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Service Manual - Genie Industries

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1. L K J l H G F E D C B A FUNCTION BRAKE VALVES 1 UO R PUMP _ 04 5 052 BRAKE Ag S POWER UNIT CC D IE E Jo i 2000 PSI ae 1 al 5 Q V WHEEL BRAKES LIFT MA i TANK PROPORTIONAL N ap di PIER COM we OF el Zug 3 1 MASTER CYLINDER EI Tw TANK mi SECONDARY BOOM PRIMARY BOOM 4 PLATFORM LEVEL LIFT CYLINDER LIFT CYLINDER EXTENSION CYLINDER CYLINDER OUT P P 7 I I CET MSC I TURNTABLE ne E E j ROTATE STEER CYLINDER WT Who zal G al Gi RH Q LEET EE GE SCENE EE GORA In ENGE rain e KT AS BAS PTL ele geen EE JM EE ee EE EE IR DEE EEN EE P m T a 6 a 0 LI d PSI sk W masse A fe is 1800 pesos poner 8 iy PSI ES i 1 A A A A 7 850 1800 W 1600 1400 PSI S PSI gt re 16003 ZH n w w D w SG Salle CAE CAE valle A XB CAL TANO HAND PUMP HS 050 69 IV 090 GA 060 68 8 Fj S x A A A T1 FUNCTION MANIFOLD Part
2. OAZA 4 Normally open poppet valve VE 5 Check VAIVE noe dE os Qi 6 Pressure Switch 1 22111111111 Sa Ai 7 Orifice Plug 0 040 in 1 27 mm We Plug Torque Specifications Function Torque Brake release circuit 10 12 ft lbs 14 16 Nm Brake release circuit 25 30 ft los 34 41 Nm Brake release circuit Brake release circuit 25 30 ft lbs 34 41 Nm Brake release circuit 25 30 ft lbs 34 41 Nm How to Check the Resistance of a Valve Coil 1 Turn the key switch to the orr position and Description Hex Size Torque disconnect the wires from the valve coil to be tested SAE No 2 1 8 50 in lbs 6 Nm 2 Connect the leads from the ohmmeter to the SAE No 4 3 16 13 ft lbs 18 Nm valve coil terminals SAE No 6 1 4 18 ft lbs 24 Nm Valve coil specifications SAE No 8 5 16 50 ft los 68 Nm 2 position 3 way solenoid valve 20V 23 240 Schematic items T and V SAE No 10 9 16 55 ft lbs 75 Nm Proportional solenoid valve 24V 19 200 SAE No 12 5 8 75 ft lbs 102 Nm Schematic item U 7 28 Genie Z 30 20 Part No 43063 Service Manual Third Edition Section 7 Repair Procedures MANIFOLDS U E Wj A Part No 43063 Genie Z 30 20 7 29 Section 7 Repair Procedures Service Manual Third Editi
3. 25 30 ft lbs 34 41 Nm 8 Hand pump valve 1 22111111 Kavita ds Manual controls AAA 11 13 ft lbs 15 18 Nm 9 3 position 4 way DO3 valve Gazetki Boom extend retract 30 35 in lbs 3 4 Nm 10 3 position 4 way DO3valve EE Primary boom upidown sssseeeeee 30 35 in lbs 3 4 Nm 11 3 position 4 way DO3 valve APES Secondary boom up down s sseseeen 30 35 in lbs 3 4 Nm 12 Orifice 0 060 inch 1 52 mm BB Primary boom up down 13 Relief valve 1600 psi 110 3 bar Dixie Secondary boom down 25 30 ft los 34 41 Nm 14 Relief valve 1400 psi 96 6 bar Gedania Primary boom down 25 30 ft lbs 34 41 Nm 15 Relief valve 850 psi 58 6 bar Boisz Turntable rotate right 25 30 ft lbs 34 41 Nm 16 Relief valve 850 psi 58 6 bar A Turntable rotate left 25 30 ft lbs 34 41 Nm 17 Orifice 0 050 inch 1 27 mm GC Turntable left right 18 3 position 4 way DO3 valve Bites Steer left right AAA 30 35 in lbs 3 4 Nm Plug Torque Specifications Description Hex Size Torque Description Hex Size Torque SAE No 2 1 8 50 in lbs 6 Nm SAE No 8 5 16 50 ft lbs 68 Nm SAE No 4 3 16 13 ft lbs 18 Nm SAE No 10 9 16 55 ft lbs 75 Nm SAE No 6 1 4 18 ft lbs 24 Nm SAE No 12 5 8 75 ft lbs 102 Nm 7 2
4. Continued from the previous page With key switch in ground position and both Emergency Stop switches pulled out to the on position activate function enable and turntable rotate toggle switch TS15 on ground panel in the right direction and check voltage on wht blk wire on boom function directional valve coil item E 20V or more Activate function enable i and turntable rotate function toggle switch TS15 on operates ground panel in the right direction and manually activate valve spool with a T handle function does not operate Install a 0 to 3000 PSI pressure gauge at the quick disconnect coupling on the boom 850 PSI function manifold and activate function enable and the turntable rotate in the right direction less than 850 PSI Resest turntable rotate right relief valve pressure OR repair turntable rotate motor or turntable rotate right relief valve OR boom function manifold could have an internal defect OR consult Genie Industries Service Department Service Manual Third Edition Repair open in wht blk wire from T38 to turntable rotate right function directional valve coil item E 0 or Disconnect wires to infinite turntable rotate right ohms directional valve coil item E and test resistance of valve coil See Repair Section 20 to 25 ohms Replace defective turntable rotate right directional valve item E OR consult Genie Industries
5. M Brake release plug K Pressure switch 6 2 Genie Z 30 20 Part No 43063 Section 6 Schematics Electrical Schematic Service Manual _ 19 940 r 13437 WHO4LY 1d o DO E O uz __ 1HWXATB ze QN3LX3 WOO Es ur o yg O AE 13 SC u 7 are 98 lt NOOS AHYNIHd a gS EE o 5 aJa SE sc SO __ mama a NOOS AHVONODIS D ma MT8 IHM Olt R I WHYTV NOS 3LVLOH J18YLNHNL a x D 1HM 5 gt e d ji SPL NHOH ZOIAHIS ol oun 981 1HM MTB E z dEr bL NMOG 1337 OLLL MA18 DHO E YH18 DHO WHO4 LV 1d a ma St gt EL An An mae H e eon DHO Duo EbL gt gt z DE
6. resistance of valve coil See Repair Section Activate function enable and platform level toggle switch TS18 on ground function operates Replace platform level panel in up direction and up directional valve coil manually activate valve spool with a T handle item L 22 to 25 ohms Replace defective platform level up function does directional valve item L not operate OR consult Genie Industries Service Department Exchange platform level function Repair or replace up and down relief operates detective relief valve OR valves items M N consult Genie Industries and activate platform Service Department level up function function does not operate Exchange platform level up and down check valves items K I and Repair or replace defective check valve OR consult Genie Industries Service Department function operates activate platform level up function function does not operate Continued on the next page Part No 43063 Genie Z 30 20 5 37 Section 5 Troubleshooting Flow Charts Service Manual Third Edition SSS CHART 16 Install a 0 to 2500 PSI Check for mechanical pressure gauge at the restrictions keeping quick disconnect platform level up coupling on the boom function from moving function manifold and OR repair cylinder or activate function enable cylinder counterbalance and the platform level up valve OR consult Genie function Industrie
7. 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 ACAUTION primary boom cable track can be damaged if it is twisted a link separation point b lower clip 1 Use a slotted screwdriver to pry down on the lower clip 2 Repeat step 1 for each link 3 To remove a single link open the lower clip and then use a screw driver to pry the link to the side 3 2 Primary Boom How to Shim the Primary Boom Measure each wear pad Replace the wear pad if it is less than 0 41 inches 1 cm thick If the wear pad is more than 0 41 inches 1 cm thick perform the following procedure 1 Extend the boom until the wear pads are accessible 2 Loosen the wear pad mounting fasteners 3 Install the new shims under the wear pad to obtain zero clearance and zero drag 4 Tighten the mounting fasteners 5 Extend and retract the boom through an entire cycle Check for tight spots that could cause scraping or binding Always maintain squareness between the outer and inner boom tubes How to Remove the Primary Boom This procedure requires specific AWARNING repair skills lifting equipment and a suitable workshop Attempting this procedure without these skills and tools may ca
8. PSI restrictions OR replace the slave cylinder counterbalance valve less than 1800 PSI Deadhead the pressure gauge into the barrel end hydraulic hose from the master cylinder and raise the primary boom one inch at a time Continually monitor the pressure gauge during boom up Do not allow the pressure to exceed 1800 PSI less than 1200 PSI Repair or replace the master cylinder 1200 PSI or more Repair or replace the slave cylinder Chart 15 Replace the defective relief valve on function manifold items M N Replace the defective check valve on function manifold items K I Part No 43063 Genie Z 30 20 Section 5 Troubleshooting Flow Charts Service Manual Third Edition Chart 16 Platform Level Up Function Inoperative Be sure key switch is in the appropriate position Be sure the Emergency Stop switches are pulled out to the on position Be sure the batteries are fully charged With key switch in ground position and both Emergency Stop switches pulled out to the on position activate function enable and platform level toggle switch TS18 on ground panel in up direction and check voltage on org wire at T66 20V or more With key switch in platform position and both Emergency Stop switches pulled out to the on position activate footswitch and platform level toggle switch TS8 on platform control panel in up direction and check v
9. TS19 to TS14 20V or more Troubleshoot primary boom extend toggle switch TS14 OR repair open in blk wire from TS14 to T29 Troubleshoot primary boom extend toggle switch TS4 OR repair open in blk wire from TS4 to T104 to T29 Replace printed circuit oard Replace printed circuit oard a a Q Part No 43063 Genie Z 30 20 5 25 Section 5 Troubleshooting Flow Charts Service Manual Third Edition EH CHART 11 Continued from the previous page no continuity Check continuity from brown ground wire at the primary boom Repair open in brown ground wire circuit to T43 extend directional valve coil continuity With key switch in Repair open in blk wire ground position and from T49 to primary both Emergency Stop boom extend function switches pulled out to directional valve coil the on position activate item G function enable and primary boom extend toggle switch TS14 on ground panel in extend direction and check voltage on blk wire on boom function directional valve coil item G 20V or more Oor Activate function enable Disconnect wires to infinite and primary boom function primary boom extend ohms Replace priman oz extend toggle switch operates directional valve coil coil item G TS14 on ground panel item G and test em G in extend direction and resistance of valve coil manually activate valve See Repair Section spool with a T handle
10. Third Edition Section 7 Repair Procedures 19 Attach an overhead crane to the rod end of the primary boom lift cylinder 20 Remove the pin retainer from the primary boom lift cylinder rod end pin Then use a soft metal drift to remove the pin Crushing hazard The boom lift ACAUTION cylinder will fall unless it is properly supported 21 Lower the rod end of the lift cylinder onto the turntable counterweight 22 Attach a lifting strap from an overhead crane to the approximate center point of the boom 23 Remove the pin retaining fastener from the boom pivot pin 24 Remove the primary boom pivot pin with a soft metal drift Crushing hazard If the overhead AWARNING crane is not properly attached the primary boom may become unbalanced and fall when it is removed from the machine Do not remove the primary boom from the machine until it is properly balanced 25 Lift the boom slightly and adjust the strap as necessary to balance the primary boom 26 Remove the primary boom from the machine PRIMARY BOOM COMPONENTS 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 3 4 How to Remove the Extension Cylinder 1 Remove the boom See 3 2 How to Remove the Primary Boom 2 Place blocks under the extension cylinder for support 3 Remo
11. When testing 48 or replacing any hydraulic component always support the structure and secure it from movement Electrocution hazard Contact with electrically charged circuits may result in death or serious injury Remove all rings watches and other jewelry 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 Perform all troubleshooting on a firm level surface Two persons will be required to safely perform some troubleshooting procedures Part No 43063 Genie Z 30 20 5 1 Section 5 Troubleshooting Flow Charts Service Manual Third Edition TROUBLESHOOTING FLOW CHARTS About This Section When a malfunction is discovered the flow charts in this section will help a service professional pinpoint the cause of the problem To use this section basic hand tools and certain pieces of test equipment are required voltmeter onmmeter pressure gauges The location of terminals mentioned in this section can be found on the appropriate electrical or hydraulic schematics provided in Section 6 Schematics Since various degrees of a particular function loss may occur selecting the appropriate flow chart may be troublesome When a function will not operate with the same speed or power as a machine in good working condition refer to the flow chart
12. and check voltage on org blk wire on boom function directional valve coil item L 20V or more Continued on the next page Check voltage at center terminal on TS18 20V or more Troubleshoot platform level toggle switch TS18 OR repair open in org blk wire from TS18 to T61 Troubleshoot platform level toggle switch TS8 OR repair open in org blk wire from TS8 to T110 to T61 Repair open from T61 to T64 to T6 o Repair open in org blk wire from T61 to platform level down function directional valve coil item L Repair open in red power wire circuit from Chart 17 Part No 43063 Genie Z 30 20 Section 5 Troubleshooting Flow Charts Service Manual Third Edition CHART 17 Check continuity from Continued from the brown ground wire at previous page the platform level down directional valve coil continuity Activate function enable and platform level toggle switch TS18 on ground panel in down direction and manually activate valve spool with a T handle function does not operate Exchange platform level down and up relief valves items M N and activate platform level down function function does not operate Exchange platform level down and up check valves items K I and activate platform level down function function does not operate Continued on the next page no continuity function operates f
13. consult Genie Industries Service Department Check ground wire on 2 good Replace C2 bad Repair open in ground wire Repair open in wht red wire from C5 to C2 Genie Z 30 20 Part No 43063 Service Manual Third pEdition Section 5 Troubleshooting Flow Charts CHART 2 Activate function enable Check voltage on Replace C5 relay or and retract function and wht red wire at terminal socket OR consult check voltage at the 14 on C5 Genie Industries Service COM terminal on C5 Department Continued from the previous page Repair short in red wire from 10A fuse 3 OR consult Genie Industries Service Department Activate function enable and retract function and check voltage to terminal T6 Repair open in wht red wire from T6 to C5 Test diodes on printed Replace printed circuit circuit board See board OR consult Genie Repair section Industries Service Department Consult Genie Industries Service Department Part No 43063 Genie Z 30 20 5 7 Section 5 Troubleshooting Flow Charts Service Manual Third Edition Chart 3 All Functions Inoperative Power Unit Starts and Runs Fill with Dexron II equivalent hydraulic fluid Check hydraulic fluid level OK Check for a positive no good connection between electric motor and pump by removing pump from motor but leave all hoses connected Visually check connection Test hydraulic pump
14. in the left direction less than 850 PSI Resest turntable rotate left relief valve pressure OR repair turntable rotate motor or turntable rotate left relief valve OR boom function manifold could have an internal defect OR consult Genie Industries Service Department Service Manual Third Edition Repair open in wht wire from T39 to turntable rotate left function directional valve coil item E Disconnect wires to 0 or turntable rotate left infinite directional valve coil ohms item E and test resistance of valve coil See Repair Section 20 to 25 ohms Replace defective turntable rotate left directional valve item E OR consult Genie Industries Service Department Check for mechanical restrictions keeping turntable rotate left function from operating OR repair turntable rotate motor OR consult Genie Industries Service Department Replace turntable rotate left directional valve coil item E Genie Z 30 20 Part No 43063 Service Manual Third pEdition Section 5 Troubleshooting Flow Charts Turntable Rotate Right Function Inoperative Be sure key switch is in the appropriate position Be sure the Emergency Stop switches are pulled out to the on position Be sure the batteries are fully charged With key switch in ground position and both Emergency Stop switches pulled out to the on position activate function enable and turntable rotate to
15. panel in down direction and check voltage on red wire at T26 20V or more With key switch in platform position and both Emergency Stop switches pulled out to the on position activate footswitch and secondary boom toggle switch TS3 on platform control panel in down direction and check voltage on blu blk wire at T26 20V or more Activate function enable ov and secondary boom toggle switch TS13 on ground control panel in down direction and check voltage at T45 20V or more Activate function enable and secondary boom toggle switch TS13 on ground control panel in down direction and check voltage at T6 20V or more Check continuity from no brown ground wire at the secondary boom down directional valve coil continuity Continued on the next page continuit Check voltage at center terminal on TS13 20V or more Troubleshoot secondary boom down toggle switch TS13 OR repair open in blu blk wire from TS13 to T26 Troubleshoot secondary boom down toggle switch TS3 OR repair open in blu blk wire from TS3 to T105 to T26 Replace printed circuit oard Replace printed circuit oard log log Q Repair open in brown ground wire circuit to T48 Repair open in red power wire circuit from Chart 10 Part No 43063 Genie Z 30 20 5 23 Section 5 Troubleshooting Flow Charts Service Manual Third Edition SSS ee aS SS CHART 10 With key
16. wire circuit from T72 brake release half stroke valve coil item V With ground control 20V Replace diode from T75 Emergency Stop switch to T72 pulled out to the on position activate remote brake release and check voltage at T75 oV With ground control Emergency Stop switch 20V pulled out to the on position activate remote brake release and check voltage at output side of remote brake release plug on ground control panel Repair open in red wire circuit from output side of remote brake release plug to T75 oV With ground control Emergency Stop switch pulled out to the on position check voltage Emergency Stop switch at input side of remote P1 to remote brake brake release plug release plug Repair open in power supply wire circuit from ground control 20V Repair open in remote break release switch OR replace remote brake release switch OR replace remote brake release plug OR consult Genie Industries Service Department 5 60 Genie Z 30 20 Part No 43063 Service Manual Third pEdition Section 5 Troubleshooting Flow Charts ST CHART 25 With ground control Repair open in red wht Gelee SC the Emergency Stop switch wie circuit from T78 to p page pulled out to the on brake release valve N C position activate remote item T brake release and check voltage at red wht wire on brake release valve N C item T 20V or more Consult Genie In
17. 20 to 25 ohms Replace defective primary boom extend directional valve item G OR consult Genie Industries Service Department function does not operate Continued on the next page 5 26 Genie Z 30 20 Part No 43063 Service Manual Third pEdition Section 5 Troubleshooting Flow Charts T CHART 11 Install a 0 to 3000 PSI Check for mechanical pressure gauge at the restrictions keeping quick disconnect primary boom from coupling on the boom extending OR repair function manifold and cylinder or cylinder activate function enable counterbalance valve and the primary boom OR consult Genie extend function Industries Service Department Continued from the previous page less than 500 PSI Repair cylinder or cylinder counterbalance valve OR boom function manifold could have an internal defect consult Genie Industries Service Department Part No 43063 Genie Z 30 20 5 27 Section 5 Troubleshooting Flow Charts Service Manual Third Edition Chart 12 Primary Boom Retract Function Inoperative Be sure key switch is in the appropriate position Be sure the Emergency Stop switches are pulled out to the on position Be sure the batteries are fully charged With key switch in ground position and both Emergency Stop switches pulled out to the on position activate function enable and primary boom retract toggle switch TS14 on ground panel in retract direction an
18. 4 2m Maximum capacity 500 Ibs 227 kg outside EE Fluid Capacities Minimum turning circle 6 ft 4 in 1 9m f inside S Hydraulic tank capacity 2 5 gallons 9 5 liters Turntable rotation 359 Hydraulic system capacity 4 gallons 15 1 liters including tank Platform rotation 130 z i Continuous improvement of our products is a Genie policy Product specifications are subject to change without notice Part No 43063 Genie Z 30 20 2 1 Section 2 Specifications SPECIFICATIONS Performance Specifications Drive speeds maximum Boom stowed 35 1 torque hubs 4 3 mph A0 ft 6 1 sec 6 9 km h 12 2 m 6 1 sec Boom stowed 49 1 torque hubs 3 2 mph A0 ft 8 6 sec 5 1 km h 12 2 m 8 6 sec Boom raised 0 6 mph 40 ft 45 5 sec Gradeability boom stowed 35 1 torque hubs 49 1 torque hubs Boom function speeds maximum from platform controls 1 0 km h 12 2 m 45 5 sec 30 37 Primary boom up 24 to 26 seconds Primary boom down 19 to 21 seconds Primary boom extend 19 to 21 seconds Primary boom retract 12 to 14 seconds Service Manual Third Edition DEEN Hydraulic Specifications Hydraulic fluid Lift pump Dexron equivalent Type gear Displacement per revolution 137 cu in 2 31 cc Displacement 2200 psi 152 bar Function manifold 1 75 gallons per minute 6 6 liters per minute Function relief 2200 psi valve pressure 152 bar Pri
19. 6 OO 8 lelo SS a8 CO del Co 3 q O CI 7 e O O of Ee SE Q OO Oona GZ 1 io el LC g E o a 5 lt L Oo Q 8 e oo 2 O Zu 2 TURNTABLE PC BOARD T64 T66 E N FIEJEJEJEJE Ee adm 4 E A GO GGGGGG QGQOCGL 3000 a 5 OO glo 99 As OO O ofl O O OSL 6 1 O O ert 821 O O sr zel O zyl 921 O 9L Sel O O StL bel O O rl ee1 O OJ CRL zel O O epl IzL O O br oel O O Owl 6 1 O O 661 8 1 O O SEL ZILIO O ZeL 9L1 O gel SILIO O SEL LL O O PEL ELLIO O EEL zi1L O O eel HLL O O IEL Q lalololalolalcoloo S R FRPEPERREE Part No 43063 Genie Z 30 20 Service Manual Third Edition Section 6 Schematics Platform Controls Legend No NC c3 FS DDD DDDNDDDO oo GEI 1 CABLE SAALE oaaao DODOODDOODO DOOODI
20. At Hd w a g Ei e E a SIS Q3H H18 S O HL YOSNAS LL dau M NOLLdO x 5 zem H313W HNOH A NOLLdO m NOOW3d DNIHSY14 ra REI MB Si ma SI gt ge lA 4 1HVLS HOLOW dWNd O NG 8 o 3 Lal aj o a 3 a mM zt o O L x ol si 7 51 1 m HM GHH Q CG Oye as ER pal Ee lt lt lt lt lt lt H O I a gt cn E 5 lo 5 lojlo SN 5 5 9 e 2l 3 19 I L PL A a N pa oO oO A 1YNOLLdO DU L HOLVOIGNI Ks 34 940 3 A w J9HVH9 AH3LLVd e E S PE a RCS QS 8 8 __ _3 I np i d D HOLOW dWNd mai D 6 2 8 gt gt gt gt gt gt gt gt lt i o o Ke o Vd of gt 0 oS crn lt pe s O Genie Z 30 20 6 3 Part No 43063 Service Manual Third Edition Section 6 Schematics Ground Controls Legend Jt Ground Control Box Brake Release Part No 43063 Plug TS19 Tilt Alarm F ncti n Enable F U Platform Turntable Emergency Level Rotate Stop O O TS18 O O O O KS1 Secondary Primary Boom Boom Boom Extend Retract O AB SELS NO NO O O olo O O Genie Z 30 20 6 Service Manual Third Edition Section 6 Schematics Contactor Box and Turntable PC Board Legend CONTACTOR BOX 2 S
21. Hydraulic system including reservoir 4 gallons 15 1 liters Part No 43063 Genie Z 30 20 Section 4 Scheduled Maintenance Procedures Service Manual Third Edition EH This page intentionally left blank 4 20 Genie Z 30 20 Part No 43063 Service Manual Third pEdition Section 5 Troubleshooting Flow Charts Troubleshooting Flow Charts Observe and Obey M Troubleshooting and 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 M Repair any machine damage or malfunction before operating the machine MI Unless otherwise specified perform each repair procedure with the machine in the following configuration Machine parked on a flat level surface Boom in stowed position Turntable rotated with the boom between the non steering wheels Key switch in the off position with the key removed Wheels chocked Before Troubleshooting MI Read understand and obey the safety rules and operating instructions printed in the Genie Z 30 20 Operator s Manual H Be sure that all necessary tools and test equipment are available and ready for use H Read each appropiate flow chart thoroughly Attempting shortcuts may produce hazardous conditions H Be aware of the following hazards and follow generally accepted safe workshop practices T Crushing hazard
