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Service Manual - Genie Industries

1. OPTION 2 1344 KEYSWITCH POWER RED 8 1 RED WHT TILT WHT 2 134 RED A6 RED KSI KEYSWITCH POWER RED C23 1 A3 BRN CB2 BLK OPTION 2 52 BRN CH BRN CR4 GROUND A2 AG i is BRN 5 BRN 2 52 BRN MH BRN SP GROUND WHT 6 WHT 8 50 LS2 LS4 JUNCTION BLU RED 1 BLK 7 BLK 6 49 LS1 LS2 JUNCTION BRN WF wHT BLK SP RED WHT CR5 48 RED WHT MH RED WHT SP BRAKE RELEASE BRN ORG BLK 1 47 ORG BLK SP JIB RIGHT ORG 1 46 ORG SP JIB LEFT i GRN BLK 1 44 GRN BLK SP JIB DOWN 9 g GRN 1 43 GRN SP JIB UP 2 6 ORG RED CR1 ORG RED 1 42 ORG RED CH ORG RED L3 SWITCHED 48V O BLK 8 40 ORG CH OFF LIMIT SPEED 0 BLUBLK 19D BLU BLK 1 37 BLU BLK MH STEER RIGHT GRN BLK i 1 BLU 1 36 BLU MH STEER LEFT WHT RED 1 32 WHT RED CH JOYSTICK POT LOW WHT BLK 1 31 WHT BLK CH REVERSE WHT 1 30 WHT CH FORWARD WHT BLK 19D 48D jii RED WHT 1 29 RED WHT CH 2 WIRE POT BRN 52A 1 ex RED BLK TILT RED BLK 1 28 TILT ALARM 1 RED CR3 RED 1 27 RED SP AUXILIARY PUM
2. 0 635 1 1 14 Limin 4 SLAVE B Resse d 1 E 7 7 TTMBBOOMMANIFOID _ EXTENSION CYLINDER EXTENSION CYLINDER JIB BOOM MANIFOLD MODELS WITHOUT MODELS WITH ROTATING JIB BOOM ROTATING JIB BOOM 1 SECONDARY BOOM CYLINDER STEER AL bes inch 5 AM la mm 1 F BRAKES 1 PLA TURNTABLE ROTATE Se wes MOTOR L ee 64 0 090 inch _ d 207 bar 5 9 cu in rev a 4 5 1 I MASTER etie Wo number 10808 1 hin aye 7 6 cu in rev 4 1 N 6 124 5 colrev gt 2500 psi 3000 3200 psi 2500 psi 172 207 bar 221 bar 172 bar 31 Ee i 0 bef ial i Am die ie ae SS ee ee AUXILIARY PRIMARY 1 0 BR
3. TB134 2 1 BLK 2 BLK FS t3 7 WHT FS WHT 4 4 5 T lt lt 2 ORG RED 1 U33 B o 6 55 34 7 1518 5 3 CB1 8 TB22 gt gt 8 4 5 2 1 gu BLK Hae i x P3 E z H HORN 1 GND L45 BLU RED 1 RED CR20 bE ORG RED WHT 30 150 WHT 1 WHT 1 WHT BLK 31 WHT BLK 1 WHT BLK 1 RED WHT 29 TB29 1 RED WHT 1 tef WHT RED 32 TB32 wHT RED 1 WHT RED 1 te ORG 40 3520 BLK 8 9 TB3 H P HI ORG RED CR2 BLUMHT 12 2 1154 BED 4 E E g 1 c 2 F1 g CR5 g 2 10 1 m RED RED 48V 500A PRI S 86 P m 448V S TB50 5 S TS55 m E FUNCTION i 5 2 5 5 E o m o B 100A 2 S m 21
4. 1 1 al x a 5 5 5 6 um 5 mu 5 a 8 50 z 5 5 amp i 1 1 1 1 i T 1 i 1 2 4 4 R42BAT OR RD C2B 4 OR RD 1 3 1 o y 5 5 RD WH C3B 3 8 BRN e tI o o BRN alg 1 zz eo 8 8 EMI ae 1 1 RD WH i e 5 8 5 RD BK C1P 2_ C28TTA RD BK C1B 2 D 2 6 E C7P 2_ P23BAT WH C7B 2 RD 4 RD BK BAN 2 BH Sloe 8 lt m lt m i 8 B q 8 8 6 a 9 C9HRN BK RD C3B 9 f T 5 dz 5 1 1 g fw C49 1 R2
