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1. April 2004 Section Ge Schematics Electrical Symbols Legend REVA P4 8 6 HORN 5 Stop button Z normally closed 4 4 Horn button Wire color il V DC Toggle switch DPDT normally open with cable TBI 6 number S Battery 1 E BLK 20 2 GA e bei Foot switch CG Terminal Tilt sensor 1 Light Ei Ground DP1 Pressure supression BRAKE 1 DRIVE Switch circuit Quick disconnect 2 Circuit breaker Flashin See Drive controller Horn dr FORWARD REVERSE a Pee T circuits connect V at terminal Dual pole relay Hour Solenoid or meter relay coil Boom function T circuits speed controller connect JA S NC a T Motor Brake release Lss Relay contact controller jack normally open Connection gt no terminal 52 Limit switch 9 pm 38 Im Relay contact ae Drive motor normally closed Circuits crossing Toggle switch SPDT no connection Relay panel contactor Sieg PUMP PLATFORM Fuse A ili lift GROUND 151 Diode SERI REIR Key switch Limit switch normally open held closed Part No 106373 Genie Z 30 20N Section 6 Schematics April 2004 Hydraulic Symbols Legend Q Hydraulic filter Check valve 0 045 1 14 Orifice with
2. REV A N M L K J G F E D B A RED 3 1 RED CB1 GRN WHT CR3 WHT RED 32 RED WHT 29 2 RED BLK CR5 ORG RED 42 ORG RED CR20 3 F4 10A 48V DC C 24V DC MOTOR 4 CONTROLLER 7 7 65 B ORG RED T m ORG RED 9 8 96 PR2 PR3 PRIMARY 1 AUXILIARY 5 LIFT PUMP DRIVE PUMP CONTACTOR CONTACTOR CONTACTOR 23 22 21 20 19 171615 14 ha GRN WHT CR3 GRN 12170 9 8 7 6 5 4 3 2 1 BLK GRN WHT PR2 CR20 LIFT PUMP ICONTACTOR RN 6 RELAY e GRN WHT PR2 b BRN CR20 LIFT PUMP CONTACTOR BRN RELAY SOCKET WIRING C E WIRE INSERTION SIDE SHOWN 7 BRN CB2 WHT BLK 31 WHT 30 8 BLK L3 ORG 40 BLU WHT 12 ORG RED CR2 Part No 106373 Genie Z 30 20N 6 15 April 2004 Section 6 Schematics Power Panel Wiring Diagram REVA April 2004 Section 6 Schematics ESCH Hydraulic Schematic L K J H G D B A JIB BOOM gt lt JIB BOOM ROTATE OPTION PLATFORM ROTATE 3 EE Um 2 ee TENER Ee Deo x i x Lp eee Seng We em ROTATE MANIFOLD 3300 psi 2000 3300 psi ROTATE MANIFOLD JIB BOOM See PLATFORM 3 JR1 JR2 J1 J2 PR1 PR2 E p
3. NOTES 1 ALL LIMIT SWITCHES WITH BOOM IN STOWED POSITION EXCEPT AS NOTED gt 5 CE 8 PLATFORM LOAD SENSE OPTION lt 2 SWITCH SHOWN WITH BOOM EXTENDED lt ADD 040 ONLY IF UNIT HAS BOTH 14 amp 148 lt 3 REDUNDANT COIL SUPPRESION DIODE FOR PR1 IS INSIDE CONTROLLER BETWEEN J1 9 AND J1 17 gt 7 ANSI CSA ONLY 6 9 Genie Z 30 20N Part No 106373 Section 6 Schematics Electrical Schematic after serial number 6289 JP1 REMOVE FOR CE VERSION April 2005 LVI BCI OPTION REV B WHT ul Ed ech uc E SE Ez 55 Lu waa 22 T gt lt BRN 2 g 5 cc YY BLU RED 3 WHT 5 V 8 5 5 B 2 T 3 E B i BLU WHT 3 E BLK 5 RED 5 S H 5 Y ORG RED 3 c pug RES I WHT uin ORG RED E 9 ul 5 9 BRAKE RELEASE
4. Li ssi Brake circuit 13 Solenoid valve N C poppet Maux Brake ier ens 20 25 ft lbs 27 34 Nm 14 Orifice 0 045 inch 1 14 mm Nas Brake circuit This list continues Please turn the page 4 30 Genie Z 30 20N Part No 106373 Section 4 Repair Procedures April 2005 MANIFOLDS REV YT ia E Ly aom 7 97777 dy 2 ff TH 6 A gt 2 Wak 6 Genie Z 30 20N Part No 106373 Section Ae Repair Procedures April 2005 T MANIFOLDS REV B Function Manifold Components continued The function manifold is locate behind the ground controls turntable cover Index Schematic No Description Item Function Torque 15 Orifice 0 045 inch 1 14 mm o S Brake and steer circuit 16 Solenoid valve poppet Paseos Brake 1 sies io otii etn 20 25 ft lbs 27 34 Nm 17 Differential sensing valve Qnis Differential sensing circuit 30 35 ft lbs 41 47 Nm 18 Relief valve 2800 psi 193 bar i System relief 20 25 ft lbs 27 34 Nm 19 Orifice 0 035 inch 0 89 S ausis Tank return circuit 20 Diagnostic fitting Testing 21 Solenoid va
5. Service Manual Refer to inside cover for additional serial number information Part No 106373 Rev A2 March 2006 Z 30 20N including rotating jib models from serial number 5934 Introduction April 2004 Important Serial Number Information Read understand and obey the safety rules and Genie Industries offers the following Service operating instructions in the Genie 2 30 20 Manuals for these models Operator s Manual before attempting any maintenance or repair procedure Title Part No This manual provides detailed scheduled 1 0 for the machine owner EE Mantal before serial number 5934 sesesseeseeseesereresee 35532 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 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 suggest
6. MEME 4 1 Platform Controls 1 1 Controllers A 4 2 B Platform Components 2 1 Platform Leveling Slave 4 4 E tel ul e ee 4 5 Jib Boom Components 2 1 dae 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 Boom Lift 4 10 Part No 106373 Genie Z 30 20N vii April 2005 p 1 TABLE OF CONTENTS Section 4 Rev Repair Procedures continued B Primary Boom Components 4 Cable Track 4 11 42 Piman BOOM CHEER 4 11 4 3 Primary Boom Lift Cylinder ssassn anioia uaaa ia 4 15 4 4 Extension Cylinder isisi ana roe eae Mis 4 17 4 5 Platform Leveling Master 4 18 B Secondary Boom Components 5 1 Secondary eite RENT e a uide hard EE ERE e planes 4 21 5 2 Secondary Boom Lift Cylinder A 4 26 Hydraulic Pumps 6 1 Auxiliary and Function 4 28 B Manifolds 7 1 Function Manifold 4 30 7 2 Valve Adjustments Function 4 34 7 3 Jib Boom and Platform Jib Boom Rotate Manifold Components 4 37 RC Ie EE 4 38 B Turntable Rotate Components 8 1 Turntable Rotation Hydraulic Motor 2 4 40 Steer Axle Components 9 1 Hub and Bearings
7. 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 AWARNING Crushing hazard Keep hands and head clear of the platform pivot weldment during rotation REV B 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 AWARNING Crushing hazard Keep hands and head clear of the platform pivot weldment during rotation Rotate the jib boom to the right until the jib boom is centered Connect the clear hose to the bottom bleed valve and open the valve Rotate the jib boom to the right and continue holding the platform rotate toggle switch until air stops coming out of the bleed valve AWARNING 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 AWARNING Crushing hazard Keep hands and head clear of the platform pivot weldment during rotation 11 Turn the ke
8. LOAD SENSE ACCESSORY O O CABLE 3 Al JIB A BCI E e RED BLK 1 BLU WHT 3 ORG RED 3 WHT BLK 3 WHT 3 BLU BLK 3 BLU 3 WHT RED 3 BP1 BOOM FUNCTION SPEED CONTROL BRN D 5 2 D 2 o D 2 2 GRN BLK 3 GRN 3 11 GRN 1 GRN WHT 3 abe GRN BLK 1 RED BLK 3 RED 3 po roses les 7 5 515 6 2 ee ORG BLK 3 BLK WHT 3 ENABLE DRIVE LED L1 BLK 3 BLU RED 3 BLU BLK 1 BLU 1 BRN RED JIB BOOM ROTATE OPTION EET ORG RED RED WHT FS WHT PO NC rO NO RED TS1 AUXILIARY 5 9 POWER 1 P3 HORN P2 EMERGENCY STOP BUTTON WHT WHT 1 WHT BLK 1 DP1 WHT RED 1 1213 415167819110 RED WHT 1 RED WHT 3 WHT 2 ORG RED 1 BLK FS BLK 2 BLK RED 3 RED 1
9. 20 25 ft lbs 27 34 Nm 5 Orifice plug 0 025 inch 0 64 mm DD Jib boom rotate circuit located under plug Models without rotating jib boom Models with rotating jib boom Part No 106373 Genie Z 30 20N 4 37 Section Ae Repair Procedures April 2005 MANIFOLDS 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 AWARNING Electrocution hazard Contact with electrically charged circuits could result in death or serious injury Remove all rings watches and other jewelry 1 Tagand disconnect the wiring from the coil to be tested 2 Testthe 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 Specification Solenoid valve 3 position 4 way 20V DC 220 schematic items J K V Y AA BB and Pro
10. RIO Wuel 1 gt CO AYN m 60 gt como ojoj Ni ojojo MINIO foj N 41 00 ATO 6 O1 o N RISIN NS 1 5 Po A A O MIN A as A Popp Ou e 85 20 6 83 Part 106373 Genie Z 30 20N 2 5 Section 2 Specifications March 2006 See This page intentionally left blank 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 AWARNING Failure to properly complete each inspection when required could result in death serious injury or substantial machine damage Immediately tag and remove from service 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
11. TB19 GRN WHT 3 j GRN WHT e RED BP1 BRN t WHT RED 3 30 87 CONTACTOR RELAY CR20 LIFT PUMP CONTACTOR COIL PR2 RED D RED lt GRN 2 CONTROL BLK RED ROTARY BRN JIB OEM FLOW ORG BLK 1 a a ROTATE TS66 ORG 1 TS16 ROTATE RED JIB YELJIB z TB46 JIB BOOM ROTATE OPTION GRN 1 WHT RED 6 GRN BLK 1 BLK JIB WHT JIB ook GRN BLK 3 d 18 PLATFORM LEVEL CUTOUT CE VERSION ONLY Su EE 50 CC RIGHT GRN 3 BLU JIB ORG JIB 4 JIB MANIFOLD GROUND ORG 3 HI TB14 RG 14 JOWN ORG BLK 3 TB15 ege EE EE BLK 3 BLK 7 FUNCTION MANIFOLD GROUND ch BLK WHT 8 TEXTEND PRIMARY BOOM BLKAWHT 3 TS13 2 8 PRIMARY BOOM RED 3 RED 1 PRI BOOM RED BLK 2 TS61 RED BLK 3 BLU 3 BLU 10 BLU BLK 11 SECONDARY TUP BLU BLK 3 FLOW CONTROL COIL PLATFORM LEVEL CUTOUT RELAY COIL PLATFORM LEVEL UP COIL PLATFORM LEVEL DOWN COIL PRIMARY BOOM EXTEND COIL PRIMARY BOOM R
12. Observe and Obey Troubleshooting and repair procedures shall be completed by a person trained and qualified on the repair of this machine Immediately tag and remove from service damaged or malfunctioning machine Repair any machine damage or malfunction before operating the 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 Schematics About This Section There are two groups of schematics in this section An illustration legend precedes each group of drawings Electrical Schematics AWARNING Electrocution hazard Contact with electrically charged circuits could result in death or serious injury Remove all rings watches and other jewelry Hydraulic Schematics AWARNING 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 General Repair Process Identify symptoms Malfunction L gt Troubleshoot discovered problem still exists Perform repair Return to service problem solved Part No 106373 Genie Z 30 20N 6 1 Sect ion 6 Schematics April 2004 Load S
13. BLUE JIB ORG JIB WHT JIB BLK JIB YEL JIB RED JIB DE REWER REMOVE JUMPER FOR CE MODELS SENSE OPTION IS REQUIRED Part No 106373 Genie Z 30 20N 6 13 Section 6 Schematics April 2004 after serial number 6289 Platform Control Box Wiring Diagram REVA A 1 SPARE WIRE BLK 1 BLK RED 1 BLK WHT 1 O TILT ALARM BATTERY CHARGE INDICATOR OPTION BOOM FUNCTION SPEED CONTROLLER DRIVE CONTROLLER DRIVE ENABLE LIGHT TILT ALARM LED PLATFORM OVERLOAD LED EMERGENCY STOP BUTTON HORN BUTTON PLATFORM ROTATE TOGGLE SWITCH JIB BOOM UP DOWN TOGGLE SWITCH PLATFORM LEVEL TOGGLE SWITCH AUXILIARY TOGGLE SWITCH LABEL DESCRIPTION Al BCI DP1 L1 L4 L48 P2 P3 TS10 SECONDARY BOOM UP DOWN TOGGLE SWITCH TS11 PRIMARY BOOM UP DOWN TOGGLE SWITCH TS12 TURNTABLE ROTATE TOGGLE SWITCH TS13 EXTEND RETRACT TOGGLE SWITCH TS15 DRIVE ENABLE TOGGLE SWITCH TS1 TS7 TS8 TS9 TS16 JIB ROTATE TOGGLE SWITCH OPTION 5 6 BRN JIB BRN 2 BLU RED 1 BLU WHT 1 RED BLK 1 WHT 2 BLU WHT 3 ORG RED 3 22 TS15 WHT BLK 3 WHT 3 BLU BLK 3 BLU 3 bu OD EE TS10
14. Genie Z 30 20N Part No 106373 April 2005 Section Scheduled Maintenance Procedures REV B 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 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 Repeatthis procedure for the other drive hub CHECKLIST D PROCEDURES 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 repla
15. 3 12 B 9 Testthe Drive Brakes 3 13 B 10 Test the Drive Speed Stowed Position 2 3 13 B 11 Test the Drive Speed Raised or Extended Position 3 14 B 12 Test the Alarm Package if equipped 14 B 13 Test the Turntable Rotation Stop eea 3 15 B 14 Check the Electrical Contactors 2 040 3 16 B 15 Perform Hydraulic Oil Analysis 3 16 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 Genie Z 30 20N Part No 106373 April 2005 TCR TABLE OF CONTENTS Section3 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 22 3 21 D 3 Check the Turntable Rotation Bearing Bolts 3 22 0 4 Replace the Drive Hub OU 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 Testor Replace the Hydraulic Oil 3 26 E 2 Grease the Steer Axle Wheel Bearings 3 28 Section 4 Rev Repair Procedures
16. REV A April 2004 Section 6 Schematics Ground Control Panel Wiring Diagram REV A after serial number 6289 N M L K J G F E D c Macc LM OPTION 2 134A KEYSWITCH POWER RED 134 1 RED WHT TILT WHT 2 134 RED A6 RED KSI KEYSWITCH POWER RED C23 1 BRN CB2 BLK OPTION 2 52 BRN CH BRN CR4 GROUND A2 6 i BRN 5 BRN 2 52 BRN MH BRN SP GROUND i WHT 6 WHT 8 50 LS2 LS4 JUNCTION BLU RED 1 T BLK 7 BLK 6 49 161 152 JUNCTION BRN WF wHT BLK SP RED WHT CR5 48 RED WHT MH RED WHT SP BRAKE RELEASE BRN ORG BLK 1 47 OR
