY COIL PWR.

PRIMARY BOOM DOWN

PRIMARY BOOM UP

RED/BLK-SP

RED-SP

A

[* SEE OPTIONAL WIRING]

[** JIB ROTATE OPTION]

G F

WHT/BLK-19D/48D

BRN-52A

RED-CH

JIB ROTATE

(OPTION)

RED/134A

RED-C23-6

BLK-22A

RED-27A

ORG/BLK-15A

BLK-7A

BLK/WHT-8A

WHT/RED-6A

ORG/BLK-47A

ORG-46A

ORG-14A

GRN/BLK-18A

GRN/WHT-19A

GRN/BLK-44A

GRN-43A

RED/BLK-2A

RED-1A

GRN-17A

WHT/BLK-5A

WHT-4A

BLU/BLK-11A

RED-C23-7

BLU-10A

1 3 4 5 6 7 8 12

C23

RED/WHT-TB3D

ORG/RED-42D

RED/WHT-48C

RED/BLK-CH

ORG/RED-16A

5

1

ORG/RED-CH

2

RED-27D

3

GRN/WHT-19C

GRN/WHT-CH

4

BLK-22B

BRN-52A

BLK/RED-HORN

RED-CH BLK/RED-9D

10A

ORG-MH

10B

ORG/BLK-MH

RED-6

ORG-14B ORG/BLK-15B

ORG-6

ORG/BLK-3

ORG-3

15

14

ORG/BLK-CR10B

ORG-CR10A

ORG/BLK-SP

ORG-SP

PLATFORM LEVEL CUTOUT (CE MODELS ONLY)

PLAT. LEVEL DOWN

PLAT. LEVEL UP

U33

E

TS55

RED C23-1

RED/WHT-48A

GRN/BLK

CB1

P1

NC

NC

TS58

D

U

L45

TS66

L R

D



C B A

A2

RED 134B

A6

1

BLU/RED-1

BRN

KS1

CB2

TILT SENSOR

BRN-52D

BRN-CH

RED

WHT

BLK

A

C

RED/WHT-134D

RED/BLK-28D

B

BRN-CB2

L3

BLK-CH

ORG/RED-42A

HM

TS51

R

TS63

E

TS59

D

U

TS61

D

U

TS57

L R

D

U

TS60

L

TS62

R

SWITCH PANEL

LABEL DESCRIPTION

A2

A3

A6

BRAKE RELEASE/TRAVEL ALARM

DESCENT ALARM (OPTION)

PLATFORM OVERLOAD ALARM (CE MODELS)

CB1 CIRCUIT BREAKER, CONTROLS, 10A

CB2 CIRCUIT BREAKER, CONTROLS RETURN, 10A

CH

CR

HM

J1

CHASSIS HARNESS

CONTROL RELAY

HOURMETER

BRAKE RELEASE JACK

KS1

L3

L45

MH

P1

SP

TS51

KEY SWITCH

CONTROLLER STATUS LED

PLATFORM OVERLOAD LED (CE MODELS)

MANIFOLD HARNESS


SWITCH PANEL


TS55

TS57

FUNCTION ENABLE TOGGLE SWITCH


TS58 JIB BOOM UP/DOWN TOGGLE SWITCH

TS59 PLATFORM LEVEL TOGGLE SWITCH

TS60 SECONDARY BOOM UP/DOWN TOGGLE SWITCH

TS61

TS62



TS63 BOOM EXTEND/RETRACT TOGGLE SWITCH

TS66 JIB BOOM ROTATE TOGGLE SWITCH (OPTION)

U33 PLATFORM OVERLOAD MODULE (CE MODELS)

2

3

4

5

6

7

8

Part No. 106373 Genie Z-30/20N 6 - 12




Section 6 • Schematics April 2004

Platform Control Box Wiring Diagram


3

4

5

6




A B C

1

D

April 2004

E F

2

G

TS1

AUXILIARY

POWER

P3

HORN

NO

WHT

P2

EMERGENCY

STOP BUTTON

NC

NC

BCI

(OPTION)

BRN

WHT

L1

DRIVE

ENABLE

LED

TS9

TS7

TS13

TS16

TS8

TS11

TS15

TS12

TS10

BP1

BOOM

FUNCTION

SPEED

CONTROL

BRN

RED

DP1

L

R

1 2 3 4 5 6 7 8 9 10

H

7

8

6 - 13

REMOVE THIS WIRE WHEN LOAD

SENSE OPTION IS REQUIRED.

Genie Z-30/20N

REMOVE JUMPER

FOR CE MODELS

Part No. 106373

JIB BOOM ROTATE

OPTION

I J K L M

REV A

N

SPARE WIRES

BLK-1

BLK/WHT-1

BLK/RED-1

BLU/WHT-1

BLU/RED-1

GRN/WHT-1

A1

CABLE

#3

CABLE

#2

F.S.