5. gt SETUP ENABLE USE SET THE BATTERY INDICATOR PROFILES gt lt SWITCH SHOWN WITH BOOM EXTENDED u 8 alio g 5 BRN C7P 3 BATGND BRN C7B 3 BATGND BRN Y 1 CI3DELBURD C4B 1 C13DEL BURD C84 WHS S 5 2 4 2 8 2 12 CI2FTS BL WH 2 C12FTS BWH 8 3 5 RD C8 1 fu z CI6DEOR RD 048 4 E 01605 OR RD E OR RD ovy 3 gt RD WH 5 TRAVEL ALARM 49 8 RD WH 5 BRAKE RELEASE ro g NC COIL F 2 BRAKE RELEASE 55 54 95 3 BRAKE RELEASE 5 lt PRESSURE SWITCH 10 10 4 Ca6scc BL C1B 10 BL 4 STEER LEFT n 5 C37SCWBUBK 77 C1B 11 5 BLBK n 5 STEER RIGHT m 3 8 5 5 e y a 58 5 4 HOUR METER 1 1 C27AUX RD C1B 1 RD AUX gt Ty o CN amp 5 5 55 g 420 9 5 lt gt 5 m 4 5 8 5 z m ja O j AUXILIARY CONTROL
6. REV A before serial number 6290 N M L K J H G F E D B A RED CR3 1 RED CB1 GRN WHT CR3 WHT RED 32 RED WHT 29 2 RED BLK CR5 ORG RED 42 ORG RED CR20 3 F4 ES 10A N 48V DC 24N DC MOTOR oe CONTROLLER Ip 009 4 T HD D 2g 96 8 5 ORG RED m ORG RED 9 PR2 i PRIMARY PR1 AUXILIARY B LIFT PUMP DRIVE TAG CONTACTOR CONTACTOR CONTACTOR 23 22 21 20 1918 17 6 15 4 GRN WHT CR3 BRN Beene ha hz he fs bai GRN BLK GRN WHT PR2 CR20 LIFT PUMP CONTACTOR 6 VL iu RELAY 6 0 GRN WHT PR2 9 BRN CR20 LIFT PUMP CONTACTOR BRN RELAY SOCKET WIRING WIRE INSERTION SIDE SHOWN 7 BRN CB2 WHT BLK 31 WHT 30 8 BLK L3 ORG 40 BLU WHT 12 ORG RED CR2 A TEREX COMPANY Part No 106373 Z 30 20N Z 30 20N RJ 6 8 April 2007 Section 6 Schematics Power Panel Diagram before serial number 6290 April 2007 Section 6 Schematics EE Power Panel Diagram from serial number 6290 to 8354 Section 6 Schematics April 2007 Power Panel Diagram from serial number 6290 to 8354
7. i 1 5 6 E 5 g 5 ess 2 2 5898 3 o dis 2 1 1 1 1 1 1 1 1 1 1 1 j 1 1 1 1 1 1 1 1 1 1 1 f 1 1 1 1 1 1 C2P 4 R42BAT OR RD C2B 4 OR RD i gi S 1 B 8 5 8 ote 5 1 C3P 3 RD WH C3B 3 5s BRN 96 TI BRN 2 Tz 3 ant DA eee 9 RDWH Sg 1 1 9 18 i 5 ES Far 2 1 2 C28TTARD BK C1B 2 RD BK 7 1 _C7P 2_ P23BAT WH C7B 2 RD g Sg vs AS 2 x ba 5 lt 8 m o y o 8 vs 8 go 29 PD C3P9 CSHRNBKRD lt C3B 9 x 9 8 3 8 2 5 49 1 R27AUX 5 a 2 1 C133PLA BURD C2B 1 5 8 5 OH KH 22 C7B 1 8 s C49 11 C19LPE GR WH 8 6 2 o7 5 g a gi 8 g 5 ls 8 RI9LPEGR WH a 9 T 5 lt gt 0 g a 2 3 C9HRN BK RD 8 BRN o LI
8. Electrical Schematic from serial number 8355 to 9346 Section 6 Schematics f a a anm g g Hr 5 84 NHE 8 8 50 PS 2 1 1 1 1 1 1 1 i 1 1 1 1 1 j 1 j 1 1 1 i 1 1 1 1 j 1 1 1 1 1 i 1 T 1 1 1 2 4 R42BAT OR RD C2B 4 OR RD NANA B ol 5 5 C3P3 RDWH C3B 3 5 5 BRN 4 Tz i 3 1 5 9 e e Fa gv RDWH 2 p 1 5 53 4 55 j 2 2 4 C28TTARD BK C1B 2 RD BK WH REM v C7P s P2SBATWH C7B 2 RD 8 y 5 8 88 8 8 oS 5 a Tere RD 4 9 BK RD C3B 9 5 8 a N 1 a a CI33PLABL RD 2 1 8 C491 RETAUX RID 5 at 5 a 9 o