17. 10000 2 3 Hydraulic Hose and Fitting Torque Specifications 2 4 SAE and Metric Fasteners Torque 2 5 Scheduled Maintenance Procedures Juttel er e Mcr 3 1 Pre Deliv ry Preparation 3 3 Maintenance Inspection 3 5 B Checklist A Procedures A 1 Perform Pre operation Inspection 3 6 2 Perform Function seein 3 6 3 Perform 30 Day 3 7 4 Grease the Turntable Rotation Bearing and Worm Drive Gear 3 7 Part No 106373 Genie Z 30 20N V March 2006 TABLE OF CONTENTS Section 3 Rev Scheduled Maintenance Procedures continued Checklist B Procedures B l Check the Batteries oon ret Ferret epus tede creo que 3 8 B 2 Inspect the Electrical Wiring nennen 3 9 3 8 resttlie Key SWIitChi iie tene ttn eit 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 00001
18. RED WHT TRAVEL ALARM A2 42 LIONNNNN g E BRAKE RELEASE 5 anna ae amp N C COIL m REDWHT 48 BRAKE RELEASE lt BRAKE RELEASE RED WHT N O COIL 5 PRESSURE SWITCH ha EH BLU 1 Bruas STEER LEFT COIL 1 1 1 e e e e 8 8 9 1 m Tw BLU BLK 1 Fi Fa BLU BLK 37 STEER RIGHT COL a x E alg 8 zB H 0889 y wy 5 Le EES gt amp i 888 HOUR METER pele fz S 5 H ES T Ez a 6 MM 36 RED E RED 27 AUXILIARY CONTROL LI eun RELAY COIL NO E 2 Se 5 e Sei os E k 2 2 E 5 8 5 5 RED 5 x i 8 8 LIFT PUMP e x 1 P xo GRNIWHT CONTACTOR RELAY NM e CR20 EN T E eh 1 1 Ji ORG RED 48V paw LIFT PUMP ORGRED D n i s 4 CONTACTOR COIL 5 2 lt 8 5 PR3 8 Ss AUXILIARY PUMP i Bete hae Pee persed senaman m 4 rem 6 E GRN WHT 3 GRN WHT SL CONTACTOR COIL N ses ou pu 9 8 z p DEN my Li 3 5 8 BE oe 9 toe Stee WHT RED 6 7 PROPORTIONAL aie 5 Es COIL 5 E ka 1 X z a z re 2 8 aSa E 5 E 1 x gt 2 1 1 E 2 E 2
19. 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 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 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 REV B 5 Open the hydraulic tank side turntable cover 6 Tag and disconnect the power cables on the auxiliary power unit AWARNING Electrocution hazard Contact with electrically charged circuits could result in death or serious injury Remove all rings watches and other jewelry 7 Close the hydraulic tank shutoff valve Tag and disconnect and plug the hydraulic hose from the hydraulic tank shutoff valve AWARNING ace injury hazard Spraying ydraulic 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 8 Open the valve on the hydraulic
20. AWARNING 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 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 AWARNING 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 Genie Z 30 20N Part No 106373 April 2005 Section 4 Repair Procedures REV B 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 AWARNING 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
21. 1 EZoz z ami o EE EE EE L E 5 ORG BLK 1 i amp 2 r a 5 ORG 1 1 o d 2 8 gt E 4 In EN g g un gt TD 5 ed ior tte 238 Wi EB GRN 1 x5uz GRN BLK 1_ i II qe eS EE GE SSS 5 i PLATFORM LEVEL m m 5 5 a9 B RED 6 CUTOUT 1 B M RELAY COIL az 72221 4 d 5 uU I miii 7 2 11 GRN BLK 3 a B GRN 3 E PLATFORM LEVEL 2 3 9 1 T DT UP COIL 3 LH PLATFORM LEVEL a Sa DOWN COIL ozi EIE eee eme 3 551 IV JE 252 zo Bn 525 B 229 ORG 3 1 6 mt ORG BLK 3 BLK 7 PRIMARY BOOM rn EXTEND COIL BLKANHT 8 PRIMARY BOOM RETRACT COIL WI i E 32 5 0 208 BLK 3 a aga 1 BLK WHT 3 a RED 1 PRIMARY BOOM IB UP COIL RED BLK 2 PRIMARY BOOM DOWN COIL in I in RED 3 al 7 0 RED BLK 3 220 SECONDARY F i BLU 0 BOOM UP COIL I B SECONDARY i m L BLUBLK 1 BOOM DOWN E COIL 8 2 1 ce 1 2 x 1 DESCENT D IO ALARM B9 p Bi OPTION oa eee Seen a e mte 225 5152
22. Refer to the machine serial plate Part No 106373 Genie Z 30 20N Section 3 Scheduled Maintenance Procedures April 2005 CHECKLIST C PROCEDURES 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 Ibs 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 W Result If the alarm does not sound 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 9 REV Carefully move the test weights to each remaining location in 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
23. 20N Section 3 Scheduled Maintenance Procedures April 2005 Checklist A Procedures 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 REV B 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 Genie Z 30 20N Part No 106373 April 2005 Section 3 Scheduled Maintenance Procedures REV 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
24. 4 41 A Motor Controller 10 1 Motor Controller gees eee citet tta nd ase eee 4 42 viii Genie Z 30 20N Part No 106373 March 2006 TABLE OF CONTENTS Section5 Rev Fault Codes lueft e 5 1 cece usin eege Dee tuae ts 5 3 Section6 Rev Schematics duet e 6 1 A Sensor Option Diagram before serial number 6290 6 2 A Electrical Symbols Legend asc cete 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 Electrical Schematic before serial number 6290 6 7 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 8 6 15 LS Kee 0 6 1
25. Manual on your machine Be sure that all necessary tools and test equipment are available and ready for use H Be aware of the following hazards and follow generally accepted safe workshop practices ADANGER Crushing hazard When testing or replacing any hydraulic component always support the structure and secure it from movement AWARNING Electrocution hazard Contact with electrically charged circuits could result in death or serious injury Remove all rings watches and other jewelry AWARNING 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 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 ADANGER 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
26. Part No 106373 April 2005 Section Scheduled Maintenance Procedures Checklist C Procedures REV 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 Genie specifications require that this procedure be performed every 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
27. 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 AWARNING Bodily injury hazard Batteries contain acid Avoid spilling or contacting battery acid Neutralize battery acid spills with baking soda and water AWARNING 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 Puton 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 9 REV Remove the battery box cover retaining fasteners Remove the battery box cover Be sure that the battery cable connections are free of corrosion Be sure that the battery retainer and cable connections are tight 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 Check the battery acid level of the battery If need
28. WHT RED 3 BRN RED BLK GRN BLK GRN BLK 3 GRN 3 WHT TS11 U GRN 1 TS8 GRN WHT 3 GRN BLK 1 RED BLK 3 RED 3 ee ORG BLK 3 BLK WHT 3 BLK 3 BLU RED 3 WHT RED RED ORG RED RED NO P3 NC NC WHT P2 BCI OPTION BLU BLK 1 RED BLU 1 WHT FS WHT 1 WHT BLK 1 WHT RED 1 12134151617 819110 RED WHT 1 RED WHT 3 ORG RED 1 BLK FS BLK 2 BLK RED 3 RED 1 BLUE JIB ORG JIB WHT JIB BLK JIB YEL JIB RED JIB JIB ROTATE OPTION REMOVE JUMPER JP1 FOR CE VERSION NOTE gt Genie Z 30 20N 6 14 Part No 106373 April 2004 Section 6 Schematics TEE Platform Control Box Wiring Diagram after serial number 6289 April 2004 Section Ge Schematics E Power Panel Wiring Diagram
29. and plug the hydraulic hoses from the jib boom rotator Cap the fittings on the rotator manifold AWARNING 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 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 AWARNING 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 AWARNING 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 Section Ae Repair Procedures April 2005 JIB BOOM COMPONENTS 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
30. 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 Test all machine functions from the platform controls Result All platform control functions should not operate 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 Section 3 Scheduled Maintenance Procedures REV CHECKLIST PROCEDURES 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 12 Test all machine functions from the ground controls Result All ground control functions should operate normally 13 Turn the key switch to platform control 14 Test all machine functions from the platform controls Result All
31. box Secondary Boom AWARNING 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 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 Remove the counterweight cover 2 Place a suitable lifting device under the platform for support Disconnect the battery packs from the machine Remove the cable cover from the side of the jib boom 5 Remove the wire loom from the cables at the platform control box 8 Tag and disconnect each wire from the cables in the platform control box AWARNING Electrocution hazard Contact with electrically charged circuits could result in death or serious injury Remove all rings watches and other jewelry 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
32. 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 Q resistor or the coil of a 24V DC relay between the B and B terminals of the motor controller Hold for approximately 5 10 seconds AWARNING Electrocution hazard Contact with electrically charged circuits could result in death or serious injury Remove all rings watches and other jewelry REVA 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 Ch
33. 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 AWARNING 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 Part No 106373 Genie Z 30 20N 4 21 Section Ae Repair Procedures April 2005 SECONDARY BOOM COMPONENTS 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 AWARNING 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 19 Lower the secondary bo
34. 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 AWARNING 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 SECONDARY BOOM COMPONENTS 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 AWARNING 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 Section Ae Repair Procedures April 2005 SECONDARY BOOM COMPONENTS 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 AWARNING P Cdily injury hazard This
35. 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 AWARNING 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 REV How to Adjust the Primary Boom Down Relief Valve Perform this procedure with the boom in the stowed position 1 Connect a 0 to 3000 psi 0 to 200 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 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 counte
36. function manifold is locate behind the ground controls turntable cover Index Schematic No Description Item Function Torque 1 Solenoid valve 3 position 4 way Platform level up down 20 25 ft lbs 27 34 Nm 2 Counterbalance valve B sue Platform level down 20 25 ft lbs 27 34 Nm 3 Counterbalance valve Platform level up 20 25 ft lbs 27 34 Nm 4 Relief valve 1100 psi 75 8 bar Das Turntable rotate left right 30 35 ft lbs 41 47 Nm 5 Relief valve 1600 psi 110 bar Secondary boom down 20 25 ft lbs 27 34 Nm 6 Relief valve 1600 psi 110 bar Eus Primary boom down 20 25 ft lbs 27 34 Nm 7 Relief valve 1800 psi 124 bar ones Primary boom extend 20 25 ft lbs 27 34 Nm 8 Proportional solenoid valve Bl os System flow regulating circuit 30 35 ft lbs 41 47 Nm 9 Check valve Brake circuit seus 10 12 ft lbs 14 16 Nm 10 Solenoid valve 3 position 4 way Jess Steer left right 20 25 ft lbs 27 34 Nm 11 Solenoid valve 3 position 4 way conu Primary boom extend retract 20 25 ft lbs 27 34 Nm 12 Pressure switch
37. level surface Boomin 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 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 ADANGER Used to indicate the presence of an imminently hazardous situation which if not avoided will result in death or serious injury AWARNING Used to indicate the presence of a potentially hazardous situation which if not avoided could result in death or serious injury ACAUTION 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 presence of a potentially hazardous situation which if not avoided may result in property damage CAUTION 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