22. No 43063 Genie Z 30 20 6 8 Service Manual Third Edition Section 7 Repair Procedures Observe and Obey H Repair procedures shall be completed by a person trained and qualified on the repair of this machine H Immediately tag and remove from service a damaged or malfunctioning machine M Repair any machine damage or malfunction before operating the machine Before Repairs Start H Read understand and obey the safety rules and operating instructions in the Genie Z 30 20 Operator s Manual MI Be sure that all necessary tools and parts are available and ready for use H Read each procedure completely and adhere to the instructions Attempting shortcuts may produce hazardous conditions H Unless otherwise specified perform each repair procedure with the machine in the following configuration Machine parked on a flat level surface Boom in the stowed position Turntable rotated with the boom between the non steering wheels Key switch in the orr position with the key removed Battery packs disconnected Wheels chocked Repair Procedures About This Section Most of the procedures in this section should only be performed by a trained service professional in a suitably equipped workshop Select the appropriate repair procedure after troubleshooting the problem Perform disassembly procedures to the point where repairs can be completed Then to re assemble perform the disassembly steps in reverse o
23. See Repair section good Consult Genie Industries Service Department Replace motor or pump no good Replace pump Genie Z 30 20 Part No 43063 Service Manual Third pEdition Section 5 Troubleshooting Flow Charts All Lift and Steer Functions Inoperative Drive Function Operational With key switch turned to ground position and both mushroom switches pulled out activate function enable and retract function and dead head the pump Check the hydraulic pressure at the quick disconnect fitting on the function manifold less than 2000 PSI Adjust the relief valve on the hydraulic power unit all the way in clockwise counting the number of turns Hold the boom retract switch and recheck the pressure 2000 PSI or more With key switch in ground position and both mushroom switches pulled out to the on position activate any boom function and manually activate boom proportional valve item R function operates Continued on the next page function inop Chart 4 Troubleshoot each function individually OR consult Genie Industries Service Department Activate boom retract function and readjust the relief pressure to 2000 PSI OR consult Genie Industries Service Department Check the function pump See Repair section Replace the pump Replace proportional valve item R OR replace differential sensing valve item Q OR function or propo
24. Stop switch cover and move the toggle switch to the on position at the ground controls Result The flashing beacon should be on and flashing 2 Activate the function enable switch and move the primary boom switch to the pown position hold for a moment and then release it Move the secondary boom switch to the Down position hold for a moment and then release it Result The descent alarm should sound when each switch is held down 3 Turn the key switch to platform control 4 Atthe platform controls pull out the Emergency Stop button to the oN position Result The flashing beacon should be on and flashing 5 Press down the foot switch Move the primary boom switch to the pown position hold for a moment and then release it Move the secondary boom switch to the pown position hold for a moment and then release it Result The descent alarm should sound when each control switch is held down Part No 43063 Genie Z 30 20 Section 4 Scheduled Maintenance Procedures Service Manual Third Edition TABLE B PROCEDURES 6 Press down the foot switch Move the drive control handle off center hold for a moment and then release it Move the drive control handle off center in the opposite direction hold for a moment and then release it Result The travel alarm should sound when the drive control handle is moved off center in either direction B 15 Perform Hydraulic Oil Analysis See D 1 Test or
25. Tag disconnect and plug the extension cylinder hydraulic hoses Cap the fittings on the cylinder Bodily injury hazard Spraying AWARNING hydraulic oil can penetrate and burn skin Loosen hydraulic connections very slowly to allow to dissipate gradually Do not allow oil to squirt or spray PRIMARY BOOM COMPONENTS Place blocks under the barrel end of the extension cylinder for support Remove the cotter pin from the barrel end clevis pin Remove the clevis pin Always use a new cotter pin when installing a clevis pin Carefully pull out and properly support the extension cylinder from the platform end of the extension tube Crushing hazard The cylinder will ACAUTION fall if it is not properly supported when it is pulled out of the extension tube Component damage hazard Be ACAUTION sure not to damage the counterbalance valve block on the barrel end of the extension cylinder To make installation of the extension cylinder easier be sure that the cylinder rod is extended 2 to 3 feet 0 6 to 0 9 m Part No 43063 Genie Z 30 20 7 15 Section 7 Repair Procedures Service Manual Third Edition PRIMARY BOOM COMPONENTS 3 5 Platform Leveling Master Cylinder The master cylinder acts as a pump for the slave cylinder It is part of the closed circuit hydraulic loop that keeps the platform level through the entire range of primary boom motion The master cylinder is located on the mid pivot at t
26. Then raise the primary lift cylinder with the crane to a vertical position 5 Remove the pin retainer from the pivot pin at the barrel end of the primary boom lift cylinder Genie Z 30 20 Part No 43063 Service Manual Third Edition Section 7 Repair Procedures 6 Place a rod through the barrel end pivot pin and twist to remove the pin Remove the primary lift cylinder from the machine Crushing hazard The primary AWARNING boom lift cylinder will fall when the barrel end pivot pin is removed if it is not properly supported 7 Tag and disconnect the power cables from the hydraulic pump Pull these down through the turntable AWARNING Electrocution hazard Contact with electrically charged circuits may cause death or serious injury Remove all rings watches and other jewelry 8 Tag disconnect and plug the hydraulic hoses from the steer cylinder Pull these hoses up through the turntable Cap the fittings on the cylinder AWARNING SC 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 TURNTABLE ROTATION COMPONENTS 9 Tag disconnect and plug the hydraulic hose to the brakes Pull this hose up through the turntable Cap the fittings on the brakes AWARNING SC injury hazard Spraying ydraulic oil can penetrate and burn skin Loosen hydraulic connections ver
27. an unsafe operating condition and component damage 1 Raise the secondary boom and place a safety chock on the secondary boom lift cylinder The lift cylinder safety chock is available through Genie part number 36555 2 Carefully lower the boom onto the lift cylinder safety chock Crushing hazard Keep hands AWARNING away from the cylinder and all moving parts when lowering the secondary boom 2 Check to ensure that each turntable bearing bolt is torqued in specified order to 190 foot pounds 258 Newton meters Bolt torque sequence 3 Remove the safety chock Lower the boom to the stowed position 4 Disconnect the battery packs from the machine 5 Remove the mounting fasteners from both battery packs Use a lifting device to remove the battery packs from the machine Part No 43063 Genie Z 30 20 Section 4 Scheduled Maintenance Procedures Service Manual Third Edition TABLE CG PROCEDURES 6 Support the large counterweight under the drive chassis with a forklift at the power unit side of the machine Lift it slightly to take the weight off of the threaded rod Support the smaller counterweight with a floor jack from the steer end of the machine and lift it slightly to take the weight off of the threaded rod 7 Remove the fasteners from the cover at the non steer end of the drive chassis Remove the cover from the machine 8 Remove the nut from the threaded rod that runs through the center of
28. and continued use may cause component damage Extremely dirty conditions may require oil changes to be performed more often The machine uses Dexron II equivalent hydraulic oil 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 Perform this procedure with the boom in the stowed position 1 Place a suitable container under the hydraulic power unit reservoir 2 Remove the power unit side turntable cover 3 Remove the drain plug from the bottom of the hydraulic power unit reservoir 4 Completely drain the reservoir into a suitable container See capacity specifications listed above 5 Remove the reservoir mounting fasteners Remove the reservoir and clean it using a mild solvent 6 Remove the suction strainer and clean it using a mild solvent 7 Install the suction strainer Install the reservoir onto the power unit 9 Install the reservoir drain plug using a thread sealant Table D Procedures 10 Fill the reservoir with hydraulic oil until the level is visible in the sight gauge Do not overfill 11 Clean up any oil that may have spilled Hydraulic Oil Specifications Hydraulic oil type Dexron equivalent Hydraulic reservoir capacity 2 5 gallons 9 5 liters
29. from T3 to C1 then to terminal 3 on Curtis controller Part No 43063 Genie Z 30 20 Section 5 Troubleshooting Flow Charts Service Manual Third Edition CHART 20 Continue down to next box With key switch in Repair open in red wire platform position and circuit from X terminal both Emergency Stop on joystick controller to switches pulled out to T113 then through red the on position activate wht wire to T13 then to footswitch and drive T3 controller in forward direction and check voltage at X terminal on drive controller Continued from the previous page With key switch in Repair open in power platform position and circuit to joystick both Emergency Stop controller to T111 to 48V or more switches pulled out to footswitch OR consult the on position activate Genie Industries Service footswitch and check Department voltage at terminal on the joystick controller Repair or replace the joystick controller With key switch in Repair open in positive platform position and cable from C1 to B both Emergency Stop terminal on Curtis switches pulled out to controller the on position activate footswitch and drive controller in forward direction and check voltage at B terminal on Curtis controller 48V or more Activate footswitch and Repair open in positive drive controller in cable from Fwd Rev forward direction and contactor to A1 terminal check voltag
30. may cause death or serious injury and property damage AWARNING Collision hazard Select a work site that is firm and level 1 Chock the steer wheels to prevent the machine from rolling 2 Center a lifting jack of ample capacity 15000 lbs 6804 kg under the drive chassis between the non steering wheels 3 Lift the wheels off the ground and then place jack stands under the drive chassis for support 4 Disengage the torque hubs by turning over the torque hub disconnect caps on each torque hub o brake disengage position Ze mj h brake engage position 5 Manually rotate each non steering wheel Result Each non steering wheel should rotate with minimum effort 6 Re engage the torque hubs by turning over the hub disconnect caps Carefully remove the jack stands lower the machine and remove the jack Collision hazard Failure to AWARNING re engage the torque hubs may cause death or serious injury and property damage TABLE C PROCEDURES C 4 Grease the Turntable Rotation Bearing and Worm Drive Gear Yearly application of lubrication to the turntable bearing and worm drive gear is essential to good machine performance and service life Continued use of an improperly greased gear will result in component damage 1 Remove the power unit side turntable cover 2 Locate the grease fitting on the inside of the turntable rotation bearing 3 Pump grease into the turntable rotation bearing Rotate the tu
31. operational Be sure that the machine is not in AWARNING free wheel or partial free wheel configuration Refer to B 4 in this section Confirm the Proper Brake Configuration Select a test area that is firm level and free of obstructions 1 Mark atest line on the ground for reference 2 Turn the key switch to platform control and lift the red Emergency Stop switch cover and move the toggle switch to the on position at the ground controls Pull out the Emergency Stop Button to the on position at the platform controls Lower the boom into the stowed position 4 Choose a 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 Braking paved surface Stopping distance 4 5 ft 1 2t0 1 5m The brakes must be able to hold the machine on any slope it is able to climb B 13 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 l
32. s and safety manuals in good condition is essential to safe machine operation Manuals are included with each machine and should be stored in the container provided in the platform An illegible or missing manual will not provide safety and operational information necessary for a safe operating condition 1 Check to be sure the storage container is present and in good condition 2 Check to make sure that the operator s responsibilities and safety manuals are present and complete in the storage container in the platform 3 Examine the pages of each manual to be sure that they are legible and in good condition 4 Always return the manuals to the storage container after use Contact your authorized Genie distributor or Genie Industries if replacement manuals are needed A 2 Inspect the Decals and Placards Maintaining all of the safety and instructional decals and placards in good condition is mandatory for safe machine operation Decals alert operators and personnel to the many possible hazards associated with using this machine They also provide users with operation and maintenance information An illegible decal will fail to alert personnel of a procedure or hazard and could result in unsafe operating conditions 1 Refer to the Decals section in the appropriate Genie Z 30 20 Operator s Manual and use the decal list and illustrations to determine that all decals and placards are in place 2 Inspect all decals for leg
33. switches from ground controls to T6 Replace key switch contact for ground controls Genie Z 30 20 Part No 43063 Service Manual Third pEdition Section 5 Troubleshooting Flow Charts CHART 5 With key switch in D4V Check continuity from Repair open in brown Gg de the ground position and the brown ground wire MAU ground wire from lift p page both Emergency Stop to T43 proportional valve coil tls pulled out to item R to T43 the on position activate Ai ch enable and the continuity retract function and check voltage at blu red Consult Genie Industries wire at lift proportional Service Department valve item R oV Activate function enable and the retract function and check voltage on the wht red wire at terminal 14 on C4 Repair open in wht red wire from T64 to terminal 14 on C4 24V no Check continuity from pntinuit the brown ground wire at terminal 13 on C4 Repair open in brown ground wire from terminal 13 on C4 to T43 continuity Check voltage on the blu wire at terminal 9 on C4 Repair open in blu wire from terminal 9 on C4 to base contact of keyswitch 24V Activate function enable Replace C4 or socket and the retract function OR repair open in blu and check voltage on wire from terminal 5 to T51 T52 OR replace diode from T52 to T51 24V Consult Genie Industries Service Department Part No 43063 Genie
34. the Hydraulic Filter ra ra za ra ra ra BEE Table D D 1 Test or Replace the Hydraulic Oil Z Ei 3 4 Genie Z 30 20 Part No 43063 Service Manual Third Edition Section 3 Scheduled Maintenance Inspections Maintenance Inspection Report Model Serial number Date Hour meter Machine owner Inspected by print Inspector signature Inspector title Inspector company Instructions Make copies of this page to use for eachinspection Select the appropriate checklist s for the type of inspection to be performed Daily Inspection A Quarterly Inspection A B Annual Inspection A B C 2 Year Inspection A B C D Place a check in the appropriate box after each inspection procedure is completed Use the maintenance tables in this section and the step by step procedures in section 4 to learn how to perform these inspections If any inspection receives an N tag and remove the machine from service repair and re inspect it After repair place a check in the R box Legend Y yes acceptable N no remove from service R repaired Comments Checklist A Checklist YNR Refer to Table A Refer to Table C A 1 Operator s and C 1 Boom wear pads Safety manuals C 2 Turntable bearing bolts A 2 Decals and placards A 3 Damage loose or missing parts A 4 Hydraulic oil level A 5 Hydraulic leaks A 6 Platform and ground controls A 7 Platfor
35. the cotter pins from the clevis pins at each end of the steer cylinder Then remove the clevis pin from each end of the steering cylinder 3 Remove the steering cylinder Always use a new cotter pin when installing a clevis pin 9 3 Tie Rod How to Remove the Tie Rod 1 Remove the cotter pin from both clevis pins then remove the clevis pin from each end of the tie rod 2 Remove the tie rod Always use a new cotter pin when installing a clevis pin Genie Z 30 20 Part No 43063 Service Manual Third Edition Section 7 Repair Procedures Non steering Axle Components 10 1 Drive Motor How to Remove a Drive Motor A drive motor can only be removed from the inside of the drive chassis 1 Disconnect the battery packs from the machine 2 Remove the drive chassis cover from the non steer end of the machine 3 Tag and disconnect the power cables from the drive motor to be removed Electrocution hazard Contact with AWARNING electrically charged circuits may result in death or serious injury Remove all rings watches and other jewelry 4 Remove the drive motor mounting fasteners 5 Guide the drive motor shaft out of the brake and then remove the drive motor 10 2 Torque Hub How to Remove a Drive Torque Hub 1 Chock the steer tires 2 Remove the drive motor See 12 1 How to Remove a Drive Motor 3 Disconnect the hydraulic hose from the brake and plug it Cap the fitting on the brak
36. the counterweights at the steer end of the machine 9 Pull the threaded rod through the counterweights and out of the non steer end of the machine Crushing hazard The AWARNING counterweights may become unbalanced and fall if they are not properly supported 10 Pull the smaller counterweight towards the steer end of the machine slightly and then lower the counterweight to the ground 11 Shift the forks of the forklift to the steer end of the machine enough for the counterweight to clear the forklift pocket tube 12 Lower the counterweight and then remove the counterweight from the machine Crushing hazard The AWARNING counterweight may become unbalanced and fall if it is not properly supported 13 Check to ensure that each bearing mounting bolt under the drive chassis is torqued in specified order to 190 foot pounds 258 Newton meters Bolt torque sequence 14 Install the counterweights back into the chassis Tip over hazard Counterweights are critical to machine stability Failure to replace the counterweights will result in death or serious injury Genie Z 30 20 Part No 43063 Service Manual Third Edition Section 4 Scheduled Maintenance Procedures C 3 Check the Free wheel Configuration Proper use of the free wheel configuration is essential to safe machine operation The free wheel configuration is used primarily for towing A machine configured to free wheel without operator knowledge
37. the toggle switch to the on position at the ground controls Pull out the Emergency Stop Button to the on position at the platform controls 2 Push down the service horn button at the platform controls Result The service horn should sound Part No 43063 Genie Z 30 20 Section 4 Scheduled Maintenance Procedures Service Manual Third Edition TABLE B PROCEDURES B 11 Test the Foot Switch A properly functioning foot switch is essential to safe machine operation Machine functions should activate and operate smoothly as long as the foot switch is pressed down and promptly stop when the foot switch is released An improperly functioning foot switch can cause an unsafe working condition 1 Turn the key switch to platform control and lift the red Emergency Stop switch cover and move the toggle switch to the on position Pull out the Emergency Stop Button to the on position at the platform controls 2 Without pressing down the foot switch check the machine functions Result The machine functions should not operate 3 Press down the foot switch and operate the machine functions Result The machine functions should operate B 12 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 not fully
38. to be sure it is in the engaged position brake disengage position mj e mj brake engage position TABLE B PROCEDURES B 5 Check the Oil Level in the Torque Hubs Failure to maintain proper torque 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 the plugs are located one on top and the other at 90 degrees 2 Remove the plug located at 90 degrees and check the oil level Result The oil level should be even with the bottom of the plug hole 3 If necessary remove the top plug and add oil until the oil level is even with the bottom of the side plug hole 4 Apply pipe thread sealant to the plugs then install the plugs into the hub 5 Repeat this procedure for the other torque hub Drive Torque Hub Oil 17 fluid ounces 0 5 liters Capacity Type SAE 90 multipurpose hypoid gear oil API service classification GL5 Part No 43063 Genie Z 30 20 Section 4 Scheduled Maintenance Procedures Service Manual Third Edition TABLE B PROCEDURES B 6 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 op
39. 0 USA If you have any questions please call Genie Industries Genie North America Telephone 425 881 1800 Toll Free 800 536 1800 in U S A Toll Free 800 426 8089 in Canada Fax 425 883 3475 http www genielift com Genie Europe Telephone 44 1636 605030 Fax 44 1636 611090 http www genielift com Genie Industries Copyright 1997 by Genie Industries First Edition First Printing December 1997 Genie and Z are a registered trademark of Genie Industries in the U S A and many other countries Printed on recycled paper Printed in U S A ii Genie Z 30 20 Part No 43063 Service Manual Third Edition Safety Rules Danger Failure to obey the instructions and safety rules in this manual and the appropriate Genie Z 30 20 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 M You are trained and qualified to perform maintenance on this machine M You read understand and obey manufacturer s instructions and safety rules employer s safety rules and worksite regulations applicable governmental regulations H You have the appropriate tools lifting equipment and a suitable workshop Part No 43063 Genie Z 30 20 iii Service Manual Third Edition SAFETY RULES Personal Safety Any
40. 0V or more Repair open in wht wire circuit with diode from pressure switch on brake manifold to T6 OR replace pressure switch OR open in wire from TB78 to pressure switch Repair open in red wht wire with diode from T81 to T78 Repair open in red wire circuit from X terminal on drive controller to T113 to T13 then to T3 Repair open in power circuit to drive controller from footswitch T111 to terminal on joystick OR consult Genie Industries Service Department Part No 43063 Genie Z 30 20 Section 5 Troubleshooting Flow Charts E CHART 20A Continued from the previous page With key switch in platform position and both Emergency Stop switches pulled out to the on position activate footswitch and drive controller in fwd direction until 1 2 stroke micro switch activates and check voltage at blk wht and ground wires on brake release valve item T on brake manifold 20V or more Disconnect red wht and ground wires from brake release valve item T and check resistance of coil See Repair Section Service Manual Third Edition Activate footswitch and drive controller in fwd 20V or direction until 1 2 stroke micro switch activates and check voltage at T15 more Activate footswitch and drive controller DP1 in 20V or fwd direction until 1 2 Lmore stroke micro switch activates and check voltage at red wht wire on 1 2 stroke micro swit
41. 4 Genie Z 30 20 Part No 43063 Service Manual Third Edition Section 7 Repair Procedures MANIFOLDS Part No 43063 Genie Z 30 20 7 25 Section 7 Repair Procedures Service Manual Third Edition MANIFOLDS 7 2 Valve Adjustments Function Manifold How to Adjust the Primary Boom Down Relief Valve 1 Connect a 0 to 3000 psi 0 to 206 bar pressure gauge to the test port on the function manifold 2 Turn the key switch to ground control and lift up the Emergency Stop Switch cover at the ground controls and move the switch to the on position 3 Activate the function enable switch and hold the primary boom down switch with the primary boom fully lowered and observe the pressure reading on the pressure gauge 4 Turn the machine off Hold the relief valve and remove the cap item 14 function manifold 5 Adjust the internal hex socket Turn it clockwise to increase the pressure or counterclockwise to decrease the pressure Then install the relief valve cap Tip over hazard Do not adjust AWARNING the relief valves higher than recommended 6 Repeat steps 2 through 3 and recheck the valve pressure How to Adjust the Secondary Boom Down Relief Valve Perform this procedure with the boom in the stowed position 1 Connect a 0 to 3000 psi 0 to 206 bar pressure gauge to the test port on the function manifold 2 Turn the key switch to ground control and lift