9. 1 RED CH jJ KS1 er TS51 o RED WHT 48A J1 NO NO RED gt WHT 23A BLK 22A RED v RED 27A ORG BLK 15A BLK 7A BLK WHT 8A WHT RED 6A 859 ORGIBLKATA 77 T963 086 464 6 5 OD AC ease R E 920 gy ORG 14A GRN BLK 18A GRN WHT 19A 4 TS61 TS57 GRN BLK 44A 558 9 pai 6 L R RED BLK 2A tM 1 GRN 17A WHT BLK 5A WHT 4A TS55 QO BLU BLK 11A BLU 10A REV A April 2007 Section 6 Schematics Ground Control Panel Wiring Diagram REV A from serial number 6290 to 8354 N M L K J H G F E D 8 4
10. X e emm zm x Ww Q 8 8 zig B gi z 8 g 5 5 amp 5 E S 9 5 a 5 a o i o 5 hoc a m 1 5 f Bee Fea ORG RED 1 ORG RED 1 e ae RED WHT 8 48V DC POWER RELAY 8 205 4 RED WHT 3 EY RED WHT 48V DC one Vo POWER 8 8 RELAY ssa e 8 d lt 83 8 8 T RED BLK 1 a RED BLK 28 WHT ju 5 3 RED 4 BLK BRN gt j eo 1 1 8 8 8 FLASHING 1 WHT 2 y 5 OPTION iQ 3 1S vC C ru MMC ECC REC 1 3 6 577 1 2 1 or BLK RED 3 BLK RED CR4 58 HORN RELAY 2 uon g c x a BLK 22 BLK RED BRN HORN 5 8 8 Ela 5 8 E tea wo 4 8 5 C WHT8 on BLK 6 7 WHT 7 DINEM EE PEDIS 1 E oz NR zye aaa guo E S58 DE
11. 5 6 7 8 9 10 11 12 42 GR WH PR2 24V 9 em PR3 AUXILIARY LIFT PUMP CONTACTOR EE DETAIL A CR20 LIFT PUMP CONTACTOR RELAY BR BR C49 5 C31REV WH BK 49 4 C30FWD WH C49 7 C178CSL BK C49 9 0401 5 OR C49 8 C12FTS BL WH C48 3 01GND BR C48 2 P42BAT OR RD 48 1 182 RD Section 6 Schematics ii Power Panel Diagram after serial number 8354 8 OR RD CR2 P42BAT OR RD CR20 GR WH IICR3 19 BR GR WH PR2 R42BAT DETAIL A RELAY SOCKET WIRING WIRE INSERTION SIDE SHOWN 106373 TEREX COMPANY Z 30 20N Z 30 20N RJ April 2007 Section 6 Schematics Power Panel Diagram after serial number 8354 REV April 2007 Electrical Schematic before serial number 6290 Section 6 Schematics
12. 5 BRN 2 5534 6 g e N BLU RED 3 Fa WHT 5 V BRN5 di T 8 A BLUWHT 3 BLK 5 RED 5 2 7 uj ORG RED 3 pup TR E WHT ORG RED N 4 lt gt g BRAKE RELEASE S 9 RED WHT TRAVEL ALARM A2 1 L 12 BRAKE RELEASE GSR eS 1 N C COIL RED WHT 8 BRAKE RELEASE 0 COIL BRAKE RELEASE RED WHT PRESSURE SWITCH cs BLU 36 BLU 1 A1 STEER LEFT COIL e 5 BLU BLK 1 EL E BLU BLK 37 Iu 5 STEER RIGHT COIL 8 5 1 E 8 FE B B EES TF Jp 5 285 2 HOUR METER 4 H E 2 fo 36 RED 860827 AUXILIARY CONTROL 915 RELAY COIL 5 1 o 1 1 1 5 o g 1 5 ei 2 i te 2 7 25 9 LIFT PUMP 55 GRNWHT 7 CONTACTOR RELAY 8 CR20 E mcr darc IE 1 ORG RED 48V 1 LIFT PUMP i ORGIRED eng g CONTACTOR COIL 4 5 LE mos PR2 mog bi 3 emwwura 2 GnNWHT 80 oo OO LLL N pE T gt a o L gt A E eee 5 WHT RED 3 _ WHT RED 6 PROPORTIONAL WHT o EH f FLOW CONTROL et 5 CO