38. 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 CAUTION hydraulic tank is plastic and may become damaged if the tank mounting fasteners are over tightened CHECKLIST E PROCEDURES 13 Install the hydraulic hoses 14 Fill the tank with hydraulic oil until the fluid is within the FULL and App 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 CAUTION Component damage hazard Be sure to open the hydraulic tank shutoff valve after installing the hydraulic tank Part No 106373 Genie Z 30 20N Section 3 Scheduled Maintenance Procedures April 2005 CHECKLIST E PROCEDURES 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 condit
39. 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 There may be an approximate 2 second delay before the overload indicator light turns on and the alarm sounds The platform will need to be moved up and down and allowed to settle in between adjustments CHECKLIST D PROCEDURES Confirm the setting 5 Turn the key switch to platform control Lift the test weight off the platform floor using a suitable lifting device 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 Add an additional 10 Ib 4 5 kg test weight to the original test 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 There may be an approximate 2 second delay before the overload indicator light turns on and the alarm sounds Test all machine functions from the platform controls Result All platform control functi
40. 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 AWARNING ud injury hazard Spraying ydraulic 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 Bodily injury hazard Beware of ACAUTION hot oil Contact with hot oil may cause severe burns Genie Z 30 20N Part No 106373 April 2005 Section 3 Scheduled Maintenance Procedures REV 5 Tag disconnect and plug the hydraulic hoses from the hydraulic tank return filter housing Cap the fittings on the filter housing AWARNING a injury hazard Spraying ydraulic 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 Bodily injury hazard Beware of ACAUTION hot oil Contact with hot oil may cause severe burns 6 Remove the hydraulic tank mounting fasteners Remove the hydraulic tank from the machine 7 Remove the tank
41. off the ground CHECKLIST B PROCEDURES Inspect the turntable center area for burnt chafed and pinched cables Lower the boom to the stowed position and turn the machine off 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 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 REV B 4 Check the Tires and Wheels including lug nut torque Maintai
42. on each non steer wheel hub disengaged position EN EN u engaged position Part No 106373 Genie 7 30 20 3 21 Section 3 Scheduled Maintenance Procedures April 2005 CHECKLIST D PROCEDURES 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 AWARNING C ushing 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 Section 2 Specifications E 4 O 5 7 NS ox 0 20 0 5 12 0 26 O 6 3 T 8 Bolt torque sequence REV B 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 Bolt torque sequence
43. platform control functions should operate If the platform overload system is not operating properly see D 6 Calibrate the Platform Overload System Part No 106373 Genie Z 30 20N 3 19 Section 3 Scheduled Maintenance Procedures April 2005 Checklist D Procedures REV B D 1 Models without rotating jib boom Check the Primary Boom Primary boom wear Wear Pads pad specifications New Minimum Top and side wear pads 3 4 inch 5 8 inch extension end of boom 19 mm 15 9 mm Maintaining the primary boom wear pads in good Bottom wear pads 3 4 inch 5 8 inch condition is essential to safe machine operation extension end of boom 19 mm 15 9 mm Wear pads are placed on boom tube surfaces to SCH SE provide a low friction replaceable wear pad Bottom 2 wear pads 4 inch s inch between moving parts Improperly shimmed wear pivot end of boom pads or continued use of worn out wear pads may se dna result in component damage and unsafe operating 1 1 pi B Bi conditions i 1 Measure each wear pad Replace the wear pad Models with rotating jib boom once it reaches the minimum allowable thickness If the wear pad is still within em b specifications shim as necessary to obtain ibd NUM minimum clearance with zero binding P P 2 Extend and retract the primary boom through All wear pads 1 2 inch 3 8 inch 12 7 mm 9 5 mm the entire range of motion to check for tight spots that could caus
44. series of steps Part No 106373 Genie Z 30 20N 3 1 Section 3 Scheduled Maintenance Procedures April 2005 SSS SSS SSS SY SCHEDULED MAINTENANCE PROCEDURES Maintenance Symbols Legend Maintenance Schedule The following symbols have been There are five types of maintenance inspections used in this manual to help that must be performed according to a schedule communicate the intent of the daily quarterly six months annual and two year instructions When one or more of The Scheduled Maintenance Procedures Section the symbols appear at the and the Maintenance Inspection Report have been beginning of a maintenance divided into five subsections A B C D and E procedure it conveys the meaning Use the following chart to determine which below group s of procedures are required to perform a scheduled inspection Indicates that tools will be required to Inspection Checklist perform this procedure E Daily or every 8 hours A A Indicates that new parts will be required Quarterly or every 250 hours A B BEES procedure Six months or every 500 hours A B C Annual or every 1000 hours A B C D Indicates that a cold motor or pump will e be required to perform this procedure Two year or every 2000 hours A B C D E Indicates that dealer service will be Maintenance trispecuoh Mapari M required to perform this procedure The maintenance inspection report contains checklists for each type of scheduled inspection Make copies of
45. size Brake Double acting cylinder Pump prime mover motor c Sal Pressure switch Fixed displacement pump Solenoid operated dump valve 2800 psi 193 bar Relief valve with pressure bosa 1100 psi 75 8 bar Dual relief valve with pressure 25 psi 1 7 bar 5 lt gt Filter with by pass 1 x Solenoid operated 3 position 4 way directional valve 3000 psi 207 bar 3 1 Counterbalance valve Differential sensing valve AML Solenoid operated proportional valve Solenoid operated 2 position 3 way directional valve BOE Normally closed poppet valve REVA ior Normally open poppet valve 1 5 5 7 L min Flow regulator valve Genie Z 30 20N Part No 106373 April 2004 Section Ge Schematics a Power Cable Diagram before serial number 6290 Section 6 Schematics April 2004 Power Cable Diagram before s
46. speed controller specifications Threshold 0 28A controller turned to CREEP Max out 0 65A controller turned to 9 Ramp rate 2 seconds Part No 106373 Genie Z 30 20N Section Ae Repair Procedures April 2005 Platform Components 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 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 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 REV B 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 cyl
47. tank and drain the oil into a container of suitable capacity Refer to Section 2 Specifications Bodily injury hazard Beware of ACAUTION hot oil Contact with hot oil may cause severe burns 9 Tag disconnect and plug the hydraulic hose from the hydraulic tank return filter housing Cap the fitting on the filter housing AWARNING 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 Bodily injury hazard Beware of ACAUTION hot oil Contact with hot oil may cause severe burns Genie Z 30 20N Part No 106373 April 2005 Section Ae Repair Procedures REV 10 Remove the hydraulic tank mounting fasteners Remove the hydraulic tank from the machine 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 Do not disconnect the wiring 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
48. 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 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 4 12 Genie Z 30 20N Part No 106373 April 2005 Section Ae Repair Procedures REV B How to Remove the Primary Boom AWARNING P dily 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 Perform this procedure with the boom in the stowed position 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 1 Remove the platform 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 S
49. to dissipate gradually Do not allow oil to squirt or spray 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 barrel ACAUTION end 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 AWARNING Cushing hazard The primary boom lift cylinder will fall if not properly supported when it is removed from the machine PRIMARY BOOM COMPONENTS 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 How to Remove the Extension Cylinder AWARNING P dily 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 compon
50. to the maintenance checklists for continued scheduled maintenance 1 Perform the following maintenance procedures 4 Grease the Turntable Rotation Bearing and Worm Drive Gear B 4 Check the Lug Nut Torque including the tires and wheels 3 Check the Turnable Rotation Bearing Bolts D 5 Replace the Hydraulic Tank Return Filter Element CHECKLIST A PROCEDURES 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 8 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 Part No 106373 Genie Z 30 20N 3 7 Section 3 Scheduled Maintenance Procedures March 2006 Checklist B Procedures B 1 Check the Batteries
51. z gu 25 02 Fea i i k F4 ORG RED z ORG RED 1 5 48V DC p POWER RELAY REDWHT 7 8 5 48V DC POWER a RELAY RED WHT wo RED WHT 3 Ir 5 2 m EN 2 5 RED BLK 28 d RED BLK 1 ri i BLK BRN TILT 5 ENSOR RED WHT 23 RED i EI 7 B 1 E 1 i ace FLASHING o 1 e pee VA BEACON 8 t E BEACON ch ES REA 1O WA E WHT 2 TP 2 Joe ll lll ibo x b 10 a T Y ELAY Seu i BLK RED CR4 eo 5 i miens pote i ME d i E BLK RED Com HORN ER 22 7 mM Y i Bl 2 2 B g 5 T 5 P d E BLK 7 WHT 7 F z 6 BLK 6 4 8 SS WHT8 g WHT E E iE ada SEES EER 0 iva E 53 i d E d 8 CONTROLLER elal a ORG
52. 00 OE 3000 psi 3200 psi 2500 psi 172 bar 1 207 221 bar 172 bar 3000 psi 3 1 3 1 3 1 N O 207 bar before serial after serial ne 1 51 number 6462 number 6461 EE Zeg Zeg S AUXILIARY PRIMARY Pil 1 0 BRAKE Ex 2 1 12 5 TR2 SC1 SC2 2 EXT RET EO 0 5 gpm 2 1 gpm 2800 psi RES g SET _ LIU LIES rn 1 89 L min 7 95 Limi 193 bar 045 k 5 psi 1 MA DE T eL HxH E 4 OT 1 8 oe 7 t i 1600 psi i i Ge oM 1 MUX 2 on Se zat ES 8 0 el E m T X T C ES 1 1 1 cor nur y ER jh HAIX 10 MICRON 100 MESH AM 60 0 8 gpm 9 1 5 5 7 Umin X 8 HYDRAULIC RESERVOIR 4 H H w i i 4 rP FUNCTION MANIFOLD DOS inch Haste added after serial number 5396 Part No 106373 Genie Z 30 20N 6 16 April 2004 Section 6 Schematics SSRIS Hydraulic Schematic Genie North America Phone 425 881 1800 Toll Free USA and Canada 800 536 1800 Fax 425 883 3475 Genie Holland Phone 31 7051 78836 Fax 31 70 51 13993 Genie Australia Pty Ltd Phone 61 7 3375 1660 Fax 61 7 3375 1002 Genie Scandi
53. 2 5 5 8 AP AP2 1 H RED 2 5 NIV DC 3 DIODES ke AUXILIARY PUMP E M CONTACTOR PRIMARY LIFT 5 100A CONTACTOR 6 PUMP CONTACTOR PR2 PR1 MOTOR CONTROLLER NOTES 9 WIRE GAUGE NOTED IN PARENTHESES AFTER 7 WIRE COLOR RED 10 40 DO NOT ROUTE POWER CABLES ACROSS FRONT OF MOTOR CONTROLLER DOING SO CAN AFFECT INTERNAL CURRENT SENSORS RIGHT SIDE CAUSING REDUCED MOTOR PERFORMANCE BLK 2 DRIVE MOTOR 8 F2 0 7 d 1 2 1 LEFT SIDE P p BLK 2 BLK 2 T DRIVE MOTOR 119 A1 A2 RED 10 Part No 106373 Genie Z 30 20N 6 6 April 2004 Section 6 Schematics Power Cable Diagram after serial number 6289 April 2005 Section 6 Schematics Electrical Schematic before serial number 6290 REV B Al 216 1 8 SG z Z a 8 E 1 EN 1 5 gg 508 E gr 8 oig D os 5 5 5 g jE B 5 8 HS pe
54. 35 1044 12 530 718 710 962 750 1016 990 1542 7139 1749 1477 12 670 908 890 1206 1080 1464 1440 1952 1220 1654 id 2074 2304 ost aso 3620 2 1640 2067 METRIC FASTENER TORQUE CHART This chart is to be used as a guide only unless noted elsewhere in this manual Size Class 4 6 Class 8 8 Class 10 9 03 Class 12 9 mm Y 5 6 Si 9 N alo o o 110 120 150 170 210 240 380 420 DR DRY B84 68 775 91 103 i32 15 116 132 155 1756 DRY DRY 2 125 8i 110 108 147 830 78 1055 682 925 909 1233 d iv 1 ile d el 1 ile ER d c i d i 1 D A 91 NJ a CO N O1 of o E oO j N m ol a oo c D 8 y lt D 8 lt D i r D i A A A 0 N ole N n go CO l d s AR po Oy co APY OINI SIN n ofja ajo olo e T A T um Gool Mal Ay 9 gt ALA ol m AR N A A e A e A A o A Em o E