42. 7 Activate drive controller in reverse direction and check voltage on wht wire on micro switch on drive controller Repair or replace micro switch on drive controller OR drive controller cams are out of adjustment Consult Genie Industries Service Department Remove wht and ground wires from reverse contactor coil and check resistance of reverse coil See Repair Section 40 ohms Repair or replace reverse contactor contacts OR repair open in brown ground wire circuit OR consult Genie Industries Service Department Repair open in wht wire circuit from T8 to reverse contactor OR replace printed circuit board Repair open in wht wire circuit from wht wire on micro switch on drive controller to T120 through wht wire to T17 Repair or replace fwd rev contactor Genie Z 30 20 Part No 43063 Service Manual Third pEdition Section 5 Troubleshooting Flow Charts Machine Will Not Drive At Full Speed Be sure machineisin fully stowedposition Besurethe batteries are fullycharged With key switch in platform position and both Emergency Stop switches pulled out to the on position activate footswitch and check voltage on X terminal on drive controller 20V or more With key switch in platform position and both Emergency Stop switches pulled out to the on position check voltage on R terminal on drive controller With key switch in platform position and both Emergency
43. Cylinder 1 Raise the boom slightly and place sawhorses under the platform for support Then lower the boom until the platform is resting on the sawhorses Do not rest the entire weight of AWARNING the boom on the sawhorses just enough to support the platform 2 Tag disconnect and plug the hydraulic hoses from the slave cylinder and connect them together with a connector Cap the fittings on the cylinder 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 3 Remove the pin retaining fastener from the rod end pin 4 Remove the pin retaining fastener from the barrel end pin Part No 43063 Genie Z 30 20 Section 7 Repair Procedures E PLATFORM COMPONENTS Use a soft metal drift and drive the rod end pin out Use a soft metal drift and drive the barrel end pin out Note the quantity and location of the shims on the barrel end pivot pin 7 Remove the cylinder from the machine How to Bleed the Slave Cylinder 1 Raise the primary boom to a horizontal position Move the platform level switch to the down position to retract the platform leveling cylinder Do not allow the platform to contact the ground Loosen the lock nut on the needle valve Do not remove the valve a locknut b primary extension boom c needlevalve d plat
44. DC to terminal 8 and a ground wire to terminal 7 then test the following terminal combinations Test Desired result terminal 1 to 2 4 546 no continuity infinite Q terminal 2 to 3 5 amp 6 no continuity terminal 1 to 3 continuity zero Q terminal 2 to 4 Nd pi Relay Schematic continuity Part No 43063 Genie Z 30 20 Section 7 Repair Procedures Service Manual Third Edition Hydraulic Pump 6 1 Main Function Pump How to Test the Main Function Pump 1 Disconnect and plug the high pressure hydraulic hose from the main function pump 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 Connect a O to 5000 psi 0 to 350 bar pressure gauge to the high pressure port on the pump 3 Turn the key switch to ground control and lift up the Emergency Stop Switch cover at the ground controls and move the switch to the on position 4 Activate the function enable switch any lift function from the ground controls Result If the pressure gauge reads 2000 psi 137 9 bar immediately stop The pump is good Result If pressure fails to reach 2000 psi 137 9 bar the internal relief valve setting is incorrect or the pump is bad and will need to be serviced or replaced 5 Remove the pressure gauge and reconnect
45. DQOOO LN OPTION leg Oe ee eg RESET DISCHARGE O O TILT SET TO A SET TO N ALARM BP1 TS9 TS1 TS2 TS7 0 O O OOO O 0 O 0 o o o o o P O O OOO O O OO o TS3 TS5 fo o o O O Ge oo jo 0 g O O O O O D Kl TS4 TS6 TS18 O 0 OOO OOO HI O O DP1 O O OOO OOO GENEE JU D X TS8 P3 P2 2 Ri O O O O gt O O NO NC NC L O 0 O olo O R O Part No 43063 Genie Z 30 20 6 6 Service Manual Third Edition Section 6 Schematics Hydraulic Symbols Legend Pressure gauge O Filter Fixed displacement pump Bi directional motor Om Pump prime mover engine or motor Double acting cylinder NYE a 0 035 Orifice with size Check valve Relief valve Priority flow divider Sach H Solenoid operated dump valve Differential sensing valve Solenoid operated proportional valve Solenoid operated 2 pos 3 way directional valve WW H RS Solenoid operated 3 pos 4 way directional valve DEER Pilot operated flow control valve Counterbalance valve Brake Genie Z 30 20 Part No 43063 Service Manual Section 6 Schematics a ee es Hydraulic Schematic
46. Genie Industries Technical Publications gt _ gt Genie Z 30 20 _ O OOOO O OO Service Manual Third Edition First Printing Part No 43063 Introduction Service Manual Third Edition Genie Z 30 20 Important Read understand and obey the safety rules and operating instructions in the appropriate Genie Z 30 20 Operator s Manual before attempting any maintenance or repair procedure This manual provides detailed scheduled maintenance information for the machine owner and user It also provides troubleshooting 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 Genie Industries has endeavored to deliver the highest degree of accuracy possible However continuous improvement of our products is a Genie policy Therefore product specifications are subject to change without notice Readers are encouraged to notify Genie of errors and send in suggestions for improvement All communications will be carefully considered for future printings of this and other manuals Please write to the technical publications team in care of Genie Industries PO Box 97030 Redmond WA 98073 973
47. Manual Third pEdition Section 5 Troubleshooting Flow Charts previous page Continued from the Check voltage on output side of 300A fuse 1 Replace 300A fuse 1 Troubleshoot lift and drive systems separately OR consult Genie Industries Service Department CHART 1 Part No 43063 Genie Z 30 20 Section 5 Troubleshooting Flow Charts Service Manual Third Edition Chart 2 Lift Pump Motor Will Not Operate Be sure key switch is in the appropriate position Be sure the Emergency Stop switches are pulled out to the on position Activate function enable 48V and retract function and check voltage at positive terminal on pump motor oV Activate function enable and retract function and 48V check voltage at positive ane on output side of 2 oV Check voltage on positive cable on input side of C2 48V Activate function enable and retract function and 24V check voltage at wht red wire at C2 Activate function enable 24V and retract function and check voltage at the N O terminal on C5 Continued on the next page Check ground cable to lift pump motor good Repair or replace lift pump motor bad Replace ground cable on lift pump motor OR repair open in ground cable from battery packs Repair or replace positive cable oe 80A fuse 2 OR repair open in positive cable from battery packs to 80A fuse 2 to C2 OR
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49. ROCEDURES A 9 Test the Manual Controls Detection of manual control system malfunctions is essential for safe machine operation An unsafe working condition exists if the manual controls do not operate in the event of a main power loss 1 Remove the function manifold side turntable cover 2 Insert the T handle into the end of the valve spool to be tested 3 Push and hold the T handle against the valve spool operate the hand pump Result Boom function should operate 4 Repeat steps 2 and 3 to test each boom function Manual controls will not operate the drive function Part No 43063 Genie Z 30 20 4 5 Section 4 Scheduled Maintenance Procedures Service Manual Third Edition TABLE A PROCEDURES A 10 Test the Drive Limit Switch Detecting a drive limit switch malfunction is essential to safe machine operation The drive limit switches are used to restrict drive speed when the boom is raised An improperly functioning limit switch will allow the boom to drive into an unsafe position 1 With the boom in the stowed position visually inspect the drive limit switches for the following Broken or missing arms or rollers Missing fasteners Loose wiring 2 Turn the key switch to ground control and lift the red Emergency Stop switch cover and move the toggle switch to the on position 3 Activate the function enable switch and raise the primary boom above the drive limit switch and turn the ma
50. Replace the Hydraulic Oil B 16 Test the Turntable Rotation Stop The turntable is capable of rotating the boom 355 degrees and is stopped midpoint between the steering 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 control and lift the red Emergency Stop switch cover and move the toggle switch to the on position at the ground controls Pull out the Emergency Stop Button to the on position at the platform controls 2 Rotate the turntable to the left full circle as far as it will go Result Movement should stop when the primary boom reaches mid point between the steer tires 3 Rotate the turntable to the right full circle as far as it will go Result Movement should stop when the primary boom reaches mid point between the steer tires B 17 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 at the non steer end and locate the electrical component compartment 2 Remove the cover on the electrical component compartment and locate the electrical contactors 3 Visually inspect the contact points of each
51. Service Department Check for mechanical restrictions keeping turntable rotate right function from operating OR repair turntable rotate motor OR consult Genie Industries Service Department Replace turntable rotate right directional valve coil item E Genie Z 30 20 Part No 43063 Service Manual Third pEdition Section 5 Troubleshooting Flow Charts All Platform Level Functions Inoperative Be sure key switch is in the appropriate position Be sure the Emergency Stop switches are pulled out to the on position Be sure the batteries are fully charged Remove both hydraulic hoses from the manifold ports A1 amp B1 Plug the hoses and cap the manifold fittings Operate primary boom up function and check if platform levels no Plumb a pressure gauge into the barrel end hydraulic hose hose connected to port A3 using a tee fitting Operate primary boom up function and read the pressure Reconnect the hoses and switch the two relief valves items M N on yes yes the function manifold Operate the primary boom in the up direction and check to see if platform levels Switch the two check valves items K I on the function manifold Operate the primary boom in the up direction and check to see if yes platform levels Replace the platform level directional valve item L OR consult Genie Industries Service Department 1800 Check for mechanical
52. Stop switches pulled out to the on position check voltage on T19 With key switch in platform position and both Emergency Stop switches pulled out to the on position check voltage on T13 Repair open in red wire from X terminal on joystick to to T13 OR replace printec circuit board on joystick OR consult Genie Industries Service Department Chart 23 Replace joystick controller OR consult Genie Industries Service Department Readjust drive controller refer to repair section OR repair or replace drive controller OR consult Genie Industries Service Department Repair open in blu wht wire circuit from T19 to T115 then to R terminal on drive controller Repair open in wire circuit from T13 through the blk wire to LS1 through wht wire to T59 through the blu wht wire to LS2 then to T19 OR repair or replace LS1 or LS2 OR check for mechanical restriction keeping LS1 or LS2 from operating Part No 43063 Genie Z 30 20 5 57 Section 5 Troubleshooting Flow Charts Service Manual Third Edition Chart 24 Machine Drives With key switch in Lower primary boom to Repair or replace LS1 platform position both stowed position With OR check for At Full Speed Emergency Stop key switch in platform mechanical restriction i switches pulled out to position and both keeping LS1 activated With Platform the on position and Emergency Stop OR consult Genie Raised primary boom raised switches pulled out to Ind
53. Stop the contact at the switches pulled out to platform controls the on position do not Emergency Stop Switch activate the foot switch to the footswitch check voltage at the wht wire at the footswitch 24V Continued on the next page 5 14 Genie Z 30 20 Part No 43063 Service Manual Third pEdition Section 5 Troubleshooting Flow Charts Continued from the previous page With key switch in platform position and both Emergency Stop switches pulled out to the on position activate the foot switch and check voltage at T111 24V Activate footswitch and check voltage on terminal 9 on C3 24V Activate footswitch and check voltage on terminal 1 on C3 24V Activate footswitch and check voltage on the center terminal of each function toggle switch at the platform controls 24V Check voltage at the red wire on the lift proportional controller 24V less than 0 7A With key switch in platform position and both Emergency Stop switches pulled out to the on position and the lift proportional controller turned to 9 activate the foot switch and check amperage on the blk red wire on the lift proportional controller 0 7 to 0 75A Continued on the next page CHART 6 Repair open in blk wire from footswitch to T111 Repair open in red wire from T111 to terminal 9 on C3 Replace C3 relay OR replace C3 relay socket Repair open in red wire termi
54. Test the Platform Self leveling Automatic platform self leveling throughout the full cycle of boom raising and lowering is essential for safe machine operation The platform is maintained at level by the platform leveling slave cylinder which is controlled by the master cylinder located at the base of the primary boom A platform self leveling failure creates an unsafe working condition 1 Turn the key switch to ground control and lift up the Emergency Stop Switch cover at the ground controls and move the toggle switch to the on position Pull out the Emergency Stop Button to the on position at the platform controls 2 Activate the function enable switch and lower the boom to the stowed position TABLE B PROCEDURES 3 Activate the function enable switch and adjust the platform to a level position using the platform leveling switch 4 Activate the function enable switch and raise and lower the primary boom through a full cycle Result The platform should remain level at all times to within 5 degrees B 10 Test the Service Horn A functional service horn is essential to safe machine operation The service horn is activated at the platform controls and sounds at the ground as a warning to ground personnel An improperly functioning horn will prevent the operator from alerting ground personnel of hazards or unsafe conditions 1 Turn the key switch to platform control and lift the red Emergency Stop switch cover and move
55. Z 30 20 5 13 Section 5 Troubleshooting Flow Charts Service Manual Third Edition Chart 6 Platform Controls Inoperative Ground Controls Operate Normally Be sure key switch is in the appropriate position Be sure the Emergency Stop switches are pulled out to the on position Be sure the batteries are fully charged Be sure boom function speed controller is Check voltage at red wire on ground controls oV contact of the key switch the red wire checked should originate at the emergency stop switch 24V Turn key switch to platform position and check output side of contact 24V 24V Check voltage at T14 ov Repair open in red wire circuit from emergency stop switch to the key switch Check if key switch internal cam is activating y platform contact Replace key switch contact for ground controls no Replace key switch Repair open in red blk wire from platform controls keyswitch contact to T14 on the printed circuit board turned to 9 Check voltage on the Repair open in red and red and red blk wires at red blk wires from T14 T123 to T123 24V Check voltage on the Repair open in red wire red wire at the from T123 to the Emergency Stop Switch Emergency Stop Switch at the platform controls at the platform controls 24V With key switch in Repair open in wht wire platform position and from the ou put side of both Emergency
56. a aaa each 5 44 20 All Drive Functions Inoperative All Other Functions Operate Normally 5 46 20A Brake Function Inoperative ee sessse eee aaa aaa aaa aaa iiawnaae 5 51 21 Drive Forward Function Inoperative ccccceeeeeeeceeeeeeeeeeeeeeeeseeeeeeeeeeeeeeeaees 5 55 22 Drive Reverse Function Inoperative cccceeceeeeceeeeeeeeeeeeeeeeseeeeeaeeeeeeeeenaees 5 56 23 Machine Will Not Drive At Full Speed seeeee sea aa aaa ena aaa aazaaecea 5 57 24 Machine Drives At Full Speed With Platform Raised eeeeseeseeeeeeeeen 5 58 25 Remote Brake Release Inoperative 20 00 ceceeeeeeeeeeeeeeeeneeeeeeeeeaaeeeeeeseaaes 5 59 Part No 43063 Genie Z 30 20 vii Service Manual Third Edition TABLE OF CONTENTS Section Six Schematics dit tele ele TT 6 1 Electrical Symbols Legend 6 2 Electrical Schematic AAA 6 3 Ground Control Panel Legend 6 4 Power Panel Legend ineens iaaa i aoe ieda iaa daa ra a EE ea Nas 6 5 Platform Control Panel Legend sssssseseessesessesssssssrnrsssrnnesntrrnnssrtnssstnnstnnnennnnnnnnne 6 6 Hydraulic Symbols Legend 6 7 Hydraulic Schematic eseee ao ee aaa eee aaa aaa aaa aaa aaa 6 8 viii Genie Z 30 20 Part No 43063 Service Manual Third Edition DEEN Section Seven TABLE OF CONTENTS Repair Procedures dit tele ele ET 7 1 Platform Controls died e Tute 7 2 EE Wee EE 7 5 1 3 Toggle Switches ue e
57. and check voltage at output side of remote break release plug on ground control panel oV With ground control Emergency Stop switch pulled out to the on position check voltage at input side of remote brake release 20V Repair or replace open in remote break release switch OR replace remote break release plug OR consult Genie Industries Service Department 20v 20V 20V Chart 25 Repair open in wht wire circuit from T78 to pressure switch PS1 OR the wht wire with diode circuit from pressure switch PS1 to T6 OR replace pressure switch PS1 OR consult Genie Industries Service Department Replace diode from T75 to T78 Repair open in red wire circui from output side of remote brake release plug to T75 Repair open in power supply wire circuit from ground control Emergency Stop switch P1 to remote break release plug Part No 43063 Genie Z 30 20 Section 5 Troubleshooting Flow Charts CHART 25 With ground control Emergency Stop switch pulled out to the on position activate remote brake release and check voltage at blk wht wire on brake release half stroke valve item V Continued from the previous page 20V Continued on the next page Service Manual Third Edition With ground control Emergency Stop switch 20V pulled out to the on position activate remote brake release and check voltage at T72 Repair open in blkAvht
58. anel in up direction and check voltage at T6 20V or more Check continuity from no brown ground wire at the secondary boom up directional valve coil continuity Continued on the next page continuit Check voltage at center terminal on TS13 20V or more Troubleshoot secondary boom up toggle switch TS13 OR repair open in blu wire from TS13 to T25 Troubleshoot secondary boom up toggle switch TS3 OR repair open in blu wire from TS3 to T106 to T25 Replace printed circuit oard Replace printed circuit board log Q Repair open in brown ground wire circuit to T48 Chart 9 Repair open in red power wire circuit from TS19 to TS13 Part No 43063 Genie Z 30 20 5 21 Section 5 Troubleshooting Flow Charts E CHART 9 Continued from the previous page With key switch in ground position and both Emergency Stop switches pulled out to the on position activate function enable and secondary boom toggle switch TS13 on ground panel in up direction and check voltage on blu wire on boom function directional valve coil item J 20V or more Activate function enable and secondary boom toggle switch TS13 on ground panel in up direction and manually activate valve spool with a T handle function operates function does not operate Install a 0 to 3000 PSI pressure gauge at the quick disconnect coupling on the boom 600 PSI function mani
59. ate repair open in brown footswitch and check voltage at T111 ground wire circuit from the joystick controller to Other Fu nections footswitch and check voltage at terminal Ope rate on joystick controller T116 to T10 Normally Be sure the unit is in the Repair open in blk wire sas circuit from footswitch to fully stowed position T111 OR repair open in with the boom located brown ground wire between the drive tires circuit from the joystick controller to T116 to T10 20V or more Repair open in blu wht wire circuit from drive enable toggle switch TS9 to TB12 OR consult Genie Industries Service Department Check voltage from B less than Repair open in power terminal on Curtis 48V cable from battery packs controller to input side of to F1 OR ground cable 300 amp fuse F1 to B terminal on Curtis controller 48V or more Check voltage on output side of 300 amp fuse F1 Replace 300 amp fuse 1 m 48V or more Check voltage positive cable on input side of C1 Repair open in positive cable from output terminal of 300 amp fuse F1 to input side of Ci 48V Continued on the next page 5 46 Genie Z 30 20 Part No 43063 Service Manual Third pEdition Continued from the previous page Check voltage at positive cable on output side of C1 48V tires dont move Jack up unit so drive tires are off the ground Disconnect white w
60. ax out trimpot adjustment screw clockwise to increase the amperage or counterclockwise to decrease the amperage Boom function speed controller specifications Threshold controller turned to cREEP 0 to 0 12 amps Max out controller turned to 9 0 72 to 0 75 amps PLATFORM CONTROLS 1 2 Foot Switch How to Test the Foot Switch 1 Turn the key switch to the orr position and separate the wiring quick disconnect plug from the platform toe board 2 Do not press down the foot switch Connect the leads from an ohmmeter or continuity tester to the wire combination listed below and check for continuity Test Desired result black to white no continuity Do not use the color of the connector as a guide for these tests Use the actual wire color to identify which connector to use for testing 3 Press down the foot switch Connect the leads from an ohmmeter or continuity tester to the wire combination listed below and check for continuity Test Desired result black to white continuity zero Q Part No 43063 Genie Z 30 20 7 5 Section 7 Repair Procedures PLATFORM CONTROLS 1 3 Toggle Switches Toggle switches used for single function switching are single pole double throw SPDT switches Dual function switching requires a double pole double throw DPDT switch How to Test a Toggle Switch Continuity is the equivalent of 0 to 3 ohms A simple continuity tester may not acc
61. ay vary depending on application of bolt Part No 43063 Genie Z 30 20 2 3 Section 2 Specifications Service Manual Third Edition i NN This page intentionally left blank 2 4 Genie Z 30 20 Part No 43063 Service Manual Third Edition Section 3 Scheduled Maintenance Inspections Scheduled Maintenance Inspections Observe and Obey M Maintenance inspections shall be completed by a person trained and qualified on the maintenance of this machine M Scheduled maintenance inspections shall be completed daily quarterly annually and every 2 years as specified on the Maintenance Inspection Report Failure to properly complete each AWARNING inspection when required may cause death serious injury or substantial machine damage M Immediately tag and remove from service a damaged or malfunctioning machine M Repair any machine damage or malfunction before operating machine MI Keep records on all inspections for three years H Machines that have been out of service for a period longer than 3 months must complete the quarterly inspection About This Section The Schedule There are four types of maintenance inspections that must be performed according to a schedule daily quarterly annual and two year To account for repeated procedures the Maintenance Tables and the Maintenance Inspection Report have been divided into four subsections A B C D Use the following chart to determine which gr
62. ble center area for burnt chafed and pinched cables 5 Activate the function enable switch and lower the boom to the stowed position and turn the machine off 6 Inspect the following areas for burnt chafed corroded pinched and loose wires Mid pivot to cable track Cable track on the primary boom Primary boom to platform cable harness Inside of the platform control box 4 8 Genie Z 30 20 Part No 43063 Service Manual Third Edition Section 4 Scheduled Maintenance Procedures B 3 Inspect the Tires and Wheels including lug nut torque Maintaining the tires and wheels in good condition 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 punctures and unusual wear 2 Check each wheel for damage bends and cracked welds 3 Check each lug nut for proper torque Tires and wheels Tire size 9 14 5 LT Lug nut torque Lubricated Dry 94 ft lbs 125 ft lbs 127 Nm 169 Nm B 4 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 torque hub disconnect cap