13. NES ee et 4 oa p lt 5 1 C2P 3 C47JRR OR BK C2B 3 H 1 5 C2P 2 C46JRL OR C2B 2 1 C2P 5 C46JRL YL C2P 5 C47JRR RD OPERI i 2 5 C43JU GR C2P 6 C44JD GRIBK 2 em 1 C47 8 C44JD WH 1 i 47 4 C43JU i gu RIGHT y 5 2 5 C47 1 C18PRLOR 0 QE o 4 x 1 my 5 LEFT a gt 5 ag o fu C47 2 C17PRR BL OF e i u 5 89 06 018008 C4B6 1 C4P 5 CI7PRL GR 0485 5 ie 55 DOWN 1 A NU p e o 5 C4P 2 C14PLU OR 3 C15PLD OR BK C4B 3 I EXTEND B BK i x lt 4 BKIWH 2 4 59 3 1 A 7 0987 8 C8PBRBKWH 0888 2 E RD gt lt RD BK zo 1 lt gt 25 TO COP CIPBURD 0881 C3P 2 C2PBD RD BK C3B2 2 8 1 E UP E BL i e 5 4 1 2 5 m BLIBK oo DOWN uo 1 eu 8 5 5 10 010880 BL 08840 hnic C3P 11 CHSBDBLBK 4 C3B 11 1 8 RIGHT WHIBK tl 25 L 1 5 Es 1 LEFT a 1 eu RIGHT C3P 5 CSTRRWHBK C3B5 1 4
14. 4 32 7 2 Valve Adjustments Function 4 36 7 3 Jib Boom and Platform Jib Boom Rotate Manifold Components 4 39 7 4 Malve Colls acier ied eet iui ei i eet 4 40 Turntable Rotation Components 8 1 Turntable Rotation Hydraulic 4 42 Steer Axle Components 91 44 040 4 43 Motor Controller 10 1 Motor 4 44 Fault Codes 5 1 Fault Code Chan E 5 3 Section 6 Rev gt gt gt gt gt gt gt gt gt gt gt gt gt gt gt gt gt gt gt TABLE CONTENTS Schematics 6 1 Load Sensor Option Diagram before serialnumber 6290 6 2 Electrical Symbols Legend 20 2 2 6 3 6 4 Power Cable Diagram before serial number 6290 6 5 Power Cable Diagram from serial number 6290 to 8354 6 6 Power Cable Diagram after serial number 8354 6 7 Power Panel Wiring Diagram before serial number 6290 6 8 Power Panel Wiring Diagram from serial number 6290 to 8354 6 9 Power Panel Wiring Diagram after serial number 8354
15. 6 ur Toggle switch DPDT 1 ni Limit switch r Relay panel contactor NOHC Limit switch normally open held closed Solenoid or relay coil Fuse PLATFORM m GROUND Key switch before serial number 6290 PLATFORM e GROUND Key switch after serial number 6289 Part No 106373 A TEREX COMPANY Z 30 20N Z 30 20N RJ Section 6 Schematics Hydraulic Symbols Legend Q Hydraulic filter Check valve Orifice Brake Double acting cylinder Pump prime mover motor Pressure switch Fixed displacement pump Flow regulator valve hd 1 1 1 Relief valve Dual relief valve Filter with by pass check valve SI AE LA 4 Way directional valve Solenoid operated 3 position dual Counterbalance valve single Differential sensing valve AXE Solenoid operated proportional valve miam Bi directional motor A TEREX COMPANY Normally closed poppet valve o Normally open poppet valve 222 5 ERST hr d Regen circuit K Shutoff valve Z 30 20N Z 30 20N RJ Part No 106373 April 200