55. 4 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 AWARNING 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 AWARNING C shing hazard The primary boom assembly could become unbalanced and fall when removed from the machine if not properly supported by the overhead crane Genie Z 30 20N Part No 106373 April 2005 Section 4 Repair Procedures REV B 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 th
56. 6 Part No 106373 Genie Z 30 20N ix April 2005 SSS This page intentionally left blank x Genie Z 30 20N Part No 106373 March 2006 Section 2 Specifications REV Machine Specifications Tires and wheels Tire size solid rubber 22 x7 18 4 in 56 x 18 x 47 cm Specifications Performance Specifications Drive speed maximum Stowed position 3 3 mph 5 3 km h 40 ft 8 3 sec Load range 7600 lbs 12 2 m 8 3 sec 3447 kg Boom raised or extended 0 6 mph Tire contact area 35 sq in 1 km h 226 sq cm 40 ft 44 sec Overall tire diameter 22 in 12 2 44 sec 96 cm Braking distance maximum Wheel diameter EH High range on paved surface 2 to 4 ft 47 cm 0 6 to 1 2m Wheel width Tin Gradeability See Operator s Manual 18 cm Wheel lugs Boom function speeds maximum from platform Front 8 6 58 18 controls with rated load secured to platform Rear 9 5 8 18 Jib boom up 26 to 32 seconds Lug nut torque dry 125 ft lbs 169 5 Nm Jib boom down 23 to 29 seconds Lug nut torque lubricated 94 ft lbs Jib boom rotate 200 127 4 Nm before serial number 8333 12 to 18 seconds Fluid Capacities Jib boom rotate 180 after serial number 8332 12 to 18 seconds Hydraulic tank capacity 4 gallons 15 1 liters Primary boom up 14 to 22 seconds Hydraulic system capacity 6 gallons Primary boom down 12 to 20 seconds including tank 22 7
57. AKER CONTROLS RETURN 10 J1 BRAKE RELEASE JACK CONTROL RELAY LD SPARE WIRE LIST OPTION NUMBERS HM HOURMETER 8 SECONDARY 48V DC POWER BLK 1 1 PLATFORM LEVEL CUTOUT CH CHASSIS HARNESS CR2 PRIMARY 48V DC POWER BLK WHT 1 2 FLASHING BEACON MH MANIFOLD HARNESS AUXILIARY PUMP BLK RED 1 3 DESCENT ALARM SP SWITCH PANEL CR4 HORN BLU WHT 1 CR CONTROL RELAY CR5 BRAKE RELEASE BLU RED 1 A2 BRAKE RELEASE TRAVEL ALARM CR10A PLATFORM LEVEL CUTOUT CE ONLY GRN WHT 1 DESCENT ALARM OPTION CR10B PLATFORM LEVEL CUTOUT CE ONLY L3 CONTROLLER STATUS LED Genie Z 30 20N Part No 106373 RED WHT BRN A2 SWITCH PANEL WHT BLK 19D 48D BRN 52A HM 1 4 CB1 RED CH 1 11 ksi e TS51 S fe RED WHT 48A MA cl le WHT 23A BLK 22A RED v v RED 27A ORG BLK 15A BLK 7A BLK WHT 8A WHT RED 6A ORG BLK47A TS59 ORG BLK 47A pee ORG 46A Oud ORG 14A GRN BLK 18A GRN WHT 19A 4 TS61 um GRN BLK 44A 5 ges GRN 43A 558 LAR RED BLK 2A OU 99 0905 RED 1A GRN 17A WHT BLK 5A WHT 4A P i CHa QUO BLU BLK 11A BLU 10A
58. D GENINHT TSC 1 BRN 5 BRN 2 52 BRN MH BRN SP GROUND a A WHT 6 WHT 8 50 LS2 LS4 JUNCTION 4 0 H PEN BLK 7 BLK 6 49 LS1 LS2 JUNCTION REDWHT TBSD 1 WHT BLK SP RED WHT CR5 48 RED WHT MH_ RED WHT SP BRAKE RELEASE mE TE WT BLRED HORN ORG BLK 1 47 ORG BLK SP JIB BOOM ROTATE RIGHT ORG RED 42D RED CH_ BLK RED 9D ORG 1 46 ORG SP JIB BOOM ROTATE LEFT GRN BLK 1 44 GRN BLK SP JIB BOOM DOWN RED WHT 48C ORG MH ORG BLK MH 2 GRN 1 43 GRN SP JIB BOOM UP 6 L fa me ORG RED CR1 ORG RED 1 42 ORG RED CH ORG RED L3 SWITCHED 48V DC D SUL BLK 8 40 ORG CH OFF LIMIT SPEED ORGIRED 164 h 4 BLU BLK 19D BLU BLK 1 37 BLU BLK MH STEER RIGHT K BLU 19D BLU 1 36 BLU MH STEER LEFT WHT RED 1 32 WHT RED CH JOYSTICK POT LOW NIME E WHT BLK 1 31 WHT BLK CH DRIVE REVERSE nao WHT 1 30 WHT CH DRIVE FORWARD C ORG BLK 3 15 ORG BLK CR10B ORG BLK SP PLAT LEVEL DOWN 3 RED WHT 1 29 RED WHT CH 2 WIRE POT ORG 3 14 ORG CR10A ORG SP PLAT LEVEL UP WHT TILT RED BLK 1 28 TILT ALARM S RED CR3 RED 1 27 RED SP AUXILIARY PUMP SELECT PLATFORM LEVEL CUTOUT CE VERSION ONLY OPTION 2 23 KEY SWITCH POWER RED TILT WHT 2 23 WHT SP KEY SWITCH POWER WHT 7 BLK 2 22 BLK CR4 BLK SP 24V DC TO PLATFORM TB36 TB37 GRN WHT CR3 19 GRN WHT MH Wl LIFT PUMP 4 WHT BLK SP GRN WHT 3 19 GRN WHT SP LIFT PUMP GRN BLK 3 18 GRN BLK SP PLATFORM ROTATE RIGHT GRN 3 17
59. E BLU BLK 3 gt 8 TURNTABLE WHT BLK 5 4 ROTATE RIGHT Fa ER COIL WHT 4 14 TURNTABLE ROTATE LEFT COIL gu E WHT BLK 3 Fa WHT 3 i 5 d i 5 8 28 E a a amp 5 E at Sjo gt gt Z x I k I 65 5 8 6 6 10 Genie 7 30 20 Part 106373 April 2005 Section 6 Schematics Electrical Schematic after serial number 6289 Section 6 Schematics April 2004 BEER Ground Control Panel Wiring Diagram before serial number 6290 Section 6 Schematics April 2004 Ground Control Panel Wiring Diagram before serial number 6290 A B D E F G H BRN CB2 BLK OPTION 2 52 BRN CH BRN CR4 GROUND ORG RED CH RED27
60. ETRACT COIL PRIMARY BOOM UP COIL PRIMARY BOOM DOWN COIL SECONDARY BOOM UP COIL SECONDARY BOOM DOWN COIL DESCENT TS10 Boom WHT BLK 3 4 TBS WHT BLK 5 WHT 4 WHT 3 4 5 ORG RED 1 ORG RED RED WHT 1 WHT BLK 1 E D E 5 BLU WHT 12 RED RED GND GND OPTION TURNTABLE ROTATE RIGHT COIL TURNTABLE ROTATE LEFT COIL BLK 24V DC BRN PR3 AUXILIARY PUMP CONTACTOR COIL Genie Z 30 20N Part No 106373 April 2005 Section 6 Schematics SSS Electrical Schematic before serial number 6290 Section 6 Schematics April 2005 z H Mc n Electrical Schematic after serial number 6289 REV A B C D E F G H J K L M N 5 BL WH 1 TB134 P2 FS1 BLK 2 BLK FS
61. G BLK SP JIB RIGHT ORG 1 46 ORG SP JIB LEFT GRN BLK 1 44 GRN BLK SP JIB DOWN g GRN 1 43 GRN SP JIB UP 2 6 ORG RED CR1 ORG RED 1 42 ORG RED CH ORG RED L3 SWITCHED 48V 2 O O BLK 8 40 ORG CH OFF LIMIT SPEED O HW BLU BLK 19D_ BLU BLK 1 37 BLU BLK MH STEER RIGHT GRN BLK K BLU 19D BLU 1 36 BLU MH STEER LEFT WHT RED 1 32 WHT RED CH JOYSTICK POT LOW WHT BLK 1 31 WHT BLK CH REVERSE WHT 1 30 WHT CH FORWARD WHT BLK 19D 48D i HM RED WHT 1 29 RED WHT CH 2 WIRE POT BRN 52A 1 RED BLK TILT RED BLK 1 28 TILT ALARM P1 RED CR3 RED 1 27 RED SP AUXILIARY PUMP SELECT aa 1 ONCO 26 LIFT LOCKOUT ONCO 3 25 BATTERY LIGHT ONCO ONCO 24 TRACTION CONTROL 23 WHT 7 BLK C23 4 22 BLK CR4 BLK SP 24V TO PLATFORM CBI TB36 TB37 GRN WHT CR8 19 GRN WHT MH Kl LIFT PUMP CBT 7 2 19 GRN WHT SP RED CH KS1 wHT BLK SP GRN WHT 3 LIFT PUMP SWITCH PANEL TS51 GRN BLK 3 18 GRN BLK SP PLAT ROTATE RIGHT Kou GRN 3 17 GRN SP PLAT ROTATE LEFT RED 5 ORG RED 3 16 ORG RED CR5 DRIVE ENABLE J1 NONO i ORG BLK 3 15 ORG BLK MH ORG BLK SP PLAT LEVEL DOWN L45 4 i olo 7 ORG 3 14 ORG MH ORG SP PLAT LEVEL UP i WHT 5 BLU RED 3 13 DRIVE ENABLE LIGHT RED m BLK 5 BLU WHT 3 12 BLU WHT CH FOOTSWITCH BL K A i BLU BLK 3 11 BLU BLK MH BLU BLK SP SEC BOOM DOWN RED 27A i BLU 3 10 BLU MH BLU SP SEC BOO
62. GRN SP PLATFORM ROTATE LEFT RED 5 ORG RED 3 16 ORG RED CR5 DRIVE ENABLE TILT SENSOR ORG BLK 3 15 ORG BLK MH ORG BLK SP PLATFORM LEVEL DOWN WIRED ORG 3 14 ORG MH ORG SP PLATFORM LEVEL UP 5 BLU RED 3 13 DRIVE ENABLE LIGHT BLK 5 BLU WHT 3 12 BLU WHT CH FOOTSWITCH 5 BLU BLK 3 11 BLU BLK MH BLU BLK SP SECONDARY BOOM DOWN CB2 L3 BLU 3 10 BLU MH BLU SP SECONDARY BOOM UP C Lane ap BLK CH BLK RED CR4 BLK RED 3 9 HORN LI J M BLK WHT 3 8 BLK WHT MH BLK WHT SP BOOM RETRACT BAN CH ORG REDH2A BLK 3 7 BLK MH BLK SP BOOM EXTEND WHT RED 3 6 WHT RED MH WHT RED SP BOOM FUNCTION FLOW CONTROL JIB ROTATE WHT BLK 3 5 WHT BLK MH WHT BLK SP TURNTABLE ROTATE RIGHT OPTION WHT 3 4 WHT MH WHT SP TURNTABLE ROTATE LEFT 6 RED WHT CR1 RED WHT 3 3 48V DC RELAY COIL POWER T m RED BLK 3 2 RED BLK MH RED BLK SP PRIMARY BOOM DOWN oi TEMEFGENCYSTOBBUTTON RED 3 1 RED MH RED SP PRIMARY BOOM UP KEY SWITCH TS51 AUXILIARY TOGGLE SWITCH D C B A TS55 FUNCTION ENABLE TOGGLE SWITCH TS57 PLATFORM ROTATE TOGGLE SWITCH TS58 JIB BOOM UP DOWN TOGGLE SWITCH TS59 PLATFORM LEVEL TOGGLE SWITCH 7 TS60 SECONDARY BOOM UP DOWN TOGGLE SWITCH TS61 PRIMARY BOOM UP DOWN TOGGLE SWITCH P SEE OPTIONAL WIRING TS62 TURNTABLE ROTATE TOGGLE SWITCH TS63 BOOM EXTEND RETRACT TOGGLE SWITCH JIB BOOM ROTATE OPTION TS66 JIB BOOM ROTATE TOGGLE SWITCH OPTION 1 CIRCUIT BREAKER CONTROLS 10 2 CIRCUIT BRE
63. M UP ORG BLK 15A i BLK RED CR4 BLK RED 3 9 HORN BLK 7A BLK WHT 3 8 BLK WHT MH BLK WHT SP BOOM RETRACT BLK WHT 8A TS59 BLK 3 7 BLK MH BLK SP BOOM EXTEND 5 WHIREDGA M S TS63 1566 T963 WHT RED 3 6 WHT RED MH WHT RED SP BOOM FUNCTION F C JIB ROTATE OBG BLK 47A rn WHT BLK 3 5 WHT BLK MH WHT BLK SP TURN ROTATE RIGHT OPTION ORG 46A LO WHT 3 4 WHT MH WHT SP TURN ROTATE LEFT Ze eee VIDI RAE 5 RED WHT CR1 RED WHT 3 3 48V RELAY COIL PWR ER us RED BLK 3 2 RED BLK MH RED BLK SP PRIMARY BOOM DOWN ORG 14A bou RED 3 1 RED MH RED SP PRIMARY BOOM UP GRN BLK 18A 8 1 GRN WHT 19A TS61 TS57 ORG D B A GRN BLK 44A OD O O SEE OPTIONAL WIRING O 0 O 0 JIB ROTATE OPTION GRN 43A 1898 RED BLK 2A OU 9 i RED 1A ORG 1 alee SS SE TS62 6 TS62 SERR EIS WHT 4A FL 6 S 5 8 B O DQ 0 ee b 5 5 a0 0 L R i I MOX o BLU BLK 11A 0 LS ORG RED CH RED 27D SENT TOO RED C23 7 GRN WHT CH BLK 22B LABEL DESCRIPTION BLU 10A A2 BRAKE RELEASE TRAVEL ALARM 1 1 2 3 4 H 6 6 6 V A3 DESCENT ALARM OPTION RED WHT TB3D BRN 52A 113 4 5 6 7 8 12 A6 PLATFORM OVERLOAD ALARM CE MODELS _ CB1 CIRCUIT BREAKER C
64. M png 1 ie t 1 gy SZ 0 025 inch X Kaes 0 635 mm X PLATFORM LEVELING 00 08 gpm 4 SLAVE 1 14 L min l EXTENSION CYLINDER EXTENSION CYLINDER JIB BOOM MANIFOLD ee WITH PRIMARY BOON ROTATING JIB BOOM ROTATING JIB BOOM SECONDARY BOOM i i CYLINDER CYLINDER STEER CT e pen 5 9 mm 1 1 BRAKES CYLINDER gt M V At 2 9 TURNTABLE ROTATE CH iP 3 Il s A MOTOR ee IMS 4 pd 5 9 cu in rev Wf i l MASTER TUS X HE v q Eo o Bul i FT eT 5 6 i 25
65. N LOE 14 ORG CR10A ORG SP PLAT LEVEL UP a BRN 52D Ska en BLK CH TS62 TURNTABLE ROTATE TOGGLE SWITCH 1 ORG 3 CR10 5 S TS63 BOOM EXTEND RETRACT TOGGLE SWITCH L ES APEERE EI 40 EC 0000002 i 242 TS66 JIB BOOM ROTATE TOGGLE SWITCH OPTION PLATFORM LEVEL CUTOUT CE MODELS ONLY BRN CH ORG RED 42A U33 PLATFORM OVERLOAD MODULE CE MODELS Part No 106373 Genie Z 30 20N 6 12 April 2004 Section 6 Schematics es Ground Control Panel Wiring Diagram after serial number 6289 Section Ge Schematics April 2004 eee Platform Control Box Wiring Diagram before serial number 6290 April 2004 Section 6 Schematics Platform Control Box Wiring Diagram before serial number 6290 REVA el 5 z o Ex 5 z S 8E B E g 4 errr Bas 445819118 ss cy 5 2355 Y 352 z al 95 E al El lt x sl 815 E uc SIE 844526256509 onnan 5 r Sjal Su giS 2565 56 8 5 28555 5 SE 8 58 955355 6 5 6 345256 216 6 5 5 a t a 56 S F oa mg 5 8 95 RR R E amp 8 zu
66. No 106373 March 2006 Section 2 Specifications REV Manifold Component SPECIFICATIONS Machine Torque Specifications Specifications Platform rotator and jib boom rotator Z 30 20NRJ Plug torque 1 8 center bolt GR 8 480 ft lbs SAE No 2 36 in Ibs 4 Nm 3 g SAE No 4 10 ftbs 13Nm 2 16 bolts GR 8 5 60 Nm SAE No 6 THES 19 Nm Turntable rotate bearing PES S8 MIDS Rotate bearing mounting bolts lubricated 180 ft lbs SAE No 10 41 ft lbs 55 Nm 244 Nm SAE No 12 56 ft lbs 76Nm Drive hubs brakes and motors Drive hub mounting bolts lubricated 180 ft lbs 244 Nm Valve Coil Resistance Specification Brake mounting bolts lubricated 93 ft lbs Description Specification 126 Nm Solenoid valve 3 position 4 way 20V DC 220 Drive motor mounting bolts 31 ft lbs schematic items A J K U V Y AA BB and CC 42 Nm Proportional solenoid valve 24V DC 19 50 schematic item Solenoid valve N C poppet 20V DC 23 5 schematic item M Solenoid valve N O poppet 20V DC 23 50 schematic item Part No 106373 Genie Z 30 20N 2 3 Section 2 Specifications March 2006 SPECIFICATIONS 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 n