CABLE

#1

JIB

LOAD SENSE

(ACCESSORY)

LABEL

P2

P3

DP1

BP1

TS1

TS7

TS8

TS9

TS10

TS11

TS12

DESCRIPTION


HORN BUTTON

DRIVE CONTROLLER


AUXILIARY POWER TOGGLE SWITCH




SECONDARY BOOM UP/DOWN TOGGLE SWITCH



TS13 BOOM EXTEND/RETRACT TOGGLE SWITCH

TS15 DRIVE ENABLE TOGGLE SWITCH

TS16

A1

L1

BCI

JIB BOOM ROTATE TOGGLE SWITCH (OPTION)

TILT ALARM

DRIVE ENABLE LIGHT

BATTERY CHARGE INDICATOR (OPTION)

REV A

N M L K

WHT

BRN

RED

1 2 3 4 5 6 7 8 9 10

6

J

6

NOTE:

REMOVE JUMPER JP1 FOR CE VERSION.

JIB ROTATE

OPTION

I H G

WHT

BRN

RED/BLK

GRN/BLK

F

April 2004

E


D



C B A

1

Part No. 106373

SPARE WIRES

BLK-1

BLK/WHT-1

BLK/RED-1

2

3

4

Genie Z-30/20N

7

LABEL

A1

BCI

BP1

DP1

DESCRIPTION

TILT ALARM

BATTERY CHARGE INDICATOR (OPTION)


DRIVE CONTROLLER

L1

L4

L48

P2

P3

TS1

TS7

TS8

TS9

TS10

TS11

TS12

TS13

TS15

TS16

DRIVE ENABLE LIGHT

TILT ALARM LED

PLATFORM OVERLOAD LED


HORN BUTTON





SECONDARY BOOM UP/DOWN TOGGLE SWITCH



EXTEND/RETRACT TOGGLE SWITCH

DRIVE ENABLE TOGGLE SWITCH

JIB ROTATE TOGGLE SWITCH (OPTION)

8

6 - 14

5

6




REV A

N M

April 2004

L

RED #CR3

RED #CB1

GRN/WHT #CR3

WHT/RED #32

RED/WHT #29

RED/BLK #CR5

ORG/RED #42

K J I H G

ORG/RED #CR20

F4

10A

48V DC

PR2

PRIMARY

LIFT PUMP

CONTACTOR

BLK

ORG/RED

PR1

DRIVE

CONTACTOR

GRN

GRN/WHT #PR2

MOTOR

CONTROLLER

ORG/RED

24 23

12 11

22 21

10 9

20

8

19 18 17

7 6 5

16 15

4 3

14

2

13

1

F

24V DC

E

CR20

LIFT PUMP

CONTACTOR

RELAY

PR3

AUXILIARY

PUMP

CONTACTOR

BRN

BRN

BRN #CB2

WHT/BLK #31

WHT #30

BLK #L3

ORG #40

BLU/WHT #12

ORG/RED #CR2

Part No. 106373

D C


Power Panel Wiring Diagram

B A

1

GRN/WHT #CR3

GRN/WHT #PR2

CR20 LIFT PUMP CONTACTOR

RELAY SOCKET WIRING

(WIRE INSERTION SIDE SHOWN)

5

BRN

6

7

Genie Z-30/20N

2

3

4

8

6 - 15


Power Panel Wiring Diagram

REV A

N M L K J I H G F

April 2004

E D C


Hydraulic Schematic

B A

1

JIB BOOM ROTATE

OPTION

JIB BOOM

PLATFORM ROTATE

2

AUXILIARY

PUMP

0.5 gpm

1.89 L/min

M

PRIMARY

PUMP

2.1 gpm

7.95 L/min

M

10 MICRON

100 MESH

HYDRAULIC RESERVOIR

T1

JR1

ROTATE MANIFOLD

(JIB BOOM)

JR1

3300 psi

227.5 bar

3:1

JR2

JR2 J1

3000 psi

207 bar

1.5:1

J2

PR1

PR1

3300 psi

227.5 bar

3:1

PR2

ROTATE MANIFOLD

(PLATFORM)

PR2

3

M

BRAKES

M

R

2800 psi

193 bar

P1 G1

T

Q

O

0.045 inch

1.14 mm

P

0.045 inch

1.14 mm

N

I

BRAKE

COM

L

N.O.

N.C.