63. ch on joystick controller oV Repair or replace drive controller OR consult Genie Industries Service Department Oor infinite ohms Replace brake release valve coil item T 22 to 24 ohms Continued on the next page Repair open in blkiwht wire circuit from T5 to T69 to T72 then to brake valve item T on brake manifold Repair open in red wht wire with from 1 2 stroke micro switch on joystick controller to T118 to T15 Genie Z 30 20 Part No 43063 Service Manual Third pEdition Continued from the previous page With key switch in platform position and both Emergency Stop switches pulled out to the on position activate footswitch and drive controller in fwd direction until first micro switch activates and the pump motor turns on Check voltage at red wht and ground wires on brake release valve N C item T on brake manifold 20V or more 0 or infinite ohms Disconnect red wire from brake release valve N C item T and check resistance of coil See Repair Section 22 to 24 ohms With key switch in platform position and bad both Emergency Stop switches pulled out to the on position connect an ammeter in series with grn blk wire and brake proportional valve coil item U on brake manifold and activate footswitch and drive controller in fwd direction until 1 2 stroke micro switch activates Amperage should proportionally increase from 10 amps
64. chine off 4 Manually activate the drive limit switch OC a secondary boom drive limit switch location b primary boom drive limit switch location Result The drive limit switch arm should move freely and spring return to center A distinct click should be felt and heard 5 Turn the key switch to ground control and lift the red Emergency Stop switch cover and move the toggle switch to the on position 6 Activate the function enable switch and lower the primary boom into the stowed position 7 Raise the secondary boom above the drive limit switch and turn the machine off 8 Manually activate the drive limit switch Result The drive limit switch arm should move freely and spring return to center A distinct click should be felt and heard 9 Turn the key switch to ground control and lift the red Emergency Stop switch cover and move the toggle switch to the on position 10 Activate the function enable switch and lower the secondary boom into the stowed position 11 Turn the key switch to platform control and pull out the Emergency Stop button to the on position at the platform controls 12 Slowly move the drive control handle off center Result The machine should move at normal drive speeds 13 Raise the primary boom above the drive limit switch 14 Slowly move the drive control handle off center Result The machine should move at a reduced drive speed 15 Lower the primary boom to the stow
65. contactor for the following items Excessive burns Excessive arcs Excessive pitting Replace the contactors if any damage is found 4 14 Genie Z 30 20 Part No 43063 Service Manual Third Edition Section 4 Scheduled Maintenance Procedures C 1 Check the Primary Boom Wear Pads Maintaining the primary boom wear pads in good condition is essential to safe machine operation Wear pads are placed on boom tube surfaces to provide a low friction replaceable wear pad between moving parts Improperly shimmed wear pads or continued use of worn out wear pads may result in component damage and unsafe operating conditions 1 Turn the key switch to ground control and lift the red Emergency Stop switch cover and move the toggle switch to the on position 2 Extend the primary boom 10 inches 25 cm 3 Measure each wear pad Replace the wear pad if it is less than 0 41 inches 1 cm thick If the wear pad is more than 0 41 inches 1 cm thick shim as necessary to obtain zero clearance and zero drag 4 Extend and retract the primary boom through the entire range of motion to check for tight spots that could cause binding or scraping Always maintain squareness between the primary boom outer and inner tubes Table C Procedures C 2 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
66. control box lid and remove the platform control box mounting fasteners Lay the platform controls off to the side Component damage hazard ACAUTION Cables can be damaged if they are kinked or pinched Part No 43063 Genie Z 30 20 7 9 Section 7 Repair Procedures Service Manual Third Edition SS PLATFORM COMPONENTS 2 Remove the seven mounting bolts from the platform rotator cover then remove the cover 3 Visually inspect the inside of the platform rotator for the following items Excessive wear Broken or damaged parts Rust or corrosion Binding Replace any worn or damaged parts If any parts are lightly rusted or corroded remove them and clean rust or corrosion off with a wire brush If parts are heavily rusted or corroded replace them 4 Loosen the locknut in the counterclockwise direction just enough to allow the handle to rotate 5 Thoroughly grease the entire mechanical platform rotator assembly 6 Tighten the locknut and check for platform tighteness by grabbing the rails of the platform and trying to twist it side to side Tighten the locknut until it is difficult to twist the platform 7 Operate the platform rotator and check for smooth operation 7 10 Genie Z 30 20 Part No 43063 Service Manual Third Edition Section 7 Repair Procedures Primary Boom Components 3 1 Plastic Cable Track The primary boom cable track guides the cables and hoses running up the boom
67. ction Identify Troubleshoot discovered symptoms problem still exists Return to Perform service repair problem solved Part No 43063 Genie Z 30 20 6 1 Section 6 Schematics Service Manual Third Edition Electrical Symbols Legend 178 940 Wire color with cable number VEH Terminal de Quick disconnect terminal BLK 21 TB21 T circuits connect at terminal T circuits connect E Connection no terminal Circuits crossing no connection Diode OU 12V 6V Battery 15AMP as Circuit breaker Solenoid or relay coil TILT ALARM Horn Tilt sensor A PUMP Auxiliary pump Curtis motor controller Dual pole relay controller TB17 iw wa NEW H Ground supression circuit NC W Ls3 Limit switch Aw NC T Limit switch normally closed held open L NO Limit switch normally open held closed Rotary OEM flow control Drive control FSi BLK RED Foot switch PLAT KS1 my GRND Key switch HORN Lon Horn button normally open Pi Emergency Stop button normally closed Relay contact normally open PR4 F Relay panel contactor TS3 am l g zo az Toggle switch SPDT 1H9IH f Toggle switch DPDT
68. ctional valve coil continuity With key switch in Repair open in blk wht ground position and wire from T50 to primary both Emergency Stop boom retract function switches pulled out to directional valve coil the on position activate item G function enable and primary boom retract toggle switch TS14 on ground panel in retract direction and check voltage on blkAwht wire on boom function directional valve coil item G 20V or more 0 or Activate function enable Disconnect wires to infinite and primary boom function primary boom retract ohms ee retract toggle switch operates directional valve coil TS14 on ground panel item G and test resistance of valve coil See Repair Section coil item G in retract direction and manually activate valve spool with a T handle 20 to 25 ohms Replace defective primary boom retract directional valve item G OR consult Genie Industries Service Department function does not operate Continued on the next page Part No 43063 Genie Z 30 20 5 29 Section 5 Troubleshooting Flow Charts Service Manual Third Edition E CHART 12 Install a 0 to 3000 PSI Check for mechanical pressure gauge at the restrictions keeping quick disconnect primary boom from coupling on the boom retracting OR repair function manifold and cylinder or cylinder activate function enable counterbalance valve and the primary boom OR consult Genie retract
69. cy Stop switches are pulled out to the on position Be sure the batteries are fully charged With key switch in ground position and both Emergency Stop switches pulled out to the on position activate function enable and primary boom toggle switch TS12 on ground panel in down direction and check voltage on red wire at T28 20V or more With key switch in platform position and both Emergency Stop switches pulled out to the on position activate footswitch and primary boom toggle switch TS2 on platform control panel in down direction and check voltage on red blk wire at T28 20V or more Activate function enable ON and primary boom toggle switch TS12 on ground control panel in down direction and check voltage at T47 20V or more Activate function enable and primary boom toggle switch TS12 on ground control panel in down direction and check voltage at T6 20V or more Check continuity from no brown ground wire at the primary boom down directional valve coil continuity Continued on the next page continuit Chart 8 Check voltage at center OV terminal on TS12 Repair open in red power wire circuit from TS19 to TS12 20V or more Troubleshoot primary boom down toggle switch TS12 OR repair open in red blk wire from TS12 to T28 Troubleshoot primary boom down toggle switch TS2 OR repair open in red blk wire from TS2 to T108 to T28 Rep
70. d check voltage on blk wire at T30 20V or more With key switch in platform position and both Emergency Stop switches pulled out to the on position activate footswitch and primary boom retract toggle switch TS4 on platform control panel in retract direction and check voltage on blk wht wire at T30 20V or more Activate function enable and primary boom retract toggle switch TS14 on ground control panel in retract direction and check voltage at T50 20V or more Activate function enable 0V and primary boom retract toggle switch TS14 on ground control panel in retract direction and check voltage at T6 20V or more Continued on the next page Check voltage at center OV terminal on TS14 Repair open in red power wire circuit from TS19 to TS14 20V or more Troubleshoot primary boom retract toggle switch TS14 OR repair open in blkiwht wire from TS14 to T30 Troubleshoot primary boom retract toggle switch TS4 OR repair open in blk wht wire from TS4 to T103 to T30 Replace printed circuit oard Replace printed circuit oard a a Q 5 28 Genie Z 30 20 Part No 43063 Service Manual Third pEdition Section 5 Troubleshooting Flow Charts eS CHART 12 no continuity Check continuity from brown ground wire at Repair open in brown ground wire circuit to Continued from the previous page the primary boom retract T43 dire
71. damage hazard ACAUTION Cables and hoses can be damaged if they are kinked or pinched 10 Support the platform pivot weldment and platform rotator with a lifting strap from an overhead crane 11 Remove the retaining fasteners from the rod end pivot pin of the platform level cylinder Use a soft metal drift to remove the pin 12 Remove the retaining fasteners from the pivot pin of the platform pivot weldment Use a soft metal drift to remove the pin Crushing hazard The platform ACAUTION pivot weldment and platform rotator will fall unless they are properly supported 13 Remove the platform pivot weldment from the machine 14 Support the cable track with an overhead crane 15 Remove the cable track mounting fasteners then remove the cable track from the boom and lay it off to the side Component damage hazard ACAUTION The boom cable track can be damaged if it is twisted 16 Remove the retaining fastener from the master cylinder barrel end pivot pin 17 Place a rod through the barrel end pivot pin and twist to remove the pin 18 Tag disconnect and plug the primary boom extension cylinder hydraulic hoses Cap the fittings on the cylinder 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 Genie Z 30 20 Part No 43063 Service Manual
72. den ties deer ae AA A A AA Meeks 7 6 Platform Components 2 1 Plama ad zza ai aa da io Elza A 7 7 2 2 Platform Leveling Slave Cylinder cccccecceeeeeeeeneeececeeeeeeeeeeeaaeseeeeeeeeeneees 7 7 2 3 Platform Rotator ee eee e eee aaa aaa aaa aaa aanita 7 9 Primary Boom Components 3 1 Plastic Cable Track 7 11 B52 Piman e 7 11 3 38 Primary Boom Lift Cylinder 0 00 ccceceeeceeeeeeeeceeeeeeeeeeeeaaeeseeaeeeeseeeeeseaeeeneaes 7 14 3 4 Extension Cylinder ua tatiana ei ea ee cain ei ee 7 15 3 5 Platform Leveling Master Cylinder ccccceeseceeeeeeeeeeeeeeeeeaeeseeeeeeetnaeeeeas 7 16 Secondary Boom Components 4 1 Secondary Boom rina a A ZE PO A ASA wad 7 17 4 2 Secondary Boom Lift Cylinder eeeessssee eee aaa aaa anawa aaa aaaaaecia 7 20 Ground Controls 5 1 Toggle Switches See 1 3 Toggle Zwitches aaa aaa ennnca 7 6 5 2 Gontr lRElAYS 0090 Aa i ee ae eee 7 21 Hydraulic Pumps 6 1 Mam Function PUMP eee eee eee ee eee aaa eee eet aaa aaa aaa 7 22 Part No 43063 Genie Z 30 20 ix Service Manual Third Edition oeU loM TABLE OF CONTENTS Section Seven Repair Procedures continued Manifolds 7 1 Function Manifold Componerts eee aaa aaa aaa aaa aaa aacna 7 24 7 2 Valve Adjustments Function Manifold sss aa aaa aaa aaaaaaaaca 7 26 7 3 Brake Manifold Components eee e aaa aaa aaa aaa aennaae 7 28 7 4 Proportional Manifold Components aaa aaa aaa annaae 7 30 Turntable Rotatio
73. dustries Service Department Part No 43063 Genie Z 30 20 5 61 Section 5 Troubleshooting Flow Charts Service Manual Third Edition ee This page intentionally left blank 5 62 Genie Z 30 20 Part No 43063 Service Manual Third Edition Section 6 Schematics Observe and Obey M Troubleshooting and 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 M Repair any machine damage or malfunction before operating the machine Before Troubleshooting H Read understand and obey the safety rules and operating instructions printed in the Genie Z 30 20 Operator s Manual MI 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 may result in death or serious injury Remove all rings watches and other jewelry Hydraulic Schematics 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 General Repair Process Malfun
74. e 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 4 Remove the brake mouniing fasteners Then slide the brake out of the torque hub 5 Loosen the wheel lug nuts Do not remove them 6 Center a lifting jack under the non steering axle Raise the machine and place blocks under the drive chassis for support 7 Remove the wheel lug nuts then the tire and wheel assembly 8 Place a second lifting jack under the torque hub for support 9 Remove the fasteners that attach the torque hub to the drive chassis then remove the torque hub Crushing hazard The torque ACAUTION hub will fall if it is not properly supported when the mounting fasteners are removed Torque specifications 125 ft lbs 169 5 Nm Lug nuts 210 ft lbs 285 Nm Drive torque hub mounting fasteners Part No 43063 Genie Z 30 20 Distributed By E Genie North America 18340 NE 76th Street P O Box 97030 Redmond Washington 98073 9730 E Genie Europe Brunel Drive Newark Nottinghamshire NG24 2EG England
75. e grease seal located on the bottom of the platform rotator PLATFORM COMPONENTS How to Adjust the Platform Rotator The platform rotator is designed to allow the platform to slip in the event of striking an object to help prevent damage to the platform If the platform rotator is too tight or is seized damage to the platform may occur If the platform rotator is too loose the platform may rotate side to side unexpectedly resulting in a unsafe operating condition 1 Raise the primary boom approximately 3 feet 0 9 m 2 Activate the function enable switch and the platform level toggle switch in the down direction until the platform is horizontal Do not allow the platform to contact the ground 3 Open the platform control box lid and remove the platform control box mounting fasteners Lay the platform controls off to the side Component damage hazard ACAUTION Cables can be damaged if they are kinked or pinched 4 Remove the fasteners from the platform rotator cover then remove the cover 5 Locate the locknut on the end of the platform pivot shaft 6 Tighten the locknut in the clockwise direction on the platform pivot weldment shaft to make the platform rotator tighter or loosen the locknut in the counterclockwise direction to make the platform rotator looser 7 Thoroughly grease the entire mechanical platform rotator assembly If the platform rotator is seized or is difficult to operate 1 Open the platform
76. e at A1 on right drive motor terminal on right drive motor 48V or more Continued on the next page 5 48 Genie Z 30 20 Part No 43063 Service Manual Third pEdition Section 5 Troubleshooting Flow Charts Activate footswitch and slowly activate drive Activate footswitch and slowly activate drive controller from neutral to full stroke in forward direction and check voltage on 1 terminal voltage on T18 Voltage on Curtis motor should ramp up from 0V controller Voltage to 5V should ramp up from 0V to 5V Continued from the previous page full stroke in forward direction and check Activate footswitch and slowly activate drive controller from neutral to full stroke in forward direction and check voltage on D terminal on joystick controller Voltage should ramp up from OV to 5V Readjust joystick controller OR refer to Chart 23 OR repair or replace joystick controller OR consult Genie Industries Service Department Continued on the next page controller from neutral to 9903 CHART 20 Repair open in blu blk wire circuit that runs from terminal 1 on Curtis motor controller to T9 to T18 Repair open in org blk wire circuit that runs from D terminal on drive controller to T117 to T18 to T9 then through blu blk wire to terminal 1 on Curtis motor controller Part No 43063 Genie Z 30 20 Section 5 Troubleshooting Flow Charts Service Manual Third Editio
77. ed to complete the repair Then re assemble the secondary boom by following the disassembly steps in reverse order UG Q SX a I O O ry Secondary Boom a secondary boom b mid pivot c tensionlink d turntable pivot Part No 43063 Genie Z 30 20 Section 7 Repair Procedures Service Manual Third Edition SECONDARY BOOM COMPONENTS 1 Lower the boom to the stowed position 2 Remove the platform See 2 1 How to Remove the Platform 3 Remove the primary boom See 3 2 How to Remove the Primary Boom 4 Tag disconnect and plug the primary boom lift cylinder and master cylinder hydraulic hoses Cap the fittings on the cylinders 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 5 Remove the two hose clamps on the mid pivot and pull all the cables and hoses through the mid pivot Component damage hazard ACAUTION Cables and hoses can be damaged if they are kinked or pinched 6 Mark the location of the primary boom limit switch and then remove the limit switch fasteners 7 Remove the pin retaining fastener from the rod end pivot pin on the master cylinder 8 Place a rod through the rod end pivot pin and twist to remove the pin 9 Support the barrel end of the primary lift cylinder with a lifting strap from a
78. ed position 16 Raise the secondary boom above the drive limit switch 17 Slowly move the drive control handle off center Result The machine should move at a reduced drive speed Drive speed maximum raised 40 feet 40 seconds 12 2 meters 40 seconds 4 6 Genie Z 30 20 Part No 43063 Service Manual Third Edition Section 4 Scheduled Maintenance Procedures SEH TABLE A PROCEDURES A 11 Perform 30 Day Service The 30 day maintenance procedure is a one time sequence of procedures to be performed after the first 30 days or 50 hours of usage After this interval refer to the maintenance tables for continued scheduled maintenance 1 Perform the following maintenance procedures B 3 Inspect Tires and Wheels C 2 Check the Turnable Rotation Bearing Bolts C 6 Replace the Hydraulic Filter Part No 43063 Genie Z 30 20 4 7 Section 4 Scheduled Maintenance Procedures Service Manual Third Edition Table B Procedures B 1 Check the Batteries Proper battery condition is essential to good machine performance and operational safety Improper fluid levels or damaged cables and connections can result in power unit component damage and hazardous conditions Batteries contain acid Avoid AWARNING spilling or contacting battery acid Neutralize battery acid spills with baking soda and water Perform this procedure with the AWARNING battery packs disconnected 1 Put on protective clothing and
79. en required may cause death serious injury or substantial machine damage H Immediately tag and remove from service a damaged or malfunctioning machine M Repair any machine damage or malfunction before operating machine MI Keep records on all inspections for three years MI Unless otherwise specified perform each procedure with the machine in the following configuration Machine parked on a flat level surface Boom in the stowed position Turntable rotated with the boom between the non steering wheels Key switch in the orF position with the key removed Wheels chocked 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 Indicates the presence of a hazard that will cause death or serious injury AWARNING Indicates the presence of a hazard that may cause death or serious injury Indicates the presence of a ACAUTION a hazard that will or may cause serious injury or damage to the machine Indicates special operation or maintenance information Indicates that a specific result is expected after performing a series of steps Part No 43063 Genie Z 30 20 4 1 Section 4 Scheduled Maintenance Procedures Service Manual Third Edition Table A Procedures A 1 Inspect the Operator s and Safety Manuals Maintaining the operator
80. er connections very slowly to allow from the machine the oil pressure to dissipate gradually Do not allow oil to squirt ACAUTION or spray Component damage hazard Be sure not to damage the counterbalance valve block on the barrel end of the primary boom lift cylinder 7 14 Genie Z 30 20 Part No 43063 Service Manual Third Edition Section 7 Repair Procedures 3 4 Extension Cylinder The extension cylinder extends and retracts the primary boom extension tube The extension cylinder is equipped with a counterbalance valve to prevent movement in the event of a hydraulic line failure How to Remove the Extension Cylinder This procedure requires specific AWARNING repair skills lifting equipment and a suitable workshop Attempting this procedure without these skills and tools may result in death or serious injury and significant component damage Dealer service is strongly recommended 1 Raise the primary boom to the horizontal position Then extend the boom until the extension cylinder rod end mounting bracket retaining fasteners are accessible 2 Activate the platform level down function until the platform level slave cylinder is fully retracted and the platform is in the horizontal position 3 Locate the inspection cover at the platform end of the extension tube 4 Remove the inspection cover fasteners then remove the inspection cover 5 Remove the cylinder rod end retaining bracket fasteners 6
81. erating situation 1 Lift the red Emergency Stop switch cover and move the toggle switch to the on position Pull out the Emergency Stop Button to the on position at the platform controls 2 Turn the key switch to platform control 3 Check the machine functions from the ground controls Result The machine functions should not operate 4 Turn the key switch to ground control 5 Check the machine functions from the platform controls Result The machine functions should not operate 6 Turn the key switch to the orF position Result No function should operate the machine should stop B 7 Test the Emergency Stop Function A properly functioning Emergency Stop button and Emergency Stop Switch are essential for safe machine operation An improperly operating Emergency Stop function may fail to shut off power and stop all machine functions resulting in a hazardous situation As a safety feature selecting and operating the ground controls will override the platform controls including the Emergency Stop button 1 Turn the key switch to ground control and lift the red Emergency Stop switch cover and move the toggle switch to the on position 2 Push down the Emergency Stop Switch cover at the ground controls to the orF position 3 Attempt to activate any function at the ground or platform controls Result No functions should operate 4 Turn the key switch to platform control and lift the red Eme
82. ergency Stop switches pulled out to the on position activate footswitch and drive controller in forward direction and check pressure 1200 psi Check for mechanical restriction keeping drive function from operating OR consult Genie Industries Service Department Install a pressure gauge on brake manifold quick disconnect Activate footswitch and drive controller in forward direction and check pressure Replace brake release valve half stroke valve item V OR replace brake release proportional valve item U OR consult Genie Industries Srevice Department Reset or replace pressure switch PS1 OR consult Genie Industries Service Department less than 1200 psi Service Manual Third Edition Replace pressure switch PS1 OR consult Genie Industries Service Department 5 54 Genie Z 30 20 Part No 43063 Service Manual Third pEdition Section 5 Troubleshooting Flow Charts Drive Forward Function Inoperative Be sure key switch is in the appropriate position Be sure the Emergency Stop switches are pulled out to the on position Be sure the batteries are fully charged With key switch in platform position and both Emergency Stop switches pulled out to the on position activate drive controller in forward direction and check voltage on wht blk wire on forward contactor Activate drive controller in forward direction and check voltage on T16 Activate drive co