67. ONTROLS 10A 0 BLK RED HORN O O CB2 CIRCUIT BREAKER CONTROLS RETURN 10A 7 i 23 Nee CHASSIS HARNESS ORG RED 42D RED CH BLK RED 9D CR CONTROL RELAY DESCENT ALARM WIRING OPTION HOURMETER eee 2 al r n c c M DE cR E ES M GU ee J1 BRAKE RELEASE JACK RED WHT 48C ORG MH ORG BLK MH U33 KEY SWITCH CONTROL RELAY I D SPARE WIRE LIST 13 CONTROLLER STATUS LED CR1 SECONDARY 48V DC POWER BLK 1 5 i 10 10B__ 145 PLATFORM OVERLOAD LED CE MODELS BLK WHT 1 RED BLK CH d RED 6 MH MANIFOLD HARNESS CR2 PRIMARY 48V DC POWER 1 I BLK RED 1 CR3 AUXILIARY PUMP TILT SENSOR A P1 EMERGENCY STOP BUTTON GRN WHT 1 one RELEASE DBGIRED TOA i 4 m gt gt 1340 SP SWITCH PANEL PLATFORM LEVEL CUTOUT CE ONLY i WHT _RED BLK 28D Tee AUXIIARY TOQQLESWITCH 8 CR10B PLATFORM LEVEL CUTOUT CE ONLY _ S TS55 FUNCTION ENABLE TOGGLE SWITCH ORG 14B ORG BLK 15B BLK BRN CB2 TS57 PLATFORM ROTATE TOGGLE SWITCH OPTION NUMBERS TS58 JIB BOOM UP DOWN TOGGLE SWITCH 77 PLATFORM LEVEL CUTOUT d 1 TS59 PLATFORM LEVEL TOGGLE SWITCH 2 FLASHING BEACON ORG 6 CB2 L3 TS60 SECONDARY BOOM UP DOWN TOGGLE SWITCH 3 DESCENT ALARM TS61 PRIMARY BOOM UP DOWN TOGGLE SWITCH ORG BLK 3 15 oRG BLK CRI0B ORG BLK SP PLAT LEVEL DOW
68. PROCEDURES 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 non steer 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 AWARNING Electrocution hazard Contact with hot or live circuits could result in death or serious injury Remove all rings watches and other jewelry Replace the contactors if any damage is found REV 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 Genie Z 30 20N
69. RED 42 B 9 9 5 5 coe E 02 gt E E Sid Sid 3H E ER 7 4948 5885 5 DRIVE P 8 2 CONTACTOR Ig gt le 4 egen e x 1 d 8 0 Fy p 1 e i 2 f 2 Ely 3 g 10 8 el S 5 t o EL i x a 8 8 z 5 5 E RED BLK BRAKE REL SEI x 8 uz R PEED INPUT if 9 8 88 1 5 R I Bo POT LOW 44 5 8 RED 2WIREPOT 8 306 7 z IN SCH INTEROCK 94 BLUWHT 12 2 8 UT 8 EET Sp 5 K x pU REVERSE 4 8 2 i E FORWARD 0 5 z 3 DIODE RETURN 448V DC INPUT ORG RED gt EC CONTACTOR P E BLK CBATTERY BLK 2 HARGER is wes Ol X zi 5 Zo tic n T d 2 BLK PRIMARY E 5 LIFT PUMP 8 5 5 rn 5 77 er 8 o IARY 8 BLK AUXIL 3 LIFT PUMP 2 lt Ms S LS 8 g RED CB1 z 1 5 e X ER Si E Fle j mE a gt 20 a itel 3 Da 9 5 74 sei SI 38 a tales Ka WaT lar TH te Sed Leer Deen 100000 NR e N Part No 106373 Genie Z 30 20N
70. Refer to Section 2 Specifications 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 Genie Z 30 20N Part No 106373 March 2006 Section 3 Scheduled Maintenance Procedures REV 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 dow
71. SE 3 5 STATUS LED 14 8 IS CURTIS 1244 79009 Vy LS1 lt 2 85 87 RED RED 100A OOD BOR m SEPEX CONTROLLER 22 7525 131 24V DC oum cam i i 6 AP1 F1 M B F2 38 GB 5 p 424V DC PR3 PR2 29 GR 3 i 1 S ZS 5 8 5 N D E cw 30 486 i E Web WES pa PS Ne ji F2 A2 A2 F1 B amp 3 A JI am 1 1 4 gt 1 E S F2 5 UMI UM ec Vw LEFT RIGHT 7 7 MOTOR MOTOR w B 2 GND GROUND Bi g 10 BLK BLK do E BRN EE 1 5 i 1 1 1 GND 225 ER 3 JR 5 082 24 328 2 0 8 ea 5 892 52 55 35 28 69 68 m 2 2 gt 50 GER gt cr f S EE x 2 26a DO 20 EX gg ER zs m 2oz 8 9 2 2 3 5 22 2 S i i E o 5 1 m 8 5 BRN BLK 24V DC S p YAYX A w
72. Section 6 Schematics April 2005 Electrical Schematic before serial number 6290 REV B JP1 REMOVE FOR CE MODELS LVI BCI OPTION p mS WHT ENABLE DRIVE LED BLU RED 3 BRN 2 DRIVE ENABLE LIMIT SWITCH Shown with boom rotated past either non steer wheel TB13 WHT 5 BRN 5 BLU WHT 3 TB12 BLK 5 RED 5 ORG RED 3 DI DRIVE ENABLE WHT BRAKE RELEASE JACK J1 RED D ORG RED TB16 RED WHT A2 m BI BRAKE RELEASE TRAVEL ALARM RED WHT 48 1 RED WHT TB48 17 RED WHT 48 10 STEER ORG RED l REV SS DRIVE BLU 1 RED WHT BRAKE RELEASE PRESSURE SWITCH rss BLU 36 BLU BLK 1 TB36 TB37 BLU BLK 37 cok BCI OPTION CONTROL BOX PLATFORM GROUND WHT BLK A2 BRAKE RELEASE N C COIL IBRAKE RELEASE IN O COIL STEER LEFT COIL STEER RIGHT COIL HOUR METER AUX POWER RED RED 27 AUXILIARY CONTROL TS51 v GRN WHT 19 HITB27 e tc o o ORG RED 48V 85 86 GRN WHT RELAY COIL LIFT PUMP saes CR20 SET TO BLK BRN
73. and or hose end must be replaced and then torqued to specification during installation Refer to Section 2 Hydraulic Hose and Fitting Torque Specifications 1 Tag disconnect and plug the hydraulic hoses from the turntable rotation motor Cap the fittings on the motor Bodily injury hazard Spraying AWARNING 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 2 Remove the turntable rotation motor mounting bolts Remove the motor from the machine 4 40 Genie Z 30 20N Part No 106373 April 2004 Section 4 Repair Procedures REVA 9 1 Hub and Bearings How to Remove the 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 Pullthe 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 Steer Axle Components How to Install the Hub and Bearings When rep
74. ap 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 AWARNING 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 Part No 106373 Genie Z 30 20N Section Ae Repair Procedures April 2005 Secondary Boom Components REV B Secondary Boom upper pivot upper compression arm mid pivot compression link lower secondary boom lower compression arm turntable pivot upper secondary boom ro Oo 09 4 20 Genie Z 30 20N Part No 106373 April 2005 Section 4 Repair Procedures E REV B SECONDARY BOOM COMPONENTS 5 1 6 Locate the cables from the primary boom cable track to the platform control box Number each Secondary Boom cable and its entry location at the platform control box How to Disassemble the 7 Open the platform control
75. art No 106373 Genie Z 30 20N Section Ae Repair Procedures April 2004 Hydraulic Pumps 6 1 Auxiliary and Function Pump How to Remove the Auxiliary Pump or Function Pump 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 1 Close the hydraulic shutoff valve located at the hydraulic tank Component damage hazard The CAUTION 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 AWARNING 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 3 Remove the pump mounting bolts from the pump Carefully remove the pump from the electric motor REVA 4 28 Genie Z 30 20N Part No 106373 April 2004 Section 4 Repair Procedures el This page intentionally left blank Part No 106373 Genie Z 30 20N 4 29 Section Ae Repair Procedures April 2005 Manifolds REV B 7 1 Function Manifold Components The
76. bs 47 5 Nm 6 30 ft lbs 40 Nm 8 60 ft lbs 81 3 Nm 8 40 ft Ibs 55 Nm 10 105 ft lbs 142 4 Nm 10 60 ft lbs 80 Nm 12 140 ft lbs 190 Nm 12 85 ft lbs 115 Nm 16 210 ft lbs 284 7 Nm 16 110 ft lbs 150 Nm 20 260 ft lbs 352 5 Nm 20 140 ft lbs 190 Nm 24 315 ft lbs 427 1 Nm 24 180 ft lbs 245 Nm Genie Z 30 20N Part No 106373 March 2006 Section 2 Specifications REVA SPECIFICATIONS SAE FASTENER TORQUE CHART This chart is to be used as a guide only unless noted elsewhere in this manual A574 High Strength Grade 8 Black Oxide Bolts LUBED DRY LUBED DRY LUBED 3113 9 140 TIO 130 120 60 140 LUBED DRY LUBED 13 18 20 23 33 26 37 14 7 15 8 LUBED I 2 m D i 9 D lt 24 27 1 44 7 50 1 67 8 81 3 108 4 122 162 176 217 244 25 27 44 49 70 33 9 28 4 36 6 32 5 59 6 51 5 66 4 58 3 e 94 7 82 7 108 4 92 1 149 126 162 142 203 176 250 189 284 242 325 271 515 133 569 474 827 591 37 50 21 6 867 one 12 80 108 4 110 6 120 6 90 122 0 362 RER Ss 760 6 130 176 170 230 180 sa 10 20 21 270 366 280 379 S10 420 ze 12 320 488 430 588 450 610 610 14 380 274 470 687 900 678 670 908 755 480 o 60 867 680 922 910 12
77. ced more often Bodily injury hazard Beware of ACAUTION 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 Remove the cap from the housing 4 Liftthe 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 Section 3 Scheduled Maintenance Procedures April 2005 CHECKLIST D PROCEDURES 6 Install the new oil filter element into the filter housing 7 Push the filter element down to be sure the o ring 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 REV D 6 Calibrate the Platform Overloa
78. connections very slowly to allow the oil pressure to dissipate gradually Do not allow oil to squirt or spray Bodily injury hazard Beware of ACAUTION hot oil Contact with hot oil may cause severe burns 33 Remove the hydraulic tank mounting fasteners Remove the hydraulic tank from the machine 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 Do not disconnect the wiring 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 7 30 20 Section Ae Repair Procedures April 2005 SECONDARY BOOM COMPONENTS 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 AWARNING Crushing hazard The upper secondary boom with compression link could become unba
79. crank at the extension boom Use a soft metal drift to remove the pin 6 Use 8 soft metal drift to remove the slave cylinder rod end pivot pin 7 Remove the jib boom bell crank from the extension boom AWARNING C Shing 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 April 2005 Section 4 Repair Procedures REV B 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 How to Remove the Jib Boom Rotator Perform this procedure with the boom in the stowed position 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 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 AWARNING 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 ins
80. ctor PR1 or brake release relay CR5 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 Battery supply voltage to motor controller less than 32V DC Battery supply voltage to motor controller more than 55V DC OR machine is being operated with the battery charger plugged in 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 Consult Genie Industries Service Department Consult Genie Industries Service Department Completely charge batteries OR check battery cable condition OR check for corrosion or loose connections at battery terminals and motor controller Be sure the battery charger is disconnected OR check for loose battery cables or poor connections 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 Section 5 Fault Codes April 2004 J A D i This page intentionally left blank 5 6 Genie Z 30 20N Part No 106373 April 2004 Section 6 Schematics
81. d System if equipped Genie specifications require that this procedure be performed every 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 Genie Z 30 20N Part No 106373 April 2005 Section 3 Scheduled Maintenance Procedures REV 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 There may be an approximate 2 second delay before the overload indicator light turns on and the alarm sounds Result The overload indicator
82. d3 2 WHT FS WHT 5 2 ORG RED 1 U33 lt lt 3 m 8 55221 7 1518 2 2 CB1 el 1 zi 3 9 PLT TB22 2212 8 My v 10A P1 n BLK 22 Gees 4 P3 5 ave a H HORN 9 Vi 2 GND A6 145 BLU RED 1 RED lt 5 ORG RED CR20 ORG RED WHT 30 TB30 WHT 1 WHT 1 4 1 wore WHT BLK 1 e RED WHT 29 TB29 RED WHT 1 RED WHT 1 ter WHT RED 32 1682 WHT RED 1 WHT RED 1 ORG 40 40 BLK 8 CH eel dc C 5C H n P 8 ORG RED CR2 BL 55 BLU WHT 12 4 1164 RED 4 9 g g ai 1 a CRS 9 S AP2 10A 2 ES Ges m 3 E RED 48V DC 1 500A o 3 86 o o m 2 PR1 8 5 8 48V DC T S 8 50 5 1 TS55 ee Seal i 5 FUNCTION D gt F2 y 2 ENABLE 100A 83 T o B Ju 5 8 8 22 mox z Y 5 1 al E RED alla 5 5 41162 5 2 S ig 2 224 D 8 T w DI dl 3 gt 5 2 5 P m 2 56 5 w T 9 g 2 ja 2 2 5 3 9 0 2 o i g 2 d 8828855555 Ee m z Je 8 n 2 all 5 lt 2 la S d 5 g 87 85 8 1 1 N 0 1 m E AP2 BLK Spa 28 2 a ls i 5 EIK
83. de 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 Ae Repair Procedures April 2005 T PLATFORM COMPONENTS REV B 2 Connecta clear hose to the top bleed valve 5 Connect the clear hose to the bottom bleed Place the other end of the hose in a container valve and open the valve Do not remove the to collect any drainage Secure the container to bleed valve the boom 6 Move the function enable toggle switch to either 3 Open the top bleed valve on the rotator but do side and hold the platform rotate toggle switch not remove it 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 AWARNING Cushing 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 clear hose top bleed valve bottom bleed valve 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 t
84. e machine 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 AWARNING C shing 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 ACAUTION 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 Genie Z 30 20N Part No 106373 April 2005 Section Ae Repair Procedures REV B 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 AWARNING Bodily injury hazard Spraying hydraulic oil can penetrate and burn skin Loosen hydraulic connections very slowly to allow the oil pressure