16. 3 1 RED MH RED SP PRIMARY BOOM UP GRN BLK 18A 7 7 7 GRN WHT 19A TS61 TS58 TS61 2 TS57 1 0 8 GRN BLK 44A SEE OPTIONAL WIRING ono JIB ROTATE OPTION GRN 43A 1858 RED BLK 2A Ou i RED 1A ORG 1 p g WEK 5A TS62 6 0 5 1595 6 o T 5 S 55 O DQ 0 2 bbs 2 6 000 LER 1 1 BLU BLK 11A 0 ORG RED CH RED 27D TETUER RED C23 7 GRN WHT CH BLK 22B LABEL DESCRIPTION BLU 10A A2 BRAKE RELEASE TRAVEL ALARM 1 2 3 4 H 6 6 6 V A3 DESCENT ALARM OPTION RED WHT TB3D BRN 52A 13456 7 8 12 6 PLATFORM OVERLOAD ALARM MODELS 081 CIRCUIT BREAKER CONTROLS 10 1 E BLK RED HORN 082 CIRCUIT BREAKER CONTROLS RETURN 10 7 C23 MV CH CHASSIS HARNESS ORG RED 42D RED CH BLK RED 9D CR CONTROL RELAY DESCENT ALARM WIRING OPTION 1 HM HOURMETER 1 J1 BRAKE RELEASE JACK RED WHT 48C ORG MH ORG BLK MH U33 KEY SWITCH CONTROL RELAY 1 0 SPARE WIRE LIST 13 CONTROLLER STATUS LED SECONDARY 48V DC POWER BLK 1 5 10 108 145 PLATFORM OVERLOAD LED MODELS CR2 PRIMARY 48V DC POWER SUCRE RED BLK CH E RED 6 MANIFOLD HARNESS
17. JIB BOOM ROTATE ORG BLK 3 BLK WHT 3 BLK 3 BLU RED 3 BLU BLK 1 BLU 1 ORG RED RED WHT FS WHT 1 WHT BLK 1 WHT RED 1 RED WHT 1 WHT o 9 NC GH DP1 1 2 3 4 5 6 7 8 9 10 BCI is RED WHT 3 WHT 2 ORG RED 1 RED TS1 AUXILIARY POWER P3 HORN P2 EMERGENCY STOP BUTTON BLK FS BLK 2 WHT BLK RED 3 RED 1 REMOVE THIS WIRE WHEN ome REMOVE JUMPER SENSE OPTION IS REQUIRED BLUE JIB ORG JIB WHT JIB BLK JIB YEL JIB RED JIB Part No 106373 FOR CE MODELS TEREX COMPANY Z 30 20N Z 30 20N RJ G 6 27 Section 6 Schematics B from serial number 6290 to 8354 Platform Control Box Wiring Diagram April 2007 REVA z SPARE WIRE BLK 1 BLK WHT 1 BLK RED 1 BATTERY CHARGE INDICATOR OPTION BOOM FUNCTION SPEED CONTROLLER DRIVE CONTROLLER EMERGENCY STOP BUTTON PLATFORM ROTATE TOGGLE SWITCH JIB BOOM UP DOWN TOGGLE SWITCH PLATFORM LEVEL TOGGLE SWITCH PRIMARY
18. A Oo NI AIN CO uA 2 oo gt Oo PN C2 A 48 00 A gt 2008 Section 3 Scheduled Maintenance Procedures Scheduled Maintenance Procedures Observe and Obey Maintenance inspections shall be completed by a person trained and qualified on the maintenance of this machine M Scheduled maintenance inspections shall be completed daily quarterly six months annually and every 2 years as specified on the Maintenance Inspection Report AWARNING Failure to properly complete each inspection when required could result in death serious injury or substantial machine damage M Immediately tag and remove from service damaged or malfunctioning machine Repair any machine damage or malfunction before operating machine Use only Genie approved replacement parts Unless otherwise specified perform each procedure with the machine in the following configuration Machine parked on a firm level surface Boomin the stowed position Turntable rotated with the boom between the non steer wheels Key switch in the off position with