83. ervice Department Repair open in 48V supply cable from 300A fuse 1 OR repair open in 48V supply cables from battery packs to 300A fuse 1 Replace 80A fuse 2 Repair open in supply wire from battery pack to input side of 10A fuse 3 Replace 10A fuse Repair open in wire circuit from 10A fuse 3 to T2 to T12 to Emergency Stop switch P1 Replace toggle switch Repair open in red wire from Emergency Stop switch to key switch Part No 43063 Genie Z 30 20 5 3 Section 5 Troubleshooting Flow Charts Service Manual Third Edition CHART 1 Continued from the previous page Turn key switch to ground control position and check output side of contact 24V Turn key switch to platform control position and check output side of contact 24V less than Check voltage on input 48V side of 300A fuse 1 48V or more Continued on the next page Check cam on key bad switch good Replace contact OR refer to Ground Controls Inoperative Chart 5 OR consult Genie Industries Service Department Check cam on key bad switch good Replace contact OR refer to Platform Controls Inoperative Chart 6 OR consult Genie Industries Service Department Repair open in 48V supply cables positive and negative from battery packs Repair or replace key switch Repair or replace key switch Genie Z 30 20 Part No 43063 Service
84. erweight towards the steer end of the machine slightly and then lower the counterweight to the ground 26 Shift the forks of the forklift to the steer end of the machine enough for the counterweight to clear the forklift pocket tube 27 Lower the counterweight and then remove the counterweight from the machine Crushing hazard The AWARNING counterweight may become unbalanced and fall if it is not properly supported Tip over hazard Counterweights are critical to machine stability Failure to replace the counterweights will result in death or serious injury 7 34 Genie Z 30 20 Part No 43063 Service Manual Third Edition Section 7 Repair Procedures How to Install the Rotation Bearing and Worm Drive The rotation bearing is a structural component It attaches the drive chassis to the turntable The turntable is bolted to the inner race with the worm gear housing sandwiched in between This housing has to be correctly positioned to provide the correct gear lash between the worm gear and the ring gear The outside bearing race is bolted to the drive chassis from the underside This procedure requires specific AWARNING repair skills lifting equipment and a suitable workshop Attempting this procedure without these skills and tools may result in death or serious injury and significant component damage Dealer service is required If a repair requires that the turntable be removed from the drive chas
85. evel and free of obstructions 1 Create start and finish lines by marking two lines on the ground 40 feet 12 2 m apart Genie Z 30 20 Part No 43063 Service Manual Third Edition Section 4 Scheduled Maintenance Procedures 2 Turn the key switch to platform control and lift the red Emergency Stop switch cover and move the toggle switch to the on position at the ground controls Pull out the Emergency Stop Button to the on position at the platform controls Lower the boom into the stowed position 4 Choose a 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 soeed and note the time when the machine reference point passes over the finish line Drive speed stowed position 35 1 torque hubs 40 ft 6 1 sec 49 1 torque hubs 40 ft 8 6 sec 12 2 m 6 1 sec 12 2 m 8 6 sec TABLE B PROCEDURES B 14 Test the Alarm Package Optional Equipment 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 function manifold side turntable cover 1 Turn the key switch to ground control and lift the red Emergency
86. eye wear 2 Be sure that the battery cable connections are free of corrosion 3 Be sure that the battery hold downs and cable connections are tight 4 Remove the battery vent caps and check the specific gravity of each battery cell with a hydrometer 5 Check the battery acid level of each battery If needed replenish with distilled water to the bottom of the battery fill tube Do not overfill Install the vent caps 7 Check each battery pack to be sure the batteries are wired correctly 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 Electrocution hazard Contact AWARNING with hot or live circuits may result in death or serious injury Remove all rings watches and other jewelry 1 Inspect the following areas for burnt chafed corroded and loose wires Electrical component compartment Turntable circuit board wiring Ground control panel Turntable manifold wiring 2 Turn the key switch to ground control and lift the red Emergency Stop switch cover and move the toggle switch to the oN position 3 Activate the function enable switch and raise the secondary boom until the mid pivot is 10 feet 3 m off the ground 4 Inspect the turnta
87. fold and activate function enable and the secondary boom up function less than 600 PSI Repair cylinder or cylinder counterbalance valve OR boom function manifold could have an internal defect consult Genie Industries Service Department Repair open in blu wire from T44 to secondary boom up function directional valve coil item J Disconnect wires to secondary boom up directional valve coil item J and test resistance of valve coil See Repair Section Service Manual Third Edition Oor infinite ohms Replace secondary boom up directional valve coil item J 22 to 25 ohms Replace defective secondary boom up directional valve item J OR consult Genie Industries Service Department Check for mechanical restrictions keeping secondary boom from moving OR repair cylinder or cylinder counterbalance valve OR consult Genie Industries Service Department 5 22 Genie Z 30 20 Part No 43063 Service Manual Third pEdition Section 5 Troubleshooting Flow Charts Secondary Boom Down Function Inoperative Be sure key switch is in the appropriate position Be sure the Emergency Stop switches are pulled out to the on position Be sure the batteries are fully charged With key switch in ground position and both Emergency Stop switches pulled out to the on position activate function enable and secondary boom toggle switch TS13 on ground
88. form Self leveling AA 4 11 B 10 Test the Service Horn eeeeeuea aaa aaa aaa aaa aaa aaa aaa aaa aianaae 4 11 B 11 Test the Foot Switch 4 12 B 12 Test the Drive Brakes ANNER 4 12 B 13 Test the Drive Speed Stowed Position 4 12 B 14 Test the Alarm Package Optional Eouipmemt aaa aa ananaaei 4 13 B 15 Perform Hydraulic Oil Analysis ee sssesea eee aaa aaa anawa anawa 4 14 B 16 Test the Turntable Rotation Stop eeeeesseee eee aaa aaa aaa 4 14 B 17 Check the Electrical Contactors aaa aaa aaa aaa aaa aaa enia 4 14 C 1 Check the Primary Boom Wear Pads eeuueeoauaaa aaa aaa aaa aaa aaa acnaae 4 15 C 2 Check the Turntable Rotation Bearing Bolts s esssauaaa as aaaaaaenaae 4 15 C 3 Check the Free wheel Configuration eeeeuas eos e aaa aaa aaa aaa aaaaacnaa 4 16 C 4 Grease the Turntable Rotation Bearing and Worm Drive Gear 4 17 C 5 Replace the Torque Hub OU 4 17 C 6 Replace the Hydraulic Eiter 4 18 D 1 Test or Replace the Hydraulic OU 4 19 vi Genie Z 30 20 Part No 43063 Service Manual Third Edition DEEN Section Five TABLE OF CONTENTS Troubleshooting Flow Charts Introductio EE 5 1 1 All Functions Will Not Operate 4 ssseeeao aaa aaa aaa aaa aaa aaa aaanaecia 5 3 2 Lift Pump Motor Will Not Operate aaa asa aaa aaa aaa aaa aaaa aaa aennae 5 6 3 All Functions Inoperative Powe
89. form pivot mount 4 Open the needle valve by turning the needle valve counterclockwise until it stops Service Manual Third Edition Hold the platform leveling switch in the down position for one minute Close the needle valve by turning the needle valve clockwise until it stops Move the platform level switch in the up position until the platform leveling cylinder is fully extended Open the needle valve by turning the needle valve counterclockwise until it stops Hold the platform leveling switch in the up position for one minute Close the needle valve by turning the needle valve clockwise until it stops Tighten the lock nut Genie Z 30 20 Part No 43063 Service Manual Third Edition Section 7 Repair Procedures 2 3 Platform Rotator The platform rotator is a manually operated gear assembly used to rotate the platform 160 degrees How to Remove the Platform Rotator 1 Remove the platform See 2 1 How to Remove the Platform 2 Open the platform control box lid and remove the platform control box mounting fasteners Lay the platform controls off to the side Component damage hazard ACAUTION Cables can be damaged if they are kinked or pinched 3 Remove the seven mounting bolts from the platform rotator cover then remove the cover 4 Remove the retaining nut from the end of the platform pivot shaft 5 Lift the platform rotator off of the platform pivot shaft Be careful not to damage th
90. ft cylinder raises and lowers the secondary boom The secondary boom lift cylinder is equipped with a counterbalance valve to prevent movement in the event of a hydraulic line failure How to Remove the Secondary Lift Cylinder This procedure requires specific AWARNING a suitable workshop Attempting this procedure without these skills and tools may result in death or serious injury and significant component damage Dealer service is strongly recommended 1 Lower the boom to the stowed position Remove all four turntable covers 3 Tag disconnect and plug the hydraulic hoses from the secondary boom lift cylinder Cap the cylinder fittings AWARNING SC 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 Secure the barrel end of the cylinder to the secondary boom using a strap to prevent the cylinder from falling when the pivot pin is removed 5 Attach a strap from an overhead crane to the rod end of the secondary boom lift cylinder Do not lift it 6 Remove the pin retaining fasteners from the secondary boom lift cylinder barrel end pivot pin Then use a soft metal drift to remove the pin repair skills lifting equipment and Remove the pin retaining fasteners from the secondary boom lift cylinder rod end pivot pin Then use a soft metal drift to re
91. function Industries Service Department Continued from the previous page less than 2000 PSI Repair cylinder or cylinder counterbalance valve OR boom function manifold could have an internal defect consult Genie Industries Service Department 5 30 Genie Z 30 20 Part No 43063 Service Manual Third pEdition Section 5 Troubleshooting Flow Charts Turntable Rotate Left Function Inoperative Be sure key switch is in the appropriate position Be sure the Emergency Stop switches are pulled out to the on position Be sure the batteries are fully charged With key switch in ground position and both Emergency Stop switches pulled out to the on position activate function enable and turntable rotate toggle switch TS15 on ground panel in the left direction and check voltage on wht wire at T21 20V or more With key switch in platform position and both Emergency Stop switches pulled out to the on position activate footswitch and turntable rotate toggle switch TS5 on platform control panel in the left direction and check voltage on wht wire at T21 20V or more Activate function enable ON and turntable rotate toggle switch TS15 on ground control panel in the left direction and check voltage at T39 20V or more Activate function enable and turntable rotate toggle switch TS15 on ground control panel in the left direction and check voltage at T6 20V o
92. ggle switch TS15 on ground panel in the right direction and check voltage on wht blk wire at T22 20V or more With key switch in platform position and both Emergency Stop switches pulled out to the on position activate footswitch and turntable rotate toggle switch TS5 on platform control panel in the right direction and check voltage on wht blk wire at T22 20V or more Activate function enable ON and turntable rotate toggle switch TS15 on ground control panel in the right direction and check voltage at T38 20V or more Activate function enable and turntable rotate toggle switch TS15 on ground control panel in the right direction and check voltage at T6 20V or more Check continuity from no brown ground wire at the turntable rotate right directional valve coil continuity Continued on the next page continuit Check voltage at center terminal on TS15 20V or more Troubleshoot turntable rotate toggle switch TS15 OR repair open in wht blk wire from TS15 to T22 Troubleshoot turntable rotate toggle switch TS5 OR repair open in wht blk wire from TS5 to T102 to T22 Replace printed circuit board Replace printed circuit board Repair open in brown ground wire circuit to T40 Chart 14 Repair open in red power wire circuit from TS19 to TS15 Part No 43063 Genie Z 30 20 Section 5 Troubleshooting Flow Charts E CHART 14
93. he pivot end of the primary boom How to Remove the Platform Leveling Master Cylinder Before cylinder removal is considered bleed the cylinder to be sure that there is no air in the closed loop See 2 2 How to Bleed the Slave Cylinder 1 Tag disconnect and plug the master cylinder hydraulic hoses Cap the fittings on the cylinder Bodily injury hazard Sprayin AWARNING TE ee 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 pin retainer from the master cylinder rod end pivot pin Place a rod through the rod end pivot pin and twist to remove the pin 3 Remove the pin retainer from the master cylinder barrel end pivot pin Place a rod through the barrel end pivot pin and twist to remove the pin 4 Remove the cylinder from the machine Genie Z 30 20 Part No 43063 Service Manual Third Edition Section 7 Repair Procedures Secondary Boom Components T 4 1 Secondary Boom How to Disassemble the Secondary Boom The procedures in this section AWARNING require specific repair skills lifting equipment and a suitable workshop Attempting this procedure without these skills and tools may result in death or serious injury and significant component damage Dealer service is required Follow the disassembly steps to the point requir
94. he strap to the forklift carriage 16 Remove the turntable mounting bolts 17 Carefully lift the turntable off the drive chassis Set the turntable on blocks for support Crushing hazard If the turntable is not properly supported by the forklift it may become unbalanced and fall during removal 18 Place reference marks on the drive chassis to note the position of the worm drive housing for proper re alignment during installation 19 Remove the fasteners from the worm drive then remove the worm drive 20 Remove the mounting fasteners from both battery packs Use a lifting device to remove the battery packs from the machine 21 Support the large counterweight under the drive chassis with a forklift at the power unit side of the machine Lift it slightly to take the weight off of the threaded rod Support the smaller counterweight with a floor jack from the steer end of the machine and lift it slightly to take the weight off of the threaded rod 22 Remove the fasteners from the cover at the non steer end of the drive chassis Remove the cover from the machine 23 Remove the nut from the threaded rod that runs through the center of the counterweights at the steer end of the machine 24 Pull the threaded rod through the counterweights and out of the non steer end of the machine Crushing hazard The AWARNING counterweights may become unbalanced and fall if they are not properly supported 25 Pull the smaller count
95. ibility and damage Replace any damaged or illegible decal immediately Contact your authorized Genie distributor or Genie Industries if replacement decals are needed 4 2 Genie Z 30 20 Part No 43063 Service Manual Third Edition Section 4 Scheduled Maintenance Procedures A 3 Inspect for Damage Loose or Missing Parts Daily machine condition inspections are essential to safe machine operation and good machine performance Failure to locate and repair damage and discover loose or missing parts may result in an unsafe operating condition 1 Inspect the entire machine for damage and improperly installed or missing parts including Electrical components wiring and electrical cables Hydraulic power unit hoses fittings cylinders and manifolds Turntable motor and worm gear Boom components and wear pads Dents or damage to machine Tires and wheels Limit switches Service horn Alarm and beacon package if equipped Nuts bolts and other fasteners Platform entry mid rail Cracks in welds or structural components Compartment covers and fasteners Battery packs and connections A 4 Check the Hydraulic Oil Level Maintaining the hydraulic oil at the proper level is essential to machine operation Improper hydraulic oil levels can damage hydraulic components Daily checks allow the inspector to identify changes in oil level that might indicate the presence of hydraulic system
96. imary boom toggle switch TS2 on platform control panel in up direction and check voltage on red wire at T27 20V or more Activate function enable 0V and primary boom toggle switch TS12 on ground control panel in up direction and check voltage at T46 20V or more Activate function enable and primary boom toggle switch TS12 on ground control panel in up direction and check voltage at T6 20V or more Check continuity from no brown ground wire at the primary boom up directional valve coil continuity Continued on the next page continuit Check voltage at center terminal on TS12 20V or more Troubleshoot primary boom up toggle switch TS12 OR repair open in red wire from TS12 to T27 Troubleshoot primary boom up toggle switch TS2 OR repair open in red wire from TS2 to T107 to T27 Replace printed circuit oard Replace printed circuit board a Q Repair open in brown ground wire circuit to T48 Repair open in red power wire circuit from Chart 7 Part No 43063 Genie Z 30 20 Section 5 Troubleshooting Flow Charts Service Manual Third Edition SSeS CHART 7 With key switch in ground position and both Emergency Stop switches pulled out to the on position activate function enable and primary boom toggle Repair open in red wire from T46 to primary boom up function Continued from the previous page directional valve coil i
97. inder onto the balancing turntable counterweight Crushing hazard When the rod ACAUTION end pivot pin is removed the 3 3 primary boom lift cylinder may Primary Boom Lift Cylinder become unbalanced and fall if it is not properly supported The primary boom lift cylinder raises and lowers 6 Attach the strap from the overhead crane to the the primary boom barrel end of the cylinder How to Remove the Primary 7 Remove the pin retainer from the pivot pin at the barrel end of the primary boom lift cylinder and remove the pin Boom Lift Cylinder This procedure requires specific 8 repair skills lifting equipment and a suitable workshop Attempting this procedure without these skills and tools may result in death or serious injury and significant component damage Dealer service is strongly recommended Place a rod through the barrel end pivot pin and twist to remove the pin AWARNING 1 Remove the two function manifold side turntable covers Support the primary boom lift cylinder with a lifting device 2 Tag disconnect and plug the primary boom lift AC Crushing hazard When the cylinder hydraulic hoses and cap the fittings on AUTION barrel end pivot pin is removed the lift cylinder the primary boom lift cylinder may Bodily injury hazard Spraying become unbalanced and fall if it is AWARNING hydraulic oil can penetrate and not properly supported burn skin Loosen hydraulic 9 Carefully remove the primary boom lift cylind
98. ir or replace bad motor OR consult Genie Industries Service Department Replace curtis controller Genie Z 30 20 Part No 43063 Service Manual Third pEdition Section 5 Troubleshooting Flow Charts Brake Function Inoperative Be sure torque hubs are not disengaged Be sure remote brake release is removed With key switch in platform position and both Emergency Stop switches pulled out to the on position activate footswitch and drive controller in fwd direction until first micro switch activates and check voltage at T6 20V or more Continued on the next page With key switch in platform position and both Emergency Stop switches pulled out to the on position activate footswitch and drive controller in fwd direction until first micro switch activates and check voltage at T78 With key switch in latform position and th Emergency Stop switches pulled out to the on position activate footswitch and drive controller in fwd direction until first micro switch activates and check voltage at T3 oV Activate footswitch and drive controller in fwd direction until first micro switch activates and check voltage at X terminal on drive controller oV Activate footswitch and check voltage at terminal on drive controller 20V or more Repair or replace drive controller Consult Genie Industries Service Department Chart 20A 20V or more 20V or more 2
99. ire on fwd rev contactor and with key switch in platform position and both Emergency Stop switches pulled out to the on position activate footswitch and drive controller to full stroke in forward direction and try to rotate the drive tires by hand will require 2 people tires move Reconnect white wire to fwd rev contactor and with key switch in less platform position and than both Emergency Stop 48V switches pulled out to the on position activate footswitch and drive controller in forward direction and check voltage at positive cable on output side of C1 48V or more Continued on the next page Section 5 Troubleshooting Flow Charts RAK IIIA E ZE Replace C1 contacts OR replace C1 OR consult Genie Industries Service Department Go to Chart 20A Brake Function Inoperative 20V or more With key switch turned to the platform position and both mushroom switches pulled out to the on position activate footswitch and drive controller in forward direction and check voltage at red wht wire on C oV With key switch turned 20V or to the platform position more and both Emergency Stop switches pulled out to the on position activate footswitch and drive controller in forward direction and check voltage at T3 oV Continued on the next page CHART 20 Replace C1 OR repair open in ground wire circuit to C1 Repair open in red wht wire circuit
100. l speed and note the time when the reference point crosses the finish line Part No 43063 Genie Z 30 20 Section 7 Repair Procedures Service Manual Third Edition PLATFORM CONTROLS 23 Adjust drive high range trimpot on the circuit board to achieve a 6 1 second drive speed time Turn the trimpot clockwise to increase the time or counterclockwise to decrease the time Drive controller specifications Boom Function Speed Controller Adjustments Do not adjust the controllers unless the static battery supply voltage is above 24V DC Electrocution hazard Contact with AWARNING electrically charged circuits may result in death or serious injury Remove all rings watches and other jewelry 1 Turn the key switch to platform control and pull the Emergency Stop switch to the on position at the ground controls Pull up the Emergency stop button to the on position at the platform controls 2 Open the platform control box lid and locate the boom function speed controller Brake Threshold 0 16 amps when pump motor turns ON Max out 0 91 amps when pump motor turns OFF Drive Threshold 0 8 to 0 9V DC when amp output is 0 28 to 0 30 amps High range 5 0 to 5 2V DC when control handle is in full forward position Lo range 1 9 to 2 0V DC when control handle is in full forward position Drive speed 0 6 mph 1 km h boom raised 40 ft 45 5 sec 12 2 m 45 5 sec Drive speed 4 3 mph 6 9 km h bo
101. lace printed circuit board Replace printed circuit board Repair open in brown ground wire circuit to T48 Part No 43063 Genie Z 30 20 5 19 Section 5 Troubleshooting Flow Charts E CHART 8 Continued from the previous page With key switch in ground position and both Emergency Stop switches pulled out to the on position activate function enable and primary boom toggle switch TS12 on ground panel in down direction and check voltage on red blk wire on boom function directional valve coil item H 20V or more Activate function enable and primary boom toggle switch TS12 on ground panel in down direction and manually activate valve spool with a T handle function does not operate Install a 0 to 3000 PSI pressure gauge at the quick disconnect 1250 coupling on the boom PSI function manifold and activate function enable and the primary boom down function less than 1250 PSI Repair cylinder or cylinder counterbalance valve OR boom function manifold could have an internal defect consult Genie Industries Service Department function operates Service Manual Third Edition Repair open in red blk wire from T47 to primary boom down function directional valve coil item H Disconnect wires to 0 or primary boom down infinite directional valve coil ohms item H and test resistance of valve coil See Repair Section 22 to 25 ohms Re