85. e 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 AWARNING Crushing hazard The boom extension tube could fall when removed from the boom if not properly supported PRIMARY BOOM COMPONENTS 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 Remove the external snap rings from the slave cylinder barrel end pivot pin Use a soft metal drift and drive the slave cylinder barrel end pivot pin out 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 During removal the overhead crane strap will need to be carefully adjusted for proper balancing Part No 106373 Genie Z 30 20N 4 15 Section Ae Repair Procedures prmm M PRIMARY BOOM COMPONENTS 4 3 Primary Boom Lift Cylinder The primary boom l
86. e binding or scraping Always maintain squareness between the primary boom outer and inner tubes 3 20 Genie Z 30 20N Part No 106373 April 2005 Section 3 Scheduled Maintenance Procedures REV 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 CHECKLIST D PROCEDURES 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 AWARNING Collision hazard Failure to engage the drive hubs could result in without operator knowledge may cause death or death or serious injury and serious injury and property damage property damage AWARNING 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 Ibs 7000 kg under the drive chassis between the non steer wheels 3 Liftthe 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
87. e 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 drive and brake printed circuit board c drive joystick REV B Boom Function Speed Controller Adjustments AWARNING 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 black red wire b diode c white red wire d function speed controller e ramp rate trimpot f threshold trimpot g max out trimpot Genie Z 30 20N Part No 106373 April 2005 Section 4 Repair Procedures REV 3 Locate the diode between the black red wire from the boom function
88. e on position If during start up problem persists replace the motor controller 12 HW FAILSAFE 1 2 3 Machine will not drive E ed Geesse the motor failed self test controller The motor controller M SHORTED Machine will not drive controller See Repair Test the motor between M and B Section terminals Check for loose or open connections at the drive Motor wiring is loose motors and motor OR motor is defective controller OR replace OR motor controller has the defective drive an internal short motor OR test the motor controller See Repair Section ARM SENSOR Machine will not drive Defective motor Replace the motor controller controller FLD SENSOR Machine will not drive Defective motor Replace the motor controller controller FIELD OPEN Machine will not drive Part No 106373 Genie Z 30 20N 5 3 Section 5 Fault Codes April 2004 FAULT CODE CHART Fault Code Programmer Condition Possible Causes Diagnostic Display THROTTLE FAULT 1 THROTTLE FAULT 2 CONT DRVR OC MAIN CONT WELDED PRECHARGE FAULT Machine will not drive Machine will not drive Machine will not drive Machine will not drive Machine will not drive 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 t
89. eck 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 F1 to F2 500k or more F1 to B 500k or more F1 to M 500k or more F1 to B 500k Q or more F2 to B 500k or more F2 to M 500k or more F2 to B 500k or more B to M 500k Q or more M to B 500k or more Pin 17 to B 500k or more Pin 20 to B 500k or more Genie Z 30 20N Part No 106373 April 2005 Section 5 Fault Codes Observe and Obey Troubleshooting and repair procedures shall be completed by a person trained and qualified on the repair of this machine Immediately tag and remove from service damaged or malfunctioning machine Repair any machine damage or malfunction before operating the machine Unless otherwise specified perform each repair procedure with the machine in the following configuration Machine parked on a firm level surface 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 All external AC power supply disconnected from the machine Fault Codes Before Troubleshooting Read understand and obey the safety rules and operating instructions printed in the Genie Z 30 20N Operator s
90. ection 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 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 no remove from service R repaired Comments A 2 Function tests Perform after 40 hours A 3 30 Day Service Perform every 100 hours A 4 Grease rotation bearing ChecklistB RevC Y NR 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 C 2 Test platform overload if equipped ChecklistD RevB Y NR 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 ChecklistE RevB Y NR E 1 Hydraulic oil E 2 Wheel bearings Part No 106373 Genie Z 30
91. ed replenish with distilled water to the bottom of the battery fill tube Do not overfill 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 Genie Z 30 20N Part No 106373 March 2006 Section 3 Scheduled Maintenance Procedures REV 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 AWARNING Electrocution hazard Contact with hot or live circuits could result in death or serious injury Remove all rings watches and other jewelry 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
92. ee 3 8 How to Remove the Jib Boom Rotator PRIMARY BOOM COMPONENTS 5 Tag disconnect cap the slave cylinder hydraulic hoses at the union Plug the hoses from the slave cylinder AWARNING 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 Remove the upper cable track mounting fasteners from the platform end of the boom 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 CAUTION cable track can be damaged if it is twisted CAUTION Component damage hazard Cables and hoses can be damaged if they are kinked or pinched 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 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 Section Ae Repair Procedures April 2005 PRIMARY BOOM COMPONENTS 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 e
93. ensor Option Diagram before serial number 6290 REVA 2 KKK 1 21 31 4 LOAD SENSE OPTION n 123456789 a g 5 5 8 4 Sc rn m CABLE CABLE CABLE 3 2 1 LOAD CELL WHT FS TS15 512 TS10 BP1 BLK RED TS7 TS11 TS8 RED TS9 TS13 TS16 m 1513 a anal ib LABEL DESCRIPTION 11 O O 12 L 2 EMERGENCY STOP BUTTON P3 HORN BUTTON M DP1 DRIVE CONTROLLER BP1 BOOM FUNCTION SPEED CONTROLLER TS1 AUXILIARY TOGGLE SWITCH ud TS7 PLATFORM ROTATE TOGGLE SWITCH TS8 JIB BOOM UP DOWN TOGGLE SWITCH 5 5 lo TS9 PLATFORM LEVEL TOGGLE SWITCH TS10 SECONDARY BOOM TOGGLE SWITCH NO NC NC TS11 PRIMARY BOOM TOGGLE SWITCH 9 TS12 TURNTABLE ROTATE TOGGLE SWITCH TS1 P3 P2 DP1 TS13 BOOM EXTEND TOGGLE SWITCH TS15 DRIVE ENABLE TOGGLE SWITCH TS16 JIB ROTATE TOGGLE SWITCH OPTION L1 DRIVE ENABLE LIGHT L2 OVERLOAD LIGHT OPTION Genie Z 30 20N Part No 106373
94. ent damage Dealer Service is strongly recommended 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 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 Section Ae Repair Procedures April 2005 PRIMARY BOOM COMPONENTS 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 AWARNING Bodily injury hazard Spraying hydraulic oil can penetrate and burn skin Loosen hydraulic connectio
95. erial number 6290 A B G H J K 1 GROUND CONTROLS SIDE TANK SIDE BATTERY PACK BATTERY PACK AMMETER BLK 10Ga WHT 10 Ga 2 A BATTERY To CHARGER Q 3 E PRIMARY LIFT PUMP 1 D BLK 4 Q 25280 AUXILIARY 4 m 2 pne LIFT PUMP Je JS 09 2 Q 2 om RED 9 Je az Ges BLK 2 Ga 5 E 24V DC 1 0 VDC RED 2 ca 2Ga wm 2 Ga CONTACTOR AUXILIARY F3 N LIFT PUMP 6 100 CONTACTOR PRIMARY 90 PR3 LIFT PUMP CONTACTOR PR2 0 MOTOR CONTROLLER 7 1 2 10 o5 cA ou 5 2 D UO BLK 2 Ga 8 D i F1 F2 A2 1 LEFT SIDE x BLK 2 Ga BLK 2 Ga RIGHT SIDE DRIVE MOTOR FID E re DRIVE MOTOR RED 10 Ga 6 5 Genie Z 30 20N Part No 106373 REVA March 2006 Section 6 Schematics Power Cable Diagram REV B after serial number 6289 N M L K J G F E D C B A LEFT SIDE P AMMETER RIGHT SIDE 1 BATTERY PACK BLK 10 oo BATTERY PACK S WHT 10 2 i Z 2 S AC mE BATTERY CHARGER 7 PRIMARY 3 LIFT PUMP p Al D1 BLK 4 4 p J D AUXILIARY E 2 PUMP m o 9 4 5 x E ES 5 m
96. ew hoses or fittings are installed SAE O ring Boss Port tube fitting installed into Aluminum SAE Dash size Torque 4 11 ft lbs 14 9 Nm 6 23 ft lbs 31 2 Nm 8 40 ft lbs 54 2 Nm 10 69 ft lbs 93 6 Nm 12 93 ft lbs 126 1 Nm 16 139 ft lbs 188 5 Nm 20 172 ft lbs 233 2 Nm 24 208 ft lbs 282 Nm SAE O ring Boss Port REV B Seal Lok fittings 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 Lubricate the O ring before installation Be sure that the face seal O ring is seated and retained properly Position the tube and nut squarely on the face seal end of the fitting and tighten the nut finger tight Tighten the nut or fitting to the appropriate torque per given size as shown in the table Operate all machine functions and inspect the hoses and fittings and related components to confirm that there are no leaks Seal Lok Fittings tube fitting installed into Steel hose end SAE Dash size Torque SAE Dash size Torque 4 16 ft lbs 21 7 Nm 4 18 ft lbs 25 Nm 6 35 ft l
97. 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 Observe the pressure reading on the pressure gauge Refer to Section 2 Specifications 4 Turn the machine off Hold the turntable relief valve s with a wrench and remove the cap item D 5 Adjust the internal hex socket Turn it clockwise to increase the pressure or counterclockwise to decrease the pressure Install the relief valve cap AWARNING Tip over hazard Do not adjust the relief valve higher than specified 6 Repeat steps 2 and 3 to confirm the relief valve pressure setting 4 36 Genie Z 30 20N Part No 106373 April 2005 Section 4 Repair Procedures E REV B MANIFOLDS 7 3 Jib Boom and Platform Jib Boom Rotate Manifold Components The jib boom platform rotate manifold is mounted to the jib boom Index Schematic No Description Item Function Torque 1 Solenoid valve 3 position 4 way AA Jib boom 20 25 ft lbs 27 34 Nm 2 Solenoid valve 3 position 4 way isspiss Platform rotate left right 20 25 ft lbs 27 34 Nm 3 Solenoid valve 3 position 4 way Jib boom rotate left right 20 25 ft lbs 27 34 Nm 4 Flow regulator valve 0 3 1 14 L MIN Platform rotate circuit
98. he 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 Genie Z 30 20N Part No 106373 April 2005 Section 3 Scheduled Maintenance Procedures z c XG H M m REV B CHECKLIST E PROCEDURES 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 CAUTION 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 20 Tighten the castle nut to 35 ft Ibs 47 Nm to seat the bearings 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 Part No 106373 Genie Z 30 20N 3 29 Section 3 Schedu
99. he 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 Section 3 Scheduled Maintenance Procedures March 2006 CHECKLIST B PROCEDURES REV C B 11 B 12 Test the Drive Speed Test the Alarm Package Raised or Extended Position if equipped 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 Select a test area that is firm level and free of obstructions 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 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
100. ift 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 AWARNING Body 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 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 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 April 2005 REV B 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 Remove the counterweight cover fasteners Remove the counterweight cover from th
101. inder hoses AWARNING 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 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 Usea soft metal drift to remove the rod end pivot pin AWARNING 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 AWARNING 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 April 2005 Section Ae Repair Procedures REV B 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 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 installa
102. ion 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 O Result There should be no side to side or up and down movement Skip to step 10 if there is no movement REV B 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 O Result If there is no side to side or up and down movement continue with step 11 and grease the wheel bearings W 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 t