19. ORG RED CR20 J N tc a 5 9 GRN WHT CR3 GRN WHT PR2 A B D E F G H RED 1 RED 4CB1 GRN WHT CR3 WHT RED 32 RED WHT 29 2 RED BLK CR5 ORG RED 42 ORG RED CR20 3 10A 48 DC e Hn 24V DC DONE CONTROLLER 5 2 4 ee o9 ORG RED ME PR2 PR3 PRIMARY PRI AUXILIARY LIFT PUMP DRIVE PUMP 5 CONTACTOR CONTACTOR CONTACTOR 23 21 17 he hs 3 GRN 12 hole 8 7 6 5 4 3 2 1 BLK GRN WHT PR2 mE CR20 f LIFT PUMP CONTACTOR 6 RELAY 4 AN 486 Ale B QN BRN CB2 WHT BLK 31 WHT 30 BLK L3 ORG 40 BLU WHT 12 ORG RED CR2 TEREX COMPANY 6 9 Z 30 20N Z 30 20N RJ Part No 106373 CR20 LIFT PUMP CONTACTOR RELAY SOCKET WIRING WIRE INSERTION SIDE SHOWN BRN REVA REV 049 1 R27AUX RD April 2007 49 11 C19LPE GR WH C49 6 03281 WH RD C49 3 C29JSH RD WH C49 2 C48BRK RD BK C49 10 R42BAT OR RD OR RD CR20 10A HH CD PR2 PRIMARY LIFT PUMP CONTACTOR P182BAT BK GR CURTIS SEPEX MOTOR CONTROLLER OR RD OR RD PR1 DRIVE CONTACTOR 24 23 22 21 20 9
20. C2P 3 C47JRR OR BK C2B 3 51 1 C2P 2 C46JRL OR C2B 2 C2P 5 C46JRL YL 1 2 5 C47JRR RD PLATFORM ROTATE RIGHT JIB BOOM UP ee PLATFORM ROTATE LEFT JIBBOOM DOWN 8 1 1 C2P 5 GR C2B 5 oS 8 C2P 6 C44JD GR BK C2B 6 g 47 3 C44JD WH 4 C474 C43JU BK 44 5 ES z 5 C471 13 5 E a 5 5 8 5 47 2 17 BL n uc 2 ER 8 PLATFORMLEVEL 8 29 6 CIBPRRGR BK 46 CUT OUT OPTION 5 C17PRLGR C4B 5 5 8 8 UP PLATFORM LEVEL 5 UP COIL Eu es ORIBK n 4 PLATFORMLEVEL Sa 2 DOWN COIL 4 1 e lt eae eter 4 4 8 F gt 2 C14PLU OR C4B 2 5 a C4P 3 C15PLD 086 C4B 3 5 5 EXTEND Gi 4 BOOM EXTEND gt 3 8 BK WH ni 4 BOOM RETRACT uj 2 9 D lt 5 gt C3P 7 C7PBE BK C3B 7 8 BK WH C3B 8 RD PRIMARY BOOM UP RD BK 4 PRIMARY 2 28 a BOOM DOWN 5 aa lt gt 5 gt 9 g 1 C1PBU RD C3B 1 z 2 C2PBD RD BK C3B 2 5 5 gt B BL 0 SECONDARY 8 BOOM UP 8 5 BL BK ra IA 4 SECONDARY 5 9
21. 28 8 l 7182 1 5 2 22 a 5 5 5 59 gt 1 if 5 iE m 5 4 2 4 as 9 o gt w 2 25 215 9 gt lt 2 1 c 2 2 3 E m 5 2 m z 2 2 1 9 e 8 3 ft NN 5 8 g 5 2 N a gt M 86 30 BLK o gt 5 17 a 5 CR1 m STATUS LED 14 5 B S co 5 9 CURTIS 1244 RED 100 88 5593 PS 59 SEPEX CONTROLLER B 3582 1 F1 M B F2 2 63 6 DC PR2 RE hi 5 E 4 5 1 2 8 n i C x 3 1 F2 A2 A2 F1 X SEHEN ca Boc 87 85 p P dcm qp m 2 peo 5 1 CENE 8 g x LEFT RIGHT 8 MOTOR MOTOR 2 2 7 z E GND GROUND E wa BLK 2 BAN BN n L i GND E S D D TB52 3 52 238 38 33 55 2 5 8 owm 5 Bg gg E ue 29 S9 0 2 405 o B5 gt 5 gt 59 3 2 m m 6 m 8 2 1 55
22. 6 10 Electrical Schematic before serial number 6290 6 11 Electrical Schematic from serial number 6290 to 8354 6 13 Electrical Schematic from serial number 8355 to 9346 6 15 Electrical Schematic CE Models from serial number 8355 to 9346 6 17 Electrical Schematic after serial number 9346 6 19 Electrical Schematic CE Models after serial number 9346 6 21 Ground Control Panel Wiring