102. latform 1 Separate the foot switch wiring quick disconnect plug from the platform toeboard If your machine is equipped with an air line to platform option the air line must be disconnected from the platform before removal 2 Raise the platform and place sawhorses under the platform for support 3 Lower the platform onto the sawhorses Do not rest the entire weight of AWARNING the boom on the sawhorses just enough to support the platform AT EE 4 Remove the platform mounting fasteners and remove the platform During installation be sure that the lower casting is pushed up as far as it will go onto the platform pivot weldment so that there is no space between the lower casting and the platform pivot weldment Do not overtighten the platform mounting fasteners during installation 2 2 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 circuit hydraulic loop with the master cylinder The slave cylinder is equipped with a counterbalance valve to prevent 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 See Repair Procedure 2 2 How to Bleed the Slave
103. lling a clevis pin 7 Remove the retaining fastener from the king 1 Be sure that both bearings are packed pin Attach a strap from a lifting device to the yoke hub assembly for support with grease Place the large inner bearing into the rear of the hub Part No 43063 Genie Z 30 20 7 37 Section 7 Repair Procedures Service Manual Third Edition STEERING AXLE COMPONENTS 3 Press the bearing grease seal evenly into the hub until it is flush 4 Apply a small amount of grease onto the yoke spindle 5 Slide the hub onto the yoke spindle Component damage Do not ACAUTION apply excessive force or damage to the lip of the seal may occur 6 Place the outer bearing into the hub 7 Install the washer and castle nut 8 Tighten the castle nut to 35 foot pounds 47 Nm 9 Loosen the castle nut then re tighten to 8 foot pounds 11 Nm 10 Install a new cotter pin Bend the cotter pin to lock it in 11 Install the dust cap then the tire and wheel assembly Torque the wheel lug nuts to 125 foot pounds 169 5 Nm 9 2 Steering Cylinder How to Remove a Steering Cylinder 1 Tag disconnect and plug the hydraulic hoses from the steering cylinder Cap the fittings on the cylinder Bodily injury hazard Spraying ACAUTION 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
104. m rotation A 8 Tilt sensor A 9 Manual controls A 10Drive limit switches A 11 30 Day Service Checklist B Refer to Table B B 1 Batteries B 2 Electrical wiring B 3 Tires and wheels B 4 Brake configuration B 5 Torque hub oil level B 6 Key Switch B 7 Emergency Stop B 8 Ground control override B 9 Platform leveling B 10 Service horn B 11 Foot switch B 12 Drive brakes B 13 Drive speed stowed B 14 Alarm package B 15 Hydraulic oil analysis B 16 Turntable stop B 17 Electrical contactors C 3 Free wheel configuration C 4 Grease rotation bearing C 5 Torque hub oil C 6 Hydraulic filter Checklist D YN R Refer to Table D D 1 Hydraulic oil l Part No 43063 Genie Z 30 20 Section 3 Scheduled Maintenance Inspections Service Manual Third Edition eee This page intentionally left blank 3 6 Genie Z 30 20 Part No 43063 Service Manual Third Edition Section 4 Scheduled Maintenance Procedures Scheduled Maintenance Procedures Observe and Obey MI Maintenance inspections shall be completed by a person trained and qualified on the maintenance of this machine M Scheduled maintenance inspections shall be completed daily quarterly annually and every 2 years as specified on the Maintenance Inspection Report Failure to properly complete each AWARNING inspection wh
105. mary Boom down relief 1250 psi Function relief 86 2 bar Secondary boom down relief 1000 psi valve pressure 69 bar Turntable rotate relief 850 psi valve pressures 58 6 bar Secondary boom up 23 to 25 seconds Secondary boom down 25 to 27 seconds Turntable rotate 180 10 to 12 seconds Platform level up 5 to 7 seconds Platform level down 8 to 10 seconds Genie Z 30 20 Part No 43063 Service Manual Third Edition Section 2 Specifications SPECIFICATIONS Bolt Torque Specifications per Torque Dry Torque Dry Torque Dry Torque Dry Torque Dry Torque Dry inch inch pounds foot pounds Newton meters inch pounds foot pounds Newton meters No 10 24 43 5 60 7 32 49 6 68 8 1 4 inch 20 96 11 144 16 28 120 14 168 19 5 16 inch 18 17 23 25 34 24 19 28 25 34 3 8 inch 16 30 41 45 61 24 35 48 50 68 716 inch 14 50 68 70 95 20 55 75 80 109 1 2 inch 13 75 102 110 149 20 90 122 120 163 9 16 inch 12 110 149 150 204 18 120 163 170 231 5 8 inch 11 150 204 220 298 18 170 231 240 326 3 4 inch 10 260 353 380 515 16 300 407 420 570 7 8 inch 9 430 583 600 814 14 470 637 660 895 1 inch 8 640 868 900 1221 12 700 949 1000 1356 Torque specifications for lubricated bolts are 25 less than dry torque specifications for each bolt size These bolt torque specifications are for general use only Specification m
106. move the pin Remove the cylinder from the machine Component damage hazard Be ACAUTION sure not to damage the counterbalance valve block on the barrel end of the secondary boom lift cylinder 7 20 Genie Z 30 20 Part No 43063 Service Manual Third Edition Section 7 Repair Procedures 5 1 Toggle Switches See 1 3 Toggle Switches 5 2 Control Relays Relays used for dual function switching are double pole double throw DPDT relays How to Test a Double Pole Double Throw Relay Electrocution hazard AWARNING Contact with electrically charged circuits may cause death or serious injury Remove all rings watches and other jewelry This procedure covers fundamental relay testing and does not specifically apply to all varieties of relays 1 Turn the key switch to the orr position and remove the key 2 Label and then disconnect all the wiring from the relay to be tested 3 Connect the leads from an ohmmeter to each terminal combination and check for continuity Terminals 7 and 8 represent the coil and should not be tested in any other combination Bubble number represents the terminal number Ground Controls Test Desired result terminal 7 to 8 640 to 650Q terminal 1 to 2 3 4 64 6 no continuity infinite Q terminal 2 to 3 4 4 5 no continuity terminal 3 to 6 no continuity terminal 2 to 6 continuity zero Q terminal 1 to 5 continuity 4 Connect 24V
107. moved from the housing In order to remove the housing the turntable has to be removed How to Remove the Turntable Rotation Motor Do not allow the turntable to rotate until the hydraulic motor is installed 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 then remove the motor 8 2 Rotation Bearing and Worm Drive How to Remove the Rotation Bearing or Worm Drive The turntable and all components above it must be removed prior to removing the rotation bearing or worm drive This procedure requires specific AWARNING repair skills lifting equipment and a suitable workshop Attempting this procedure without these skills and tools may result in death or serious injury and significant component damage Dealer service is required Be sure that the drive chassis is level 1 Remove the platform See 2 1 How to Remove the Platform 2 Remove the primary boom See 3 2 How to Remove the Primary Boom 3 Remove the turntable rotation motor See 8 1 How to Remove the Turntable Rotation Motor 4 Attach a lifting strap from an overhead crane to to the rod end of the primary boom lift cylinder
108. n CHART 20 previous page Continued from the Disconnect white wire on fwd rev contactor With key switch in platform position and both Emergency Stop switches pulled out to the on position connect meter to B and M terminals on curtis motor controller than activate footswich and slowly activate drive controller from neutral to full stroke in forward direction Voltage should ramp up from OV to 48V Reconnect white wire on fwd rev contactor With key switch in platform position and both Emergency Stop switches pulled out to the on position connect meter to B and M terminals on curtis motor controller than activate footswitch and slowly activate drive controller from neutral to full stroke in forward direction Voltage should ramp up from OV to 48V Repair open in motor cable circuit that runs from curtis motor controller to Fwd Rev contactor to drive motors OR repair open in ground circuit to Fwd Rev contactor coils OR repair or replace Fwd Rev contactor OR repair or replace bad motor OR consult Genie Industries Service Department Replace curtis motor controller Disconnect battery packs from unit and positive cable from A2 terminal on curtis motor controller and using an ohmmeter check resistance in both directions across terminals A2 and B terminals on curtis motor controller Resistance should be high in one direction and low in the other Repa
109. n Chart 18 Steer Left Function Inoperative Be sure key switch is in the appropriate position Be sure the Emergency Stop switches are pulled out to the on position Be sure the batteries are fully charged With key switch in platform position and both Emergency Stop switches pulled out to the on position activate footswitch and steer rocker switch on drive controller DP1 in left direction and check voltage on T24 20V or more Activate footswitch and steer rocker switch on drive controller DP1 in left direction and check voltage on T42 20V or more With key switch in platform position and both mushroom switches pulled out to the on position activate footswitch and steer rocker switch on drive controller DP1 in left direction and check voltage on the blu bik wire on the steer left directional valve coil 20V or more no Check continuity rom ontinuit brown ground wire at the steer left directional valve coil to T40 continuity Continued on the next page With key switch in 20Vor Repair open in blu blk wire circuit from drive platform position and more both Emergency Stop switches pulled out to the on position activate footswitch and steer controller DP1 to T121 to T24 then to T42 rocker switch on drive controller DP1 in left direction and check voltage at the controller terminal with the blu blk wire attached oV Repair
110. n manifold could have an internal defect consult Genie Industries Service Department 5 24 Genie Z 30 20 Part No 43063 Service Manual Third pEdition Section 5 Troubleshooting Flow Charts Primary Boom Extend Function Inoperative Be sure key switch is in the appropriate position Be sure the Emergency Stop switches are pulled out to the on position Be sure the batteries are fully charged With key switch in ground position and both Emergency Stop switches pulled out to the on position activate function enable and primary boom extend toggle switch TS14 on ground panel in extend direction and check voltage on blk wire at T29 20V or more With key switch in platform position and both Emergency Stop switches pulled out to the on position activate footswitch and primary boom extend toggle switch TS4 on platform control panel in extend direction and check voltage on blk wire at T29 20V or more Activate function enable 0V and primary boom extend toggle switch TS14 on ground control panel in extend direction and check voltage at T49 20V or more Activate function enable 0V and primary boom extend toggle switch TS14 on ground control panel in extend direction and check voltage at T6 20V or more Continued on the next page Chart 11 Check voltage at center OV terminal on TS14 Repair open in red power wire circuit from
111. n Components 8 1 Rotation Hydraulic Motor eee eeeee eee aaa aaa aaa aaa aaa aaa aaa 7 32 8 2 Rotation Bearing and Worm Drive sssesssssssssssiissseserrsssrrirrrnsrinnrssrrinnnsssrnn 7 32 Steering Axle Components 9 1 Yoke ue AUD TTT 7 37 9 2 Steering Cylinder eee eee ee aaa aaa aaa wanna aennae 7 38 Ge MIO ROA e RPA ZO hea tase teat MR AO a OR 7 38 Non steering Axle Components TOT Drive Motto ai aide lta teh leh leat aad 7 39 10228 Torque AUD Ee e 7 39 X Genie Z 30 20 Part No 43063 Service Manual Third Edition Section 2 Specifications Machine Specifications Specifications Tires and wheels Stowed dimensions Tire size 9 14 5 LT Length 15 ft 9 in 4 8 m Load range F Width 5 ft 10 in 18m Tire contact area 43 5 sq in 280 sq cm Height 6 ft 7 in gt m Overall tire diameter 28 in 71 cm Machine Weight 8700 lbs 3946 3kg Wheel diameter 14 5 in 36 8 cm Ground clearance 7 38 in 18 7 cm Wheel width 7 in 17 8 cm 5 Wheel lugs Operational dimensions s Front 8 5 8 18 Maximum platform height 31 ft 9 4 m Rear 9 5 8 18 Maximum platform working height 38 ft 11 6m Lug nut torque 125 ft lbs 169 5 Nm Maximum horizontal reach 20 ft 6 1 m Platform dimensions Maximum turntable tailswing 14 in 35 6 cm Length 48 in 121 9 cm Wheelbase 6 ft 1 8m Width 30 in 76 2 cm Minimum turning radius 13 ft 9 in
112. n overhead crane to support it when the barrel end pivot pin is removed 10 Remove the pin retaining fasteners from the barrel end pivot pin on the primary boom cylinder Then use a soft metal drift to remove the pin 11 Remove the primary boom lift cylinder from the machine Crushing hazard The primary ACAUTION boom lift cylinder will fall when it is removed from the machine unless it is properly supported 12 Remove the hose clamps from the turntable pivot above the ground controls 13 Mark the location of the secondary boom limit switch and then remove the limit switch fasteners 14 Pull all the hoses cables and limit switches out of the mid pivot and through the secondary boom and lay them off to the side Component damage hazard ACAUTION Cables and hoses can be damaged if they are kinked or pinched 15 Support the mid pivot with a lifting strap from an overhead crane 16 Remove the pin retaining fasteners from the secondary boom pivot pin and the tension link pivot pin at the mid pivot Do not remove the pins 17 Support the tension link with a lifting device 18 Use a soft metal drift to remove the tension link pivot pin at the mid pivot Crushing hazard The tension link ACAUTION will fall when the tension link pivot pin is removed from the mid pivot if it is not properly supported 19 Lower the tension link and rest it on the chassis 20 Use a soft metal drift to remove the secondary boom pivot
113. nal 9 on C3 to red wire jumper circuit at each function toggle switch Repair open in red wire from terminal 1 on C3 to red wire at the lift proportional controller Adjust boom function speed controller See Repair Section Part No 43063 Genie Z 30 20 5 15 Section 5 Troubleshooting Flow Charts Service Manual Third Edition SSeS ee aS SS CHART 6 With key switch in Repair open in blk red Continued from the platform position and i with diode from previous page both Emergency Stop T126 to T51 switches pulled out to the on position and the lift proportional controller turned to 9 activate the foot switch an check voltage at 51 Consult Genie Industries Service Department 5 16 Genie Z 30 20 Part No 43063 Service Manual Third pEdition Section 5 Troubleshooting Flow Charts Primary Boom Up Function Inoperative Be sure key switch is in the appropriate position Be sure the Emergency Stop switches are pulled out to the on position Be sure the batteries are fully charged With key switch in ground position and both Emergency Stop switches pulled out to the on position activate function enable and primary boom toggle switch TS12 on ground panel in up direction and check voltage on red wire at T27 20V or more With key switch in platform position and both Emergency Stop switches pulled out to the on position activate footswitch and pr
114. nction fails to operate properly or either Emergency Stop button and Emergency Stop Switch fail to stop all the machine functions Each function should activate operate smoothly and be free of hesitation jerking and unusual noise 1 Turn the key switch to ground control and lift the red Emergency Stop switch cover and move the toggle switch to the on position 2 Do not hold the function enable switch to either side Attempt to activate each boom and platform function toggle switch Result All boom and platform functions should not operate 3 Hold the function enable switch in either direction and activate each boom and platform function toggle switch Result All boom and platform functions should operate through a full cycle Descent alarm if equipped should sound while boom is lowering 4 Push in the Emergency Stop Switch to the orr position Result No function should operate the machine should stop 5 Turn the key switch to platform control and lift the red Emergency Stop switch cover and move the toggle switch to the on position Pull out the Emergency Stop Button to the on position at the platform controls 6 Operate each machine function through a partial cycle Result All machine functions should operate smoothly 7 Push in the Emergency Stop button to the OFF position Result No function should operate the machine should stop As a Safety feature selecting and operating the grou
115. nd controls will override the platform controls including the Emergency Stop button A 7 Test the Platform Rotation Detection of platform rotation malfunctions is essential for safe machine operation The platform rotator is operated by manually turning the hand crank in either a clockwise or counterclockwise direction 1 Turn the hand crank at the platform in the clockwise direction Result The platform should rotate to the right and operate smoothly without any hesitation or binding 2 Turn the hand crank at the platform in the counterclockwise direction Result The platform should rotate to the left and operate smoothly without any hesitation or binding 4 4 Genie Z 30 20 Part No 43063 Service Manual Third Edition Section 4 Scheduled Maintenance Procedures A 8 Test the Tilt Sensor The tilt sensor sounds an alarm in the platform when the incline of the drive chassis exceeds 4 5 degrees Select a level test area The tilt alarm should not be sounding prior to test 1 Turn the key switch to platform control and lift the red Emergency Stop switch cover and move the toggle switch to the on position at the ground controls Pull out the Emergency Stop Button to the on position at the platform controls 2 Remove the function manifold side turntable cover and press down on one side of the tilt sensor Result After a 1 5 second delay the alarm in the platform should sound TABLE A P
116. ntroller in forward direction and check voltage on wht blk wire on micro switch on drive controller Repair or replace micro switch on drive controller OR drive controller cams are out of adjustment Consult Genie Industries Service Department Chart 21 Remove wht blk and infinite ground wires from ohms forward contactor coil and check resistance of forward coil See Repair Section Repair or replace forward contactor 40 ohms Repair or replace forward contactor contacts OR repair open in brown ground wire circuit OR consult Genie Industries Service Department Repair open in wht blk wire circuit from T7 to forward contactor OR replace printed circuit board Repair open in wht blk wire circuit from wht blk wire on micro switch on drive controller to T119 through blk wht wire to T16 Part No 43063 Genie Z 30 20 5 55 Section 5 Troubleshooting Flow Charts Service Manual Third Edition Chart 22 Drive Reverse Function Inoperative Be sure key switch is in the appropriate position Be sure the Emergency Stop switches are pulled out to the on position Be sure the batteries are fully charged With key switch in platform position and both Emergency Stop switches pulled out to the on position activate drive controller in reverse direction and check voltage on wht wire on fwd rev contactor Activate drive controller in reverse direction and check voltage on T1
117. oltage on org wire at T66 20V or more Activate function enable and platform level toggle switch TS18 on ground control panel in up direction and check voltage at T6 20V or more With key switch in ground position and both Emergency Stop switches pulled out to the on position activate function enable and platform level toggle switch TS18 on ground panel in up direction and check voltage on org wire on boom function directional valve coil item L 20V or more Continued on the next page Check voltage at center terminal on TS18 20V or more Troubleshoot platform level toggle switch TS18 OR repair open in org wire from TS18 to T66 Troubleshoot platform level toggle switch TS8 OR repair open in org wire from TS8 to T109 to T66 Repair open from T66 to T64 to T6 o Repair open in org wire from T66 to platform level up function directional valve coil item L Repair open in red power wire circuit from TS19 to TS18 Genie Z 30 20 Part No 43063 Service Manual Third pEdition Section 5 Troubleshooting Flow Charts eS CHART 16 no continuity Check continuity from Repair open in brown brown ground wire at ground wire circuit to Continued from the previous page the platform level up T43 directional valve coil continuity Disconnect wires to 0 or platform level up infinite directional valve coil ohms item L and test
118. om stowed 40 ft 6 1 sec 12 2 m 6 1 sec 35 1 torque hubs 5 1 km h 12 2 m 8 6 sec Drive speed boom stowed 49 1 torque hubs 3 2 mph 40 ft 8 6 sec OH O black red wire diode white red wire boom function speed controller max out adjustable trimpot threshold adjustable trimpot zo Oo o 3 Remove the function manifold side turntable cover 4 Locate the lift proportional manifold and disconnect the blue red wire from the lift proportional valve coil 5 Connect the red lead from a amp meter to the wire connector of the blue red wire that was removed from the valve coil Connect the black lead to the spade terminal on the valve coil where the blue red wire was removed from Genie Z 30 20 Part No 43063 Service Manual Third Edition Section 7 Repair Procedures 6 Turn the boom function speed controller at the platform controls to the creer position 7 Set the threshold Press down the foot switch then move the primary boom switch to the uP position until the amperage reading appears Adjust the amperage to 0 to 0 12 amps Turn the threshold trimpot adjustment screw clockwise to increase the amperage or counterclockwise to decrease the amperage 8 Turn the boom function speed controller to the 9 position 9 Set the max out Press down the foot switch then move the primary boom switch to the uP position Adjust the amperage to 0 72 to 0 75 amps Turn the m
119. on EH MANIFOLDS 7 4 Proportional Manifold Components The Proportional Manifold is located on the turntable underneath the function manifold cover Index Schematic No Description Item Function Torque 1 Proportional solenoid valve PZ dzie Boom functions 1 11111111111 10 12 ft lbs 14 16 Nm 2 Differential sensing Valve Okaz Differential sensing circuit 10 12 ft lbs 14 16 Nm Plug Torque Specifications How to Check the Resistance Description Hex Size Torque of a Valve Coil SAE No 2 1 8 50 in lbs 6 Nm 1 Turn the key switch to the orr position and disconnect the wires from the valve coil to be SAE No 4 3 16 13 ft lbs 18 Nm tested SAE No 6 1 4 18 ft lbs 24 Nm 2 Connect the leads from the ohmmeter to the valve coil terminals SAE No 8 5 16 50 ft lbs 68 Nm Valve coil specifications SAE No 10 9 16 55 ft lbs 75 Nm Proportional solenoid valve 24V 19 200 SAE No 12 5 8 75 ft lbs 102 Nm schematic item P 7 30 Genie Z 30 20 Part No 43063 Service Manual Third Edition Section 7 Repair Procedures MANIFOLDS Part No 43063 Genie Z 30 20 Section 7 Repair Procedures Service Manual Third Edition Turntable Rotation Components 8 1 Rotation Hydraulic Motor The rotation hydraulic motor is the only serviceable component of the turntable rotation assembly The worm gear may not be re
120. op and observe the pressure reading on the pressure gauge 4 Turn the machine off Hold the relief valve and remove the cap item 15 function manifold If adjusting the turntable rotate left hold switch to the left and adjust the left relief valve item 16 function manifold 5 Adjust the internal hex socket Turn it clockwise to increase the pressure or counterclockwise to decrease the pressure Then install the relief valve cap Tip over hazard Do not adjust AWARNING the relief valves higher than recommended 6 Repeat steps 2 through 3 and recheck the valve pressure Turntable rotate relief valve specifications Pressure 850 psi 58 6 bar MANIFOLDS How to Check the Resistance of a Valve Coil 1 Turn the key switch to the orr position and disconnect the wires from the valve coil to be tested 2 Connect the leads from the ohmmeter to the valve coil terminals Valve coil specifications Function Manifold 3 position 4 way DOS solenoid valve 20V schematic items E F G H J and L 23 240 Part No 43063 Genie Z 30 20 Section 7 Repair Procedures Service Manual Third Edition MANIFOLDS 7 3 Brake Manifold Components The Brake Manifold is located on the turntable underneath the function manifold cover Index Schematic No Description Item 1 Proportional solenoid valve Heu 2 Normally closed poppet valve ISA 3 Orifice 0 052 in 1 32 mm
121. or replace steer microswitch on drive controller Consult Genie Industries Service Department oV Replace printed circuit board Repair open in blu blk wire circuit that runs from T42 to steer left directional valve coil on function manifold Repair open in brown ground wire circuit to T40 5 42 Genie Z 30 20 Part No 43063 Service Manual Third pEdition Section 5 Troubleshooting Flow Charts CHART 18 Disconnect wires to Sen steer left directional Replace steer left valve coil tem F on ohms directional valve coil item F test resistance of valve coil See Repair Section Continued from the previous page 20 to 25 ohms Install a 0 to 3000 PSI Check for mechanical pressure gauge at the restrictions keeping quick disconnect steer left function from coupling on the boom moving OR repair or function manifold and replace steer cylinder activate the steer left OR consult Genie function Industries Service Department less than 2200 PSI Repair or replace steer cylinder OR function manifold could have an internal defect Consult Genie Industries Service Department Part No 43063 Genie Z 30 20 5 43 Section 5 Troubleshooting Flow Charts Service Manual Third Edition Chart 19 Steer Right Function Inoperative Be sure key switch is in the appropriate position Be sure the Emergency Stop switches are pulled out to the on