103. ions for improvement All communications will be carefully considered for future printings of this and all other manuals Contact Us http Awww genieindustries com e mail techsup genieind com Copyright 1996 by Genie Industries 106373 Rev A April 2004 Genie and 2 are registered trademarks of Genie Industries in the USA and many other countries 4 Printed on recycled paper Printed in U S A li 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 shou
104. lacing 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 CAUTION 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 7 Tighten the castle nut to 35 ft lbs 47 Nm to seat the bearings 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 Refer to Section 2 Specifications Part No 106373 Genie Z 30 20N Section Ae Repair Procedures April 2004 Motor Controller 10 1 Motor Controller The drive motor controller is located under the non Steer end drive chassis cover The drive motor controller can recognize machine drive malfunctions and display motor controller fault
105. lanced 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 A DANGER 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 AWARNING Crushing hazard The counterweight could become unbalanced and fall when removed from the machine if not properly supported by the overhead crane REV 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
106. ld 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 ADANGER Used to indicate the presence of an imminently hazardous situation which if not avoided will result in death or serious injury AWARNING 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 ACAUTION indicate the presence of a potentially hazardous situation which if not avoided may cause minor or moderate injury Be sure to wear protective eye wear and other protective clothing if the situation warrants it Be aware of potential crushing hazards EI such as moving parts free swinging or unsecured components when lifting or placing loads Always wear approved steel toed shoes Workplace Safety Be sure to keep sparks flames and Ae 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 othe
107. led Maintenance Procedures April 2005 pr X H This page intentionally left blank 3 30 Genie Z 30 20N Part No 106373 April 2005 Section 4 Repair Procedures Observe and Obey Repair procedures shall be completed by a person trained and qualified on the repair of this machine M Immediately tag and remove from service a damaged or malfunctioning 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 Machine parked on a firm level surface 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 All external AC power supply disconnected from the machine Repair Procedures About This Section Most of the procedures in this section should only be performed by a trained service professional i
108. 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 AWARNING lift cylinder could fall when the pin is removed if not properly supported by the overhead crane REV B 3 2 Jib Boom Bell Crank models without rotating jib boom How to Remove the Jib Boom Bell Crank Perform this procedure with the boom in the stowed position 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 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
109. liters Primary boom extend Drive hubs models with rotating jib boom 14 to 24 seconds 61 1 23 ounces 0 68 liter models without rotating jib boom 9 to 15 seconds 62 5 1 25 6 ounces 0 76 liter Drive hub oil type SAE 90 multipurpose hypoid gear oil API service classification GL5 Continuous improvement of our products is a Genie policy Product specifications are subject to change without notice Primary boom retract 12 to 18 seconds Secondary boom up 11 to 18 seconds Secondary boom down 7 to 15 seconds Turntable rotate 355 50 to 65 seconds Platform rotate 160 5 to 11 seconds Platform level up 14 to 19 seconds Platform level down 13 to 18 seconds Part No 106373 Genie Z 30 20N 2 1 Section 2 Specifications April 2005 SPECIFICATIONS Hydraulic Specifications Hydraulic Oil Specifications Hydraulic oil type ISO viscosity grade Chevron Rykon MV equivalent Multi viscosity Viscosity index 200 Cleanliness level minimum 15 13 Water content maximum 200 ppm Chevron Rykon MV oil is fully compatible and mixable with Shell Donax TG Dexron 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 inhibitio
110. lve 3 position 4 way Secondary boom up down 20 25 ft lbs 27 34 Nm 22 Solenoid valve 3 position 4 way Primary boom up down 20 25 ft lbs 27 34 Nm 23 Flow regulator valve 1 5 5 7 L min UU Turntable rotate circuit 20 25 ft lbs 27 34 Nm 24 Flow regulator valve 0 8 3 L min pq Jib boom platform rotate circuit 20 25 ft Ibs 27 34 Nm 25 Solenoid valve 3 position 4 way poem Turntable rotate left right 20 25 ft lbs 27 34 Nm 4 32 Genie Z 30 20N Part No 106373 Section 4 Repair Procedures April 2005 MANIFOLDS REV YT ia E Ly aom 7 97777 dy 2 ff TH 6 A gt 2 Wak 6 Genie Z 30 20N Part No 106373 Section Ae Repair Procedures April 2005 MANIFOLDS 7 2 Valve Adjustments Function Manifold How to Adjust the System Relief Valve Perform this procedure with the boom in the stowed position 1 Connect 0 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
111. m 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 Usea soft metal drift to remove the jib boom lift cylinder rod end pivot pin Remove the jib boom lift cylinder from the machine AWARNING 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 Section Ae Repair Procedures April 2005 Primary Boom Components 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 CAUTION 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 a link separation point b lower clip 1 Use 8 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 REV B 4 2 Primary Boom How to Shim the Primary Boom 1 Extend
112. 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 REVA 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 Motor cs bh CS Controler Status 10 AMD Indicator Light 5 2 Genie Z 30 20N Part No 106373 April 2004 Section 5 Fault Codes Fault Code Chart REVA Fault Code Programmer Condition Possible Causes Diagnostic Display Push in the ground control red Emergency The key switch or Stop button to the off Emergency Stop position and wait for 5 Fault code LED COMMUNICATION button s was cycled seconds Pull out the is off or is on ERROR Machine will not drive and off faster than 5 ground control red but not blinking seconds OR controller Emergency Stop button sensed an internal error to th
113. n seal conditioning and foam and aeration suppression properties Optional fluids Petro Canada Premium ECO 46 Statoil Hydra Way Bio Pa 32 BP Biohyd SE S Biodegradable UCON Hydrolube HP 5046 Quintolubric 822 Fire resistant Shell Tellus T32 Shell Tellus T46 Chevron Aviation A Mineral based Use Chevron Aviation A hydraulic oil when in ambient temperatures consistently below O 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 REV B Function pump Type Fixed displacement gear pump Displacement 0 183 cu in 3 cc Flow rate 2 1 gpm 2800 psi 172 bar 7 9 L min 10 micron with 25 psi 1 7 bar bypass Hydraulic tank return filter Function manifold System relief valve pressure 2800 psi 193 bar Primary boom down relief pressure 1600 psi 110 bar Secondary boom down relief pressure 1600 psi 110 bar Primary boom extend relief pressure 2800 psi Models without rotating jib 193 bar Primary boom extend relief pressure 1800 psi Models with rotating jib 124 bar Turntable rotate relief pressure 1100 psi 76 bar Auxiliary pump Type Fixed displacement gear pump Displacement 0 3 gpm 1 14 L min Genie Z 30 20N Part
114. n 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 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 ADANGER Used to indicate the presence of an imminently hazardous situation which if not avoided will result in death or serious injury AWARNING Used to indicate the presence ofa potentially hazardous situation which if not avoided could result in death or serious injury With safety alert symbol used to ACAUTION 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 presence of a potentially hazardous situation which if not avoided may result in property damage CAUTION Used to indicate operation or maintenance information Indicates that a specific result is expected after performing a series of steps W Indicates that an incorrect result has occurred after performing a series of steps Part No 106373 Genie Z 30 20N 4 1 Section Ae Repair Procedures April 2005 Platform Controls 1 1 Controllers The drive joystick is connected to the driv
115. n 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 CHECKLIST B PROCEDURES 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 Section 3 Scheduled Maintenance Procedures March 2006 CHECKLIST B
116. n the stowed position Connect a 0 to 3000 psi 0 to 200 bar pressure gauge to the test port on the function manifold Turn the key switch to ground control and pull out the red Emergency Stop button to the on position 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 Observe the pressure reading on the pressure gauge Refer to Section 2 Specifications Turn the machine off Hold the primary booom extend relief valve with a wrench and remove the cap item G Adjust the internal hex socket Turn it clockwise to increase the pressure or counterclockwise to decrease the pressure Install the relief valve cap AWARNING Tip over hazard Do not adjust 6 the relief valves higher than specified Repeat steps 2 and 3 to confirm the relief valve pressure setting Part No 106373 Genie Z 30 20N 4 35 Section Ae Repair Procedures April 2005 rmm H MM M MANIFOLDS REV B How to Adjust the Turntable Rotate Relief Valve Perform this procedure with the boom in the stowed position 1 Connecta 0 to 3000 psi 0 to 200 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
117. navia Phone 46 31 3409612 Fax 46 31 3409613 Genie China Phone 86 21 53852570 Fax 86 21 53852569 Genie France Phone 33 0 2 37 26 09 99 Fax 33 0 2 37 26 09 98 Genie Malaysia Phone 60 4 228 1235 Fax 60 4 226 6872 Genie Ib rica Phone 34 93 579 5042 Fax 34 93 579 5059 Genie Japan Phone 81 3 3453 6082 Fax 81 3 3453 6083 Genie Germany Phone 49 0 4202 88520 Fax 49 0 4202 8852 20 Genie Korea Phone 82 2 558 7267 Fax 82 2 558 0 Genie U K Phone 44 0 1476 584333 Fax 44 0 1476 584334 Genie Africa Phone 27 11 455 0373 Fax 27 11 455 0355 Genie Mexico City Phone 52 55 5666 5242 Fax 52 55 5666 3241 Genie Latin America Phone 55 11 4055 2499 Fax 55 11 4043 1661
118. ne 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 Adgjust 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 Genie Z 30 20N Part No 106373 March 2006 Section 3 Scheduled Maintenance Procedures REV C CHECKLIST B PROCEDURES B 9 B 10 Test the Drive Brakes 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 AWARNING 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 Lower the boom to the s
119. ning 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 Genie Z 30 20N Part No 106373 March 2006 Section 3 Scheduled Maintenance Procedures REV CHECKLIST B PROCEDURES B 5 B 6 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 DONE disengaged position es EM art engaged position 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 drive hub plugs 2 Rem
120. ns very slowly to allow the oil pressure to dissipate gradually Do not allow oil to squirt or spray 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 AWARNING 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 to 4 feet 1 m During removal the overhead crane strap will need to be carefully adjusted for proper balancing REV B 4 5 Platform Leveling Master Cylinder The platform leveling master cylinder acts as a pump for the slave cylinder It is part of the closed loop 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 AWARNING 2 09 Y 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 When removing a hose assembl
121. ntry 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 Component damage hazard CAUTION Cables and hoses can be damaged if they are kinked or pinched 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 REV B 21 Tag disconnect and plug the extension cylinder hydraulic hoses Cap the fittings on the cylinder AWARNING 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 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 2