PS

M

H

STEER

CYLINDER

FUNCTION MANIFOLD

PLATFORM LEVELING

SLAVE

P

0.025 inch

0.635 mm

DD

3000 psi

207 bar

4.5:1

MASTER

TURNTABLE ROTATE

MOTOR

5.9 cu in/rev

96.7 cc/rev

CC

AA

EE

BB

0.3 gpm

1.14 L/min

T

JIB BOOM MANIFOLD

SECONDARY BOOM

CYLINDER

PRIMARY BOOM

CYLINDER

0.032 inch

0.81 mm

EXTENSION CYLINDER

(MODELS WITHOUT

ROTATING JIB BOOM)

0.090 inch /

2.29 mm

P2 L1

L2

TR1

D

TR2

J

X

0.8 gpm

3 L/min

C

3000 psi

207 bar

3:1

B

A

1100 psi

75.8 bar

1.5 gpm

5.7 L/min

W

Y

SC1

3000 psi

207 bar

1.5:1

SC2

E

1600 psi

110 bar

U

PC1

3000 psi

207 bar

3:1

(before serial number 6462)

3200 psi

221 bar

3:1

(after serial number 6461)

PC2

EXT

2500 psi

172 bar

3:1

RET

F

1600 psi

110 bar

2800 psi

193 bar

G

V K

EXTENSION CYLINDER

(MODELS WITH

ROTATING JIB BOOM)

2500 psi

172 bar

3:1

1800 psi

124 bar

G

S

0.035 inch

0.89 mm

T2

Note:

Orifice added after serial number 5396

4

5

6

7

8

Part No. 106373 Genie Z-30/20N 6 - 16


Hydraulic Schematic

Genie Holland

Phone +

31 70 51 78836

Fax +

31 70 51 13993

Genie Scandinavia

Phone +

46 31 3409612

Fax +

46 31 3409613

Genie France

Phone +

Fax +

33 (0)2 37 26 09 99

33 (0)2 37 26 09 98

Genie Iberica

Phone +

34 93 579 5042

Fax +

34 93 579 5059

Genie Germany

Phone +

Fax +

49 (0)4202 88520

49 (0)4202 8852-20

Genie U.K.

Phone +

Fax +

44 (0)1476 584333

44 (0)1476 584334

Genie Mexico City

Phone +

52 55 5666 5242

Fax +

52 55 5666 3241

Genie North America

Phone

425.881.1800

Toll Free

Fax

USA and Canada

800.536.1800

425.883.3475

Genie Australia Pty Ltd.

Phone +

Fax +

61 7 3375 1660

61 7 3375 1002

Genie China

Phone +

86 21 53852570

Fax +

86 21 53852569

Genie Malaysia

Phone +

Fax +

60 4 228 1235

60 4 226 6872

Genie Japan

Phone +

81 3 3453 6082

Fax +

81 3 3453 6083

Genie Korea

Phone +

82 2 558 7267

Fax +

82 2 558 3910

Genie Africa

Phone +

Fax +

27 11 455 0373

27 11 455 0355

Genie Latin America

Phone +

55 11 4055 2499

Fax +

55 11 4043 1661

Genie Z 30/20N Aerial Work Platform Service Manual

Assistant Bot

Service Manual

Refer to inside cover for additional serial number information

including rotating jib models

(from serial number 5934)

Important

Serial Number Information

Technical Publications

Contact Us:

Safety Rules

Danger

Do Not Perform Maintenance

Unless:

Personal Safety

Workplace Safety

Table of Contents

Specifications

Machine Specifications

Performance Specifications

Hydraulic Specifications

Manifold Component

Specifications

Machine Torque Specifications

Hydraulic Hose and Fitting

Torque Specifications

SAE O-ring Boss Port

SAE O-ring Boss Port

Seal-Lok

Fittings

SAE FASTENER TORQUE CHART

METRIC FASTENER TORQUE CHART

Scheduled Maintenance Procedures

Observe and Obey:

About This Section

CAUTION

Pre-Delivery Preparation

Fundamentals

Instructions

Maintenance Inspection Report

Checklist A Procedures

A-1

Perform Pre-operation Inspection

A-2

Perform Function Tests

A-3

Perform 30 Day Service

A-4

Grease the Turntable Rotation

Bearing and Worm Drive Gear

Checklist B Procedures

B-1

Check the Batteries

B-2

Inspect the Electrical Wiring

B-3

Test the Key Switch

B-4

Check the Tires and Wheels

(including lug nut torque)

B-5

Confirm the Proper

Brake Configuration

B-6

Check the Oil Level in the Drive Hubs

B-7

Test the Ground Control Override

B-8

Test the Platform Self-leveling

B-9

Test the Drive Brakes

B-10

Test the Drive Speed -

Stowed Position

B-11

Test the Drive Speed -

Raised or Extended Position

B-12

Test the Alarm Package

(if equipped)