122. oup s of procedures are required to perform a scheduled inspection Inspection Table or Checklist Daily A Quarterly A B Annual A B C Two year A B C D Maintenance Tables The maintenance tables contained in this section provide summary information on the specific physical requirements for each inspection Complete step by step instructions for each scheduled maintenance procedure are provided in section 4 Scheduled Maintenance Procedures Maintenance Inspection Report The maintenance inspection report contains checklists for each type of scheduled inspection Make copies of the Maintenance Inspection Report to use for each inspection Store completed forms for three years Part No 43063 Genie Z 30 20 3 1 Section 3 Scheduled Maintenance Inspections Service Manual Third Edition Maintenance Tables Warm Cold Dealer Table A Tools are New parts engine engine service required required required required suggested A 1 Inspect the Operator s and Safety Manuals A 2 Inspect the Decals and Placards A 3 Inspect for Damage Loose or Missing Parts A 4 Check the Hydraulic Oil Level A 5 Check for Hydraulic Leaks A 6 Test the Platform and Ground Controls A 7 Test the Platform Rotation A 8 Test the Tilt Sensor A 9 Test the Manual Controls A 10 Test the Drive Limit Switches A 11 Perform 30 Day Service Table B B 1 Check the Batteries B 2 Inspect the Electrical Wi
123. person working on or around a machine must be aware of all known safety hazards Personal safety and the continued safe operation of the machine should be your top priority Read each procedure thoroughly This manual and the decals on the machine use signal words to identify the following Indicates the presence of A DANGER a hazard that will cause death or serious injury Indicates the presence of AWARNING A a hazard that may cause death or serious injury Indicates the presence of ACAUTION a hazard that will or may cause serious injury or damage to the machine NOTICE Indicates special operation or maintenance information Be sure to wear protective eye wear and CS other protective clothing if the situation warrants it such as moving parts free swinging or unsecured components when lifting or placing loads Always wear approved steel toed shoes e Be aware of potential crushing hazards d 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 are properly maintained and ready for use Keep work surfaces clean and free of debris that could get into machine components and cause damage 1 Be sure that all tools and working areas Be sure that your workshop or work area ET is properly ventilated and well lit other lifting or suppo
124. pin at the mid pivot 7 18 Genie Z 30 20 Part No 43063 Service Manual Third Edition Section 7 Repair Procedures 21 Remove the mid pivot from the machine Crushing hazard The mid pivot AWARNING will fall when the secondary boom pivot pin is removed from the mid pivot if it is not properly supported 22 Tag disconnect and plug the hydraulic hoses from the secondary boom lift cylinder Cap the fittings on the cylinder 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 23 Remove the retaining fasteners from the secondary boom lift cylinder rod end pivot pin Do not remove the pin 24 Support each end of the secondary boom with a lifting strap from an overhead crane Lift the boom slightly to support it Crushing hazard The secondary AWARNING boom will fall unless it is properly supported 25 Place a block of wood approximately 3 feet long 0 9 m across the turntable counterweights 26 Support the rod end of the secondary boom lift cylinder with a lifting device Use a soft metal drift to remove the pin Crushing hazard The secondary ACAUTION boom lift cylinder will fall unless it is properly supported 27 Lower the rod end of the secondary boom lift cylinder onto the wood block SECONDARY BOOM COMPONENTS 28 Remove the pin re
125. place defective primary boom down directional valve item H OR consult Genie Industries Service Department Check for mechanical restrictions keeping primary boom from moving OR repair cylinder or cylinder counterbalance valve OR consult Genie Industries Service Department Replace primary boom down directional valve coil item H Genie Z 30 20 Part No 43063 Service Manual Third pEdition Section 5 Troubleshooting Flow Charts Secondary Boom Up Function Inoperative Be sure key switch is in the appropriate position Be sure the Emergency Stop switches are pulled out to the on position Be sure the batteries are fully charged With key switch in ground position and both Emergency Stop switches pulled out to the on position activate function enable and secondary boom toggle switch TS13 on ground panel in up direction and check voltage on blu wire at T25 20V or more With key switch in platform position and both Emergency Stop switches pulled out to the on position activate footswitch and secondary boom toggle switch TS3 on platform control panel in up direction and check voltage on red wire at T25 20V or more Activate function enable ON and secondary boom toggle switch TS13 on ground control panel in up direction and check voltage at T44 20V or more Activate function enable and secondary boom toggle switch TS13 on ground control p
126. position Be sure the batteries are fully charged With key switch in platform position and both Emergency Stop switches pulled out to the on position activate footswitch and steer rocker switch on drive controller DP1 in right direction and check voltage on T23 20V or more Activate footswitch and steer rocker switch on With key switch in 20V or platform position and more both Emergency Stop switches pulled out to the on position activate footswitch and steer Repair open in blu wire circuit from drive controller DP1 to T122 to T23 then to T41 rocker switch on drive controller DP1 in right direction and check voltage at the controller terminal with the blu wire attached oV Repair or replace steer microswitch on drive controller Consult Genie Industries Service Department 0V Replace printed circuit board drive controller DP1 in right direction and check voltage on T41 20V or more With key switch in platform position and both mushroom switches pulled out to the on position activate footswitch and steer rocker switch on drive controller DP1 in right direction and check voltage on the blu wire on the steer right directional valve coil 20V or more Check continuity from 9 brown ground wire at the steer right directional valve coil to T40 continuity Continued on the next page continuit Repair open in blu wire circuit that run
127. problems 1 Be sure that the boom is in the stowed position TABLE A PROCEDURES 2 Visually inspect the sight gauge on the hydraulic power unit reservoir Result The hydraulic oil level should be visible inside the sight gauge Hydraulic Oil Specifications Hydraulic oil type Dexron equivalent Hydraulic reservoir capacity 2 5 gallons 9 5 liters Hydraulic system 4 gallons including tank 15 1 liters A 5 Check for Hydraulic Leaks Detecting hydraulic fluid leaks is essential to operational safety and good machine performance Undiscovered leaks can develop into hazardous situations impair machine functions and damage machine components 1 Inspect for hydraulic oil puddles dripping or residue on or around the following areas Hydraulic power unit fittings hoses and turntable surface Drive motor compartment brakes fittings hoses and compartment surface All hydraulic cylinders All hydraulic manifolds Primary and secondary booms The underside of the turntable The underside of the drive chassis Ground area under the machine Part No 43063 Genie Z 30 20 4 3 Section 4 Scheduled Maintenance Procedures Service Manual Third Edition TABLE A PROCEDURES A 6 Test the Platform and Ground Controls Testing the machine functions and the Emergency Stop buttons for malfunctions is essential for safe machine operation An unsafe working condition exists if any fu
128. r Replacement of the hydraulic filter is essential for good machine performance and service life A dirty or clogged filter may cause the machine to perform poorly and continued use may cause component damage Extremely dirty conditions may require that the filter be replaced more often Beware of hot oil Contact with ACAUTION hot oil may cause severe burns The hydraulic filter is located next to the hydraulic power unit 1 Remove the power unit side turntable cover 2 Clean the area around the oil filter then remove the filter with an oil filter wrench 3 Apply a thin layer of oil to the new oil filter gasket 4 Install the new filter Genie part no 44788 and tighten it securely by hand 5 Clean up any oil that may have spilled during the replacement procedure 6 Turn the key switch to ground control and lift the red Emergency Stop switch cover and move the toggle switch to the on position Activate function enable and hold the primary boom up toggle switch 7 Inspect the filter and related components to be sure that there are no leaks Return oil filter Genie part number 44788 Genie Z 30 20 Part No 43063 Service Manual Third Edition Section 4 Scheduled Maintenance Procedures D 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
129. r Unit Starts and Runs 2 2ss1111122111 5 8 4 All Lift and Steer Functions Inoperative Drive Function Operational 5 9 5 Ground Controls Inoperative Platform Controls Operate Normally 5 12 6 Platform Controls Inoperative Ground Controls Operate Normally 5 14 7 Primary Boom Up Function Inoperative A 5 17 8 Primary Boom Down Function Inoperative ssseeeeeaaaa ane eennaaae 5 19 9 Secondary Boom Up Function Inoperative ee e ssseea aaa ezaaaanaaaaccea 5 21 10 Secondary Boom Down Function Inoperative ena aasanaaaei 5 23 11 Primary Boom Extend Function Inoperative s e ssssseeeaaaaaaaseenanaae 5 25 12 Primary Boom Retract Function Inoperative eeeeeaaa aaa aaa aa c acea 5 28 13 Turntable Rotate Left Function Inoperative eeeeeeeaea aaa aaa ania 5 31 14 Turntable Rotate Right Function Inoperative eeseaeaae aaa anawa 5 33 15 All Platform Level Functions Inoperative seeee aaa aaa aaa annnaa 5 35 16 Platform Level Up Function Inoperative e sseee aaa aaa aaa 5 36 17 Platform Level Down Function Inoperative seeeaaaaae aaa aaa 5 39 18 Steer Left Function Inoperative cececeeceeeeeeeeeeeeeceeeeeeeeeeeaeeeseeeeeeeeaeeee 5 42 19 Steer Right Function Inoperative sseeeee eee a aa
130. r more Check continuity from no brown ground wire at the turntable rotate left directional valve coil continuity Continued on the next page continuit Check voltage at center terminal on TS15 20V or more Troubleshoot turntable rotate toggle switch TS15 OR repair open in wht wire from TS15 to T21 Troubleshoot turntable rotate toggle switch TS5 OR repair open in wht wire from TS5 to T101 to T21 Replace printed circuit board Replace printed circuit board Repair open in brown ground wire circuit to T40 Repair open in red power wire circuit from Chart 13 Part No 43063 Genie Z 30 20 5 31 Section 5 Troubleshooting Flow Charts SEH CHART 13 Continued from the previous page With key switch in ground position and both Emergency Stop switches pulled out to the on position activate function enable and turntable rotate toggle switch TS15 on ground panel in the left direction and check voltage on wht wire on boom function directional valve coil item E 20V or more Activate function enable and turntable rotate function toggle switch TS15 on operates ground panel in the left direction and manually activate valve spool with a T handle function does not operate Install a 0 to 3000 PSI pressure gauge at the quick disconnect coupling on the boom 850 PSI function manifold and activate function enable and the turntable rotate
131. r the secondary boom approximately 5 feet 1 5 m to activate the drive limit switch PLATFORM CONTROLS 13 Set the drive lo range on the circuit board Press down the foot switch then move the control handle all the way to the FORWARD position Adjust the drive lo range trimpot on the circuit board to 1 9 to 2 0V DC Turn the lo range trimpot adjustment screw clockwise to increase the voltage or counterclockwise to decrease the voltage 14 Lower the boom to the stowed position and remove the lifting jacks from under the drive chassis 15 Raise the primary boom off the drive limit switch 16 Create start and finish lines by marking two lines on the ground 40 feet 12 2 m apart Choose a reference point on the machine as a reference for use when crossing the start and finish lines 17 Bring the machine to top drive speed before reaching the start line Begin timing when your reference point on the machine crosses the start line 18 Continue at full speed and note the time when the reference point crosses the finish line 19 Adjust drive lo range trimpot on the circuit board to achieve a 40 second drive speed time Turn the trimpot clockwise to increase the time or counterclockwise to decrease the time 20 Lower the primary boom to the stowed position 21 Bring the machine to top drive speed before reaching the start line Begin timing when your reference point on the machine crosses the start line 22 Continue at ful
132. rators and Safety Manuals ana aa cana aaaanaae 4 2 A 2 Inspect the Decals and Placards aaa a aaa aaa aaa aaa 4 2 A 3 Inspect for Damage Loose or Missing Parts AA 4 3 A 4 Check the Hydraulic Oil Level 4 3 A 5 Check for Hydraulic Leaks esse ea aaa aaa aaa aanaa 4 3 A 6 Test the Platform and Ground Controls e eeaa asa ea aaa asa aa aaa aaaaananaa 4 4 A 7 Test the Platform Rotation aaa eee aaa aaa anawa aaa 4 4 A 8 Test the Tilt Sensor ooo ea aaa aaa aaa aaa asian ae 4 5 A 9 Test the Manual Controls asa e aaa een aianaae 4 5 A 10 Test the Limit Gwitches uu aaa Eaa 4 6 Part No 43063 Genie Z 30 20 v Service Manual Third Edition CT TABLE OF CONTENTS Section Four Scheduled Maintenance Procedures continued A 11 Perform 30 Day Service eeeeeea ooo aaa wawa aaa aaa aaa aaa eaaa anawa 4 7 B T Check the Batteries wastes aaa Gi WE dee Et yty 4 8 B 2 Inspect the Electrical Wiring eeee eee aaa aaa aaa aaa aaa aaa aaa aaa 4 8 B 3 Inspect the Tires and Wheels including lug nut torque sesessesseeseeees 4 9 B 4 Confirm the Proper Brake Configuration esee esse aaa aaa aaa aanaacei 4 9 B 5 Check the Oil Level in the Torque Hubs aaa aaa eaaa aa aaaaaac 4 9 B 6 Test the Key Switch 4 10 B 7 Test the Emergency Stop Buttons see aaa aaa aaa zaa anna 4 10 B 8 Test the Ground Control Override sseeeee osa ea aaa aaa aaa aaa cznaca 4 11 B 9 Test the Plat
133. rder General Repair Process Malfunction Identify Troubleshoot discovered symptoms problem still exists Return to Perform service problem repair solved Symbols Legend Indicates the presence of a hazard that will cause death or serious injury Indicates the presence of a hazard that may cause death or serious injury AWARNING Indicates the presence of a ACAUTION hazard that will or may cause serious injury or damage to the machine Indicates special operation or maintenance information Indicates that a specific result is expected after performing a series of steps Part No 43063 Genie Z 30 20 7 1 Section 7 Repair Procedures Service Manual Third Edition Platform Controls 1 1 Controllers Maintaining the controllers at the proper setting is essential to safe machine operation Each controller should operate smoothly and provide proportional speed control through its entire range of motion boom function speed controller drive and brake printed circuit board c drivecontroller o o Drive Controller Adjustments Do not adjust the controllers unless the static battery supply voltage is above 24V DC This procedure will require the use of two multi meters One will be used for measuring amps and the other for voltage Electrocution hazard Contact with AWARNING electrically charged circui
134. removed if it is not properly supported How to Remove the Yoke and Hub 1 Remove the cotter pin and the clevis pin from both the steering cylinder and the tie rod Torque specifications Lug nuts 125 foot pounds 169 5 Newton meters How to Remove the Hub and Bearings 1 Loosen the wheel lug nuts Do not remove them 2 Block the non steering wheels and place a lifting jack under the steering axle a axle b kingpin 3 Raise the machine and place blocks under 4 the drive chassis for support u e clevis pin and cotter pin 4 Remove the lug nuts Then remove the tire f steering cylinder and wheel assembly g tierod 2 Loosen the wheel lug nuts Do not 5 Remove the dust cap cotter pin and castle nut remove them 6 Pull the hub off the spindle The washer and 3 Block the non steering wheels and then outer bearing should fall loose from the hub center a lifting jack under the steering axle 7 Place the hub on a flat surface and gently pry the bearing seal out of the hub Remove the 4 Raise the machine 6 inches 15 cm and place rear bearing blocks under the drive chassis for support How to Install the Hub and Bearings 5 Remove the lug nuts then the tire and wheel assembly 6 Remove the cotter pin from the tie rod and the When replacing a wheel bearing steer cylinder both the inner and outer bearings including the pressed in races Always use a new cotter pin when must be replaced insta
135. rgency Stop switch cover and move the toggle switch to the on position at the ground controls Pull out the Emergency Stop Button to the on position at the platform controls 5 Push down the Emergency Stop button to the OFF position at the platform controls 6 Attempt to activate any function at the platform controls Result No machine functions should operate The ground Emergency Stop Switch will stop all machine operation even if the key switch is switched to platform control Genie Z 30 20 Part No 43063 Service Manual Third Edition Section 4 Scheduled Maintenance Procedures B 8 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 or not the 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 platform Emergency Stop button to the orF position 2 Turn the key switch to ground control and lift the red Emergency Stop switch cover and move the toggle switch to the on position 3 Activate the function enable switch and operate each boom function through a partial cycle at the ground controls Result All boom functions should operate B 9
136. ring B 3 Inspect the Tires and Wheels including lug nut torque B 4 Confirm the Proper Brake Configuration B 5 Check the Oil Level in the Torque Hubs ra Ea ra ra 3 2 Genie Z 30 20 Part No 43063 Service Manual Third Edition Section 3 Scheduled Maintenance Inspections 0 MAINTENANCE TABLES Table B continued Warm Cold Dealer Tools are New parts engine engine service required required required required suggested B 6 Test the Key Switch B 7 Test the Emergency Stop Buttons B 8 Test the Ground Control Override B 9 Test the Platform Self leveling B 10 Test the Service Horn B 11 Test the Foot Switch B 12 Test the Drive Brakes B 13 Test the Drive Speed Stowed Position B 14 Test the Alarm Package Optional Equipment B 15 Perform Hydraulic Oil Analysis gt See D 1 Test or Replace the Hydraulic Oil B 16 Test the Turntable Rotation Stop B 17 Check the Electrical Contactors Part No 43063 Genie Z 30 20 3 3 Section 3 Scheduled Maintenance Inspections Service Manual Third Edition MAINTENANCE TABLES Tools are New parts engine engine service required required required required suggested C 1 Check the Primary Boom Wear Pads C 2 Check the Turntable Rotation Bearing Bolts C 3 Check the Free wheel Configuration CA Grease the Turntable Rotation Bearing and Worm Drive Gear C 5 Replace the Torque Hub Oil C 6 Replace
137. rntable 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 4 Locate the grease fittings on the worm drive housing a grease fittings 5 Pump grease into each fitting until you see it coming out of the side of the gear housing 6 Grease each tooth on the turntable rotation bearing Lubricant Type Multipurpose grease Part No 43063 Genie Z 30 20 Section 4 Scheduled Maintenance Procedures Service Manual Third Edition TABLE CG PROCEDURES C 5 Replace the Torque Hub Oil Replacing the torque hub oil is essential for good machine performance and service life Failure to replace the torque hub oil at yearly intervals may cause the machine to perform poorly and continued use may cause component damage 1 Select the drive torque hub to be serviced Then drive the machine until one of the two plugs is at the lowest point 2 Remove both plugs and drain the oil 3 Drive the machine until one plug is at the top and the other is at 90 degrees 4 Fill the hub with oil from the top hole until the oil level is even with the bottom of the side hole 5 Apply pipe thread sealant to the plugs then install the plugs 6 Repeat steps 1 through 5 for the other drive torque hub 17 fluid ounces 0 5 liters Oil capacity per hub Type SAE 90 multipurpose hypoid gear oil API service classification GL5 C 6 Replace the Hydraulic Filte
138. rting 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 that fasteners intended for one ZA time use e cotter pins and self locking nuts are not reused These components may fail if they are used a second time s Be sure to properly dispose of old oil or other fluids Use an approved container Se Please be environmentally safe iv Genie Z 30 20 Part No 43063 Service Manual Third Edition Introduction Section One Section Two Section Three Section Four Table of Contents Important Information sed i ceived ented en ante ieee AAA PE A ii Safety Rules General Safety Rules uuu aaa aaa aaa aaa aaa aaa aaa aaanaae iii Specifications Machine Specifications use aiz EE Z A Ea r det w 2 1 Performance Specifications eeeeeea ooo aaa aaa aaa aaa nenene 2 2 Hydraulic Specifications eeeua eee eee aaa aaa aaa aaa 2 2 Bolt Torque Specifications A 2 3 Scheduled Maintenance Inspections rodu el EEN 3 1 Tables A ctw ei ea ct ea a ee ae ee ARA 3 2 Table EE 3 2 RE E 3 4 Ee RE 3 4 Maintenance Inspection Report eeeeee aaa aaa aaa aaa aaa aaa 3 5 Scheduled Maintenance Procedures IRtFOAUCHOMy ciwie 4500 oz EE ree er a CEA er pcre cere PRACE EGO errr reer reece s GEE CE EiS 4 1 A 1 Inspect the Ope
139. rtional manifolds could have an internal defect Consult Genie Service Department Part No 43063 Genie Z 30 20 5 9 Section 5 Troubleshooting Flow Charts Service Manual Third Edition CHART 4 Continued from the previous page Disconnect wires from boom function proportional valve item R and check resistance across the coil terminals With key switch in ground position and both Emergency Stop switches pulled out to the on position activate function enable and any boom function and check voltage across blu red and ground wires Check continuity on brown ground wire on boom proportional valve coil item R to T43 With key switch in ground position and both mushroom switches pulled out to the on position activate function enable and any boom function and check voltage at T6 Continued on the next page 19 to 20 ohms full continuity Replace defective coil Reconnect wires to boom function proportional valve coil item R and consult Genie Industries Service Department Repair open in brown ground wire circuit to boom proportional valve coil item R from T43 Repair open in wht red 6 wire from T6 to T64 to terminal 14 on C4 relay Genie Z 30 20 Part No 43063 Service Manual Third pEdition Section 5 Troubleshooting Flow Charts CHART 4 Test diodes on the printed circuit board Replace the printed circuit board Con
140. s Service Department Continued from the previous page less than 1800 PSI Repair cylinder or cylinder counterbalance valve OR boom function manifold could have an internal defect consult Genie Industries Service Department 5 38 Genie Z 30 20 Part No 43063 Service Manual Third pEdition Section 5 Troubleshooting Flow Charts Platform Level Down Function Inoperative Be sure key switch is in the appropriate position Be sure the Emergency Stop switches are pulled out to the on position Be sure the batteries are fully charged With key switch in ground position and both Emergency Stop switches pulled out to the on position activate function enable and platform level toggle switch TS18 on ground panel in down direction and check voltage on org wire at T61 20V or more With key switch in platform position and both Emergency Stop switches pulled out to the on position activate footswitch and platform level toggle switch TS8 on platform control panel in down direction and check voltage on org wire at T61 20V or more Activate function enable and platform level toggle switch TS18 on ground control panel in down direction and check voltage at T6 20V or more With key switch in ground position and both Emergency Stop switches pulled out to the on position activate function enable and platform level toggle switch TS18 on ground panel in down direction