122. o power or ground OR the potentiometer on the drive joystick is defective 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 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 External short between B terminal on motor controller and ground OR motor controller is defective REV A Consult Genie Industries Service Department Consult Genie Industries Service Department Replace main contactor PR1 or brake release relay CR5 OR replace the motor controller Consult Genie Industries Service Department 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 Genie Z 30 20N Part No 106373 April 2004 Section 5 Fault Codes REVA FAULT CODE CHART Fault Code Programmer Condition Possible Causes Diagnostic Display MISSING CONTACTOR Machine will not drive MAIN CONT DNC LOW BATTERY VOLTAGE OVERVOLTAGE THERMAL CUTBACK Machine will not drive Machine will not drive Machine will not drive Machine will not drive Motor controller does not detect the main conta
123. oggle switch until air stops coming out of the bleed valve Close the bleed valve AWARNING Crushing hazard Keep clear of the platform during rotation 4 6 Genie Z 30 20N Part No 106373 April 2005 Section 4 Repair Procedures REV B 3 1 Jib Boom How to Remove the Jib Boom Perform this procedure with the boom in the stowed position 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 1 Remove the platform 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 AWARNING 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 Remove the cable cover from the side of the jib boom Jib Boom Components 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 CAUTION Hoses and cables can be damaged if they are kinked or pinched 6 Models with rotating jib boom Tag disconnect
124. om to the fully stowed position 20 Pull all the cables and hoses through the upper pivot REV B 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 AWARNING 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 During removal the overhead crane strap will need to be carefully adjusted for proper balancing CAUTION Component damage hazard 26 Place the entire assembly onto a structure Cables and hoses can be capable of supporting it damaged if they are kinked or pinched 4 22 Genie Z 30 20N Part No 106373 April 2005 Section 4 Repair Procedures REV B 27 Remove
125. ons should not operate 10 Turn the key switch to ground control 11 Test all machine functions from the ground controls 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 Section Scheduled Maintenance Procedures April 2005 Checklist E Procedures 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 REV B 1 Close the hydraulic shutoff valve located at the hydraulic tank CAUTION Component damage hazard The
126. ove 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 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 Repeat this procedure for each drive hub Part No 106373 Genie Z 30 20N Section 3 Scheduled Maintenance Procedures March 2006 CHECKLIST B PROCEDURES 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 REV C B 8 Test the Platform Self leveling Automatic platform self leveling throughout the full cycle of boom raising and lowering is essential for safe machi
127. portional solenoid valve 24V DC 19 5 Q schematic item H Solenoid valve N C poppet 20V DC 23 5 schematic item M Solenoid valve N O poppet 20V DC 23 5 schematic item P REV B 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 AWARNING Electrocution hazard Contact with electrically charged circuits could result in death or serious injury Remove all rings watches and other jewelry 1 Test the coil for resistance See How to Test a Coil 2 Connecta 100 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 10Q Genie part number 27287 4 38 Genie Z 30 20N Part No 106373 April 2005 Section 4 Repair Procedures REV B MANIFOLDS GU 0 9 RESISTOR BATTERY Mir d Le re b a multimeter b ON DC battery 100 resistor Note Dotted lines in ill
128. r 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 any forklift overhead crane or Be sure de 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 CAUTION Without safety alert symbol used to indicate the presense of a Be sure to properly dispose of old oil or potentially hazardous situation 6 other fluids Use approved container which if not avoided may result in Please be environmentally safe property damage Be sure that your workshop or work area Indicates special operation or Boni is properly ventilated and well lit maintenance information Cane iv Genie Z 30 20N Part No 106373 March 2006 Section 1 Safety Rules Table of Contents Introduction Important ii Section 1 Safety Rules Section2 Rev lt 0 0 Section3 Rev General Safety Rules iii Specifications Machine Specifications 2 1 Performance Specifications 21 Hydraulic Specifications 2 2 Manifold Component Specifications 2 3 Machine Torque Specifications
129. rclockwise to decrease the pressure Then install the relief valve cap AWARNING Tip over hazard Do not adjust the relief valve higher than specified 6 Repeat steps 2 and to confirm the relief valve pressure setting Genie Z 30 20N Part No 106373 April 2005 Section 4 Repair Procedures REV B How to Adjust the Secondary Boom Down Relief Valve Perform this procedure with the boom in the stowed position 1 Connect 0 to 3000 psi 0 to 200 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 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 5 Adjust the internal hex socket Turn it clockwise to increase the pressure or counterclockwise to decrease the pressure Install the relief valve cap AWARNING Tip over hazard Do not adjust the relief valve higher than specified 6 Repeat steps 2 and to confirm the relief valve pressure setting MANIFOLDS How to Adjust the Primary Boom Extend Relief Valve 1 2 Perform this procedure with the boom i
130. 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 Setthe 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 Setthe 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 PLATFORM CONTROLS 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
131. sts 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 Y N R Pre operation inspection completed Maintenance items completed Function tests completed Model Serial number Date Machine owner Inspected by print Inspector signature Inspector title Inspector company Section 3 Scheduled Maintenance Procedures April 2005 pc M J s This page intentionally left blank 3 4 Genie Z 30 20N Part No 106373 March 2006 Section 3 Scheduled Maintenance Procedures a a Maintenance Inspection Report Model Checklist A Rev B YNR ChecklistC RevB Y NR 1 Pre operation C 1 Grease platform Serial number inspection overload if equipped 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 A Quarterly or 250 hour Insp
132. talling the jib boom rotator be sure to torque the fasteners to specification Refer to Section 2 Specifications JIB BOOM COMPONENTS Support and secure the jib boom bell crank to an appropriate lifting device Remove the pin retaining fasteners from the slave cylinder rod end pivot pin Do not remove the pin Place a block of wood under the platform leveling slave cylinder for support Protect the cylinder rod from damage Remove the pin retaining fasteners from the jib boom bell crank at the extension boom Use a soft metal drift to remove the pin 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 AWARNING Cushing 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 Section Ae Repair Procedures April 2005 JIB BOOM COMPONENTS 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 top bleed valve clear hose container bottom bleed valve
133. 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 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 Genie A TEREX COMPANY Genie Industries USA 18340 NE 76th Street PO Box 97030 Redmond WA 98073 9730 425 881 1800 Genie UK The Maltings Wharf Road Grantham Lincolnshire NG31 6BH England 44 1476 584333 Copyright 2002 by Genie Industries Genie is a registered trademark of Genie Industries RevA 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 Te
134. 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 SECONDARY BOOM COMPONENTS 21 Use a soft metal drift to remove the secondary boom rod end pivot pin Crushing hazard The secondary ACAUTION 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 Component damage hazard CAUTION 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 AWARNING 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 24 Remove the cylinder through the top of the secondary boom AWARNING 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 P
135. 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 AWARNING 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 AWARNING med injury hazard Spraying ydraulic 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 31 Open the valve on the hydraulic tank and drain the oil into a container of suitable capacity Refer to Section 2 Specifications Bodily injury hazard Beware of ACAUTION hot oil Contact with hot oil may cause severe burns SECONDARY BOOM COMPONENTS 32 Tag disconnect and plug the hydraulic hose from the hydraulic tank return filter housing Cap the fitting on the filter housing AWARNING Bodily injury hazard Spraying hydraulic oil can penetrate and burn skin Loosen hydraulic
136. tion Refer to Section 2 Hydraulic Hose and Fitting Torque Specifications 1 Remove the platform 2 Tag disconnect and plug the hydraulic hoses from the platform rotate manifold AWARNING 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 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 PLATFORM COMPONENTS 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 ACAUTION 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 Section 2 Specifications How to Bleed the Platform Rotator This procedure will require two people 1 Move the function enable toggle switch to either si
137. towed position Turn the key switch to platform controls I Choose 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 Section 2 Specifications The brakes must be able to hold the machine on any slope it is able to climb Test the Drive Speed Stowed 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 Select a test area that is firm level and free of obstructions 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 t
138. ustration indicate a reversed connection as specified in step 6 3 Seta 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 Atthe 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 8 minimum of 20 The coil is good W 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 Part No 106373 Genie Z 30 20N 4 39 Section Ae Repair Procedures April 2005 Turntable Rotation Components REV B 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 When removing a hose assembly or fitting the O ring on the fitting
139. y 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 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 Genie Z 30 20N Part No 106373 April 2005 Section Ae Repair Procedures 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 AWARNING injury hazard Spraying ydraulic 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 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 str
140. y switch to the off position and clean up any hydraulic oil that may have spilled 4 10 Genie Z 30 20N Part No 106373 April 2005 Section 4 Repair Procedures REV B 3 4 Jib Boom Lift Cylinder How to Remove the Jib Boom Lift Cylinder Perform this procedure with the boom in the stowed position 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 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 AWARNING 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 3 Remove the pin retaining fasteners from the jib boom lift cylinder rod end pivot pin Do not remove the pin JIB BOOM COMPONENTS 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 boo

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