141. s from T41 to steer right directional valve coil on function manifold Repair open in brown ground wire circuit to T40 5 44 Genie Z 30 20 Part No 43063 Service Manual Third pEdition Section 5 Troubleshooting Flow Charts CHART 19 Disconnect wires to ue steer right directional Replace steer right valve col tem F on ohms s directional valve coil item F test resistance of valve coil See Repair Section Continued from the previous page 22 to 25 ohms Install a 0 to 3000 PSI Check for mechanical pressure gauge at the restrictions keeping quick disconnect steer right function from coupling on the boom moving OR repair or function manifold and replace steer cylinder activate the steer right OR consult Genie function Industries Service Department less than 2200 PSI Repair or replace steer cylinder OR function manifold could have an internal defect Consult Genie Industries Service Department Part No 43063 Genie Z 30 20 5 45 Section 5 Troubleshooting Flow Charts Service Manual Third Edition Chart 20 All Drive With key switch in With key switch in Repair open in red wire i platform position and platform position and circuit from T111 to Functions both Emergency Stop both Emergency Stop SE terminal on drive j switches pulled out to switches pulled out to controller DP1 OR Inope rative all the on position activate the on position activ
142. sis installing a new rotation bearing is recommended Consider the service life of the rotation bearing before installing a used bearing 1 Position the rotation bearing on the drive chassis Use appropriate lifting techniques 2 Locate the G mark stamped on the outside bearing race Align the mark with the rotation stop block on the chassis TURNTABLE ROTATION COMPONENTS a yellow mark b outerbearing c innerbearing d dowel e G mark f rotation stop block 3 Install the mounting fasteners from underneath the chassis Use a torque wrench to tighten the fasteners in sequence to specifications 5 10 1 13 6 18 12 4 3 7 o AE 14 Specifications torque First rotation 95 foot pounds 129 Newton meters Second rotation 190 foot pounds 258 Newton meters Part No 43063 Genie Z 30 20 Section 7 Repair Procedures Service Manual Third Edition TURNTABLE ROTATION COMPONENTS 4 Locate the painted mark on the outside bearing and the dowel on the inside bearing 5 Position the inside bearing dowel 90 degrees counterclockwise from the painted mark on the outside bearing 6 Install a grease fitting on the inside bearing and apply grease until it comes out of the inner seal 7 Apply grease to 10 gear teeth on each side of the painted mark on the outside bearing 8 Center the worm drive over the painted mark on the outside bearing and install the t
143. switch in ground position and both Emergency Stop switches pulled out to the on position activate function enable and secondary boom toggle Repair open in blu blk wire from T45 to secondary boom down Continued from the previous page function directional valve coil item J switch TS13 on ground panel in down direction and check voltage on blu blk wire on boom function directional valve coil item J 20V or more Disconnect wires to 0 or secondary boom down infinite directional valve coil ohms item J and test resistance of valve coil See Repair Section Activate function enable and secondary boom toggle switch TS13 on ground panel in down direction and manually activate valve spool with a T handle function Replace secondary operates boom down directional valve coil item J 20 to 25 ohms Replace defective secondary boom down directional valve item J OR consult Genie Industries Service Department function does not operate Install a 0 to 3000 PSI pressure gauge at the Check for mechanical restrictions keeping quick disconnect 1000 secondary boom from coupling on the boom PSI moving OR repair function manifold and activate function enable and the secondary boom down function cylinder or cylinder counterbalance valve OR consult Genie Industries Service Department less than 1000 PSI Repair cylinder or cylinder counterbalance valve OR boom functio
144. taining fasteners from the secondary boom pivot pin at the turntable pivot Use a soft metal drift to remove the pin If the overhead crane is not AWARNING properly attached the secondary boom may become unbalanced and fall when it is removed from the machine 29 Remove the secondary boom from the machine 30 Attach the strap from an overhead crane to the secondary boom lift cylinder 31 Remove the pin retaining fasteners from the barrel end of the secondary boom lift cylinder pivot pin Use a soft metal drift to remove the pin Crushing hazard The secondary ACAUTION boom lift cylinder will fall unless it is properly supported 32 Remove the cylinder from the machine Component damage hazard Be ACAUTION sure not to damage the counterbalance valve block on the barrel end of the secondary boom lift cylinder 33 Attach a lifting strap from an overhead crane to the mid pivot end of the tension link 34 Raise the tension link to a vertical position 35 Remove the pin retaining fasteners from the tension link pivot pin at the turntable pivot Use a soft metal drift to remove the pin ACAUTION the overhead crane is not properly attached the tension link may become unbalanced and fall when it is removed from the machine Part No 43063 Genie Z 30 20 Section 7 Repair Procedures Service Manual Third Edition SECONDARY BOOM COMPONENTS 4 2 Secondary Boom Lift Cylinder The secondary boom li
145. tem H switch TS12 on ground panel in up direction and check voltage on red wire on boom function directional valve coil item H 20V or more Disconnect wires to Dor primary boom up infinite directional valve coil ohms item H and test resistance of valve coil See Repair Section Activate function enable and primary boom toggle switch TS12 on ground panel in up direction and manually activate valve spool with a T handle function Operates Replace primary boom up directional valve coil item H 22 to 25 ohms Replace defective primary boom up directional valve item kosa H OR consult Genie H Industries Service Department Install a 0 to 3000 PSI pressure gauge at the quick disconnect Check for mechanical restrictions keeping primary boom from coupling on the boom 600 PSI moving OR repair function manifold and activate function enable and the primary boom up function cylinder or cylinder counterbalance valve OR consult Genie Industries Service Department less than 600 PSI Repair cylinder or cylinder counterbalance valve OR boom function manifold could have an internal defect consult Genie Industries Service Department 5 18 Genie Z 30 20 Part No 43063 Service Manual Third pEdition Section 5 Troubleshooting Flow Charts Primary Boom Down Function Inoperative Be sure key switch is in the appropriate position Be sure the Emergen
146. the hydraulic hose How to Remove the Main Function Pump 1 Drain the reservoir into a suitable container 2 Remove the mounting fasteners from the hydraulic reservoir Remove the reservoir 3 Remove the pump mounting bolts Carefully remove the pump 7 22 Genie Z 30 20 Part No 43063 Service Manual Third Edition Section 7 Repair Procedures sss This page intentionally left blank Part No 43063 Genie Z 30 20 7 23 Section 7 Repair Procedures Service Manual Third Edition Manifolds 7 1 Function Manifold Components The Function Manifold is located on the turntable underneath the function manifold turntable cover Index Schematic No Description Item Function Torque 3 position 4 way DO3 valve Eee ts Turntable rotate left right 30 35 in lbs 3 4 Nm 2 Relief valve 1800 psi 124 bar Neie Platform level up 21122211111112 25 30 ft los 34 41 Nm 3 Check valve 0u 0ouuaounaaaniaa1 Keates Platform level up 11 13 ft lbs 15 18 Nm 4 Orifice 0 030 inch 0 76 mm AA Platform level up down 5 3 position 4 way DU valve Lee Platform level up down 30 35 in lbs 3 4 Nm 6 Check valve aaa a sd ise Platform level down 11 13 ft lbs 15 18 Nm 7 Relief valve 1800 psi 124 bar Mises Platform level down
147. the on position at both the ground and platform controls 8 Set the brake threshold on the circuit board Press down the foot switch then slowly move the control handle off center until you hear the pump motor turn on Adjust the amps to 0 16 amps Turn the threshold trimpot adjustment screw clockwise to increase the amps or counterclockwise to decrease the amps 9 Set the brake max out on the circuit board Press down the foot switch then slowly move the control handle off center until you hear the pump motor turn off Adjust the amps to 0 91 amps Turn the max out trimpot adjustment screw clockwise to increase the amps or counterclockwise to decrease the amps 10 Set the drive threshold on the circuit board Press down the foot switch then slowly move the control handle off center until you see 0 28 to 0 30 amps on the amp meter Hold the joystick in this position then adjust the drive threshold trimpot on the circuit board to 0 80 to 0 90V DC Turn the threshold trimpot adjustment screw clockwise to increase the volts or counterclockwise to decrease the volts 11 Set the drive high range on the circuit board Press down the foot switch then slowly move the control handle all the way to the FoRwARD position Adjust the high range trimpot on the circuit board to 5 00 to 5 20V DC Turn the high range trimpot adjustment screw clockwise to increase the voltage or counterclockwise to decrease the voltage 12 Raise the primary boom o
148. tinued from the previous page Troubleshoot ground and platform control functions seperately refer to charts 5 and 6 OR consult Genie Industries Service Department Part No 43063 Genie Z 30 20 5 11 Section 5 Troubleshooting Flow Charts Service Manual Third Edition Chart 5 Ground Controls Inoperative Platform Controls Operate Normally Be sure key switch is in the appropriate position Be sure the Emergency Stop switches are pulled out to the on position Be sure the batteries are fully charged Check voltage at red wire on ground controls oV contact of the key switch the red wire checked should originate at the emergency stop switch 24V Turn key switch to ground position and check output side of contact 24V Activate function enable and check voltage at the OV center terminal of each toggle switch 24V With key switch in ground position and both Emergency Stop switches pulled out to the on position activate function enable and the retract function and check voltage at T6 24V Continued on the next page Repair open in red wire circuit from emergency stop switch to the key switch Check if key switch internal cam is activating ground contact yes Replace key switch Repair open in wire circuit from function enable switch to each toggle switch at the ground controls Repair open in wire circuits from toggle
149. to 90 amps at 1 2 stroke of drive controller good Continued on the next page Section 5 Troubleshooting Flow Charts DE EEE TZ LLL Repair open in rediwht wire circuit from T78 to pressure switch to brake release valve N C on brake manifold OR repair open in brown ground wire circuit to brake release valve N C on brake manifold Replace brake release valve N C coil item T Disconnect grn blk wire from brake proportional 18 to 20 valve coil item U and ohms check resistance of coil See Repair Secion 0 or infinite ohms Replace brake proportional valve coil item U CHART 20A Readjust drive controller refer to repair section OR repair open in grn blk wire circuit from B terminal on drive controller to T1 to T11 to proportional brake release valve coil OR repair open in brown ground wire to proportional brake release valve coil OR repair or replace drive controller OR consult Genie Industries Service Department Part No 43063 Genie Z 30 20 Section 5 Troubleshooting Flow Charts E CHART 20A Continued from the previous page With key switch in platform position and both Emergency Stop switches pulled out to the on position activate footswitch and drive controller in fwd direction to full stroke and check voltage at T81 Install a pressure gauge on brake manifold quick disconnect With key switch in platform position and both Em
150. ts may result in death or serious injury Remove all rings watches and other jewelry 1 3 Block the steering wheels and then center a lifting jack under the drive chassis between the non steer tires Raise the drive chassis 1 to 2 inches 2 54 to 5 0 cm off the ground and place jack stands under the chassis Open the platform control box lid and locate the printed circuit board on the drive controller d xa d terminal R activates max out range terminal D drive output terminal X terminal ground terminal positive terminal B brake output drive lo range adjustable trimpot drive threshold adjustable trimpot drive hi range adjustable trimpot brake threshold adjustable trimpot brake max out adjustable trimpot ATT ZO zo Oo o Disconnect the white red wire from the B terminal on the printed circuit board Connect the black lead from an amp meter to the white red wire that was removed from the circuit board Connect the red lead to the B terminal on the printed circuit board 7 2 Genie Z 30 20 Part No 43063 Service Manual Third Edition Section 7 Repair Procedures 6 Connect the red lead from a volt meter to the D terminal on the drive controller printed circuit board Connect the black lead to ground 7 Turn the key switch to platform control and pull the Emergency Stop button to
151. unction operates function operates Repair open in brown ground wire circuit to 143 0 or infinite ohms Disconnect wires to platform level down directional valve coil item L and test resistance of valve coil See Repair Section Replace platform level down directional valve coil item L 22 to 25 ohms Replace defective platform level down directional valve item L OR consult Genie Industries Service Department Repair or replace detective relief valve OR consult Genie Industries Service Department Repair or replace defective check valve OR consult Genie Industries Service Department Genie Z 30 20 Part No 43063 Service Manual Third pEdition Section 5 Troubleshooting Flow Charts SEH CHART 17 Install a 0 to 2500 PSI Check for mechanical pressure gauge at the restrictions keeping quick disconnect platform level down coupling on the boom function from moving function manifold and OR repair cylinder or activate function enable cylinder counterbalance and the platform level valve OR consult Genie down function Industries Service Department Continued from the previous page less than 1800 PSI Repair cylinder or cylinder counterbalance valve OR boom function manifold could have an internal defect consult Genie Industries Service Department Part No 43063 Genie Z 30 20 5 41 Section 5 Troubleshooting Flow Charts Service Manual Third Editio
152. up the Emergency Stop Switch cover at the ground controls and move the switch to the on position 3 Activate the function enable switch and hold the secondary boom down switch with the secondary boom fully lowered and observe the pressure reading on the pressure gauge 4 Turn the machine off Hold the relief valve and remove the cap item 13 function manifold 5 Adjust the internal hex socket Turn it clockwise to increase the pressure or counterclockwise to decrease the pressure Then install the relief valve cap Tip over hazard Do not adjust AWARNING the relief valves higher than recommended 6 Repeat steps 2 through 3 and recheck the valve pressure Secondary boom down relief valve specifications Pressure 1600 psi Primary boom down relief valve specifications 110 bar Pressure 1400 psi 97 bar 7 26 Genie Z 30 20 Part No 43063 Service Manual Third Edition Section 7 Repair Procedures How to Adjust the Turntable Rotate Relief Valves Perform this procedure with the boom in the stowed position 1 Connect a 0 to 3000 psi 0 to 206 bar pressure gauge to the test port on the function manifold 2 Turn the key switch to ground control and lift up the Emergency Stop Switch cover at the ground controls and move the switch to the on position 3 Activate the function enable switch and hold the turntable rotate right switch with the turntable rotated to the right until it is against the rotation st
153. urately test the switch This procedure covers fundamental switch testing and does not specifically apply to all varieties of toggle switches 1 Turn the key switch to the orr position Tag and disconnect all wiring from the toggle switch to be tested 2 Connect the leads of an ohmmeter to the switch terminals in the following combinations listed below to check for continuity Center Right Single pole double throw SPDT ee CLE GED GRE GLa Caw Double pole double throw DPDT Service Manual Third Edition E Test Left position Desired result terminal 1 to 2 3 4 5 amp 6 no continuity infinite Q terminal 2 to 3 continuity zero Q terminal 2 to 4 5 4 6 no continuity terminal 3 to 4 5 amp 6 no continuity terminal 4 to 5 4 6 no continuity terminal 5 to 6 Center position continuity There are no terminal combinations that will produce continuity infinite Q Right position terminal 1 to 2 continuity zero Q terminal 1 to 3 4 54 6 no continuity infinite Q terminal 2 to 3 4 54 6 no continuity terminal 3 to 4 5 4 6 no continuity terminal 4 to 5 continuity terminal 4 to 6 no continuity terminal 5 to 6 no continuity 7 6 Genie Z 30 20 Part No 43063 Service Manual Third Edition Section 7 Repair Procedures Platform Components 2 1 Platform How to Remove the P
154. use death or serious injury and significant component damage Dealer service is strongly recommended Perform this procedure with the boom in the stowed position 1 Remove the platform See 2 1 How to Remove the Platform 2 Disconnect the battery pack plugs from the machine 3 Remove the turntable covers Part No 43063 Genie Z 30 20 7 11 Section 7 Repair Procedures Service Manual Third Edition PRIMARY BOOM COMPONENTS 4 Locate the 3 cables that enter the platform control box Number each cable and it s entry location at the platform control box 5 Open the platform control box Label and disconnect each wire of the 3 cables in the platform control box Electrocution hazard Contact with AWARNING electrically charged circuits may result in death or serious injury Remove all rings watches and other jewelry 6 Pull all the cables out of the platform control box 7 Tag disconnect and plug the hydraulic hoses from the platform leveling slave cylinder Cap the fittings on the cylinder 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 8 Remove all the hose and cable clamps from the platform pivot weldment cable track and the primary boom 9 Pull all the cables and hoses through the cable track then through the mid pivot Component
155. ustries Service activate footswitch and the on position activate Department check voltage on R footswitch and check terminal on drive voltage on R terminal controller on drive controller Readjust drive controller 20V or more OR repair or replace drive controller OR consult Genie Industries Service Department With keyswitch in al or replace LS3 platform position both OR check for Emergency Stop mechanical restriction switches pulled out to keeping LS3 activated the on position and OR consult Genie secondary boom raised Industries Service activate footswitch and Department check voltage on R terminal on drive controller 20V or more Check for mechanical restriction keeping LS1 and LS2 activated OR repair or replace LS1 and LS2 OR consult Genie Industries Service Department 5 58 Genie Z 30 20 Part No 43063 Service Manual Third pEdition Section 5 Troubleshooting Flow Charts Remote Brake Release Inoperative With ground control Emergency Stop switch pulled out to the on position activate remote brake release and check voltage at T6 20V Continued on the next page Activate remote brake release and check voltage at T78 With ground control Emergency Stop switch pulled out to the on position activate remote brake release and check voltage at T75 oV With ground control Emergency Stop switch pulled out to the on position activate remote brake release
156. ve the cotter pin from the extension cylinder barrel end clevis pin Remove the clevis pin Always use a new cotter pin when installing a clevis pin 4 Remove and label the wear pads from the outer boom tube at the platform end of the boom Pay careful attention to the location and amount of shims used with each wear pad 5 Support the extension tube with an overhead crane at the platform end of the boom Crushing hazard The boom ACAUTION extension tube will fall when it is removed from the primary boom tube if it is not properly supported 6 Support and slide the outer tube off of the inner tube Place the outer tube on blocks for support During removal the overhead crane strap will need to be carefully adjusted for proper balancing 7 Remove the retaining fasteners from the extension cylinder rod end mounting brackets at the platform end of the inner tube Part No 43063 Genie Z 30 20 Section 7 Repair Procedures Service Manual Third Edition as SS PRIMARY BOOM COMPONENTS 8 Support and slide the extension cylinder out of 3 Support the rod end of the cylinder with a lifting the pivot end of the inner tube Place the strap from an overhead crane li locks f l E i 10k Suppo 4 Remove the pin retainer from the primary boom During removal the overhead lift cylinder rod end pin Then use a soft metal crane strap will need to be drift to remove the pin caranilly SEET 5 Lower the rod end of the cyl
157. which most closely describes the problem General Repair Process Malfunction Identify Troubleshoot discovered symptoms problem still exists Return to Perform service repair problem solved 5 2 Genie Z 30 20 Part No 43063 Service Manual Third pEdition Section 5 Troubleshooting Flow Charts All Functions Will Not Operate Be sure key switch is in the appropriate position Be sure the Emergency Stop switches are pulled out to the on position Be sure the circuit breaker and fuses are not tripped or blown Be sure the battery packs are properly connected Be sure the batteries have been charged Disconnect battery on each pack 24V or more Reconnect battery packs and check voltage OV on input side of 80A fuse 2 48V Check voltage on output OV side of 80A fuse 2 48V Check voltage on input ON side of 10A fuse 3 24V Check voltage at output ON side of 10A fuse 3 24V Check voltage at input side of Emergency Stop switch P1 24V Check voltage at output side of Emergency Stop switch P1 24V Check voltage at input OV side of key switch 24V Continued on the next page less than Charge batteries OR packs and check voltage 24V Chart 1 check battery condition and replace bad batteries OR check for short circuits OR check battery cables OR consult Genie Industries S
158. wo 5 16 inch fasteners Hand tighten the bolts 9 Push the worm drive towards the rotation bearing to be as close as possible 10 Position a dial indicator to measure the worm drive in relation to the ring gear Pull the worm drive away from the rotate bearing 0 035 inches 0 889 mm 0 020 inches 0 508 mm 11 Tighten the two 5 16 fasteners Observe the dial indicator to be sure that the worm drive does not move while tightening the fasteners 12 Locate the 1 inch hex head on the end of the worm gear housing Turn the hex head to rotate the worm drive until it is positioned within the original reference marks on the drive chassis 13 Position the turntable so that the flat side of the turntable is parallel with the worm drive gear 14 Install the turntable mounting fasteners Use a torque wrench to tighten the fasteners in sequence to specifications 20 22 3 e om 16 7 ae 8 3 12 4 11 i7 23 14 0009 5 21 2 10 Specifications torque First rotation 95 foot pounds 129 Newton meters Second rotation 190 foot pounds 258 Newton meters After complete assembly the turntable should rotate smoothly without jerking or grinding Genie Z 30 20 Part No 43063 Service Manual Third Edition Section 7 Repair Procedures Steering Axle Components 9 1 9 Use a soft metal drift to remove the pin Yoke and Hub Grushing hazard The yoke hub AWARNING assembly will fall when the king pin is
159. y slowly to allow the oil pressure to dissipate gradually Do not allow oil to squirt or spray 10 Label and then disconnect all the wiring from the contactor panel to the ground controls Pull the wiring up through the turntable Electrocution hazard AWARNING Contact with electrically charged circuits may cause death or serious injury Remove all rings watches and other jewelry 11 Label and then disconnect all the wiring from the battery charger Pull the wiring up through the turntable AWARNING Electrocution hazard Contact with electrically charged circuits may cause death or serious injury Remove all rings watches and other jewelry 12 Prepare a forklift with a minimum rating of 10 000 pounds 4536 kg by spreading the forks to an approximate inside width of 16 inches 40 6 cm 13 Position the forklift at the counterweight end of the turntable Center the forks between the turntable main frame tubes and the drive chassis Do not lift it AWARNING Crushing hazard Turntable may be become unbalanced and fall if the forks do not extend past the center point of the turntable Use fork extensions if necessary Part No 43063 Genie Z 30 20 Section 7 Repair Procedures Service Manual Third Edition TURNTABLE ROTATION COMPONENTS a mainframe tube b fork 14 Raise the forks up against the turntable Do not lift 15 Place a safety strap around the mid pivot then secure t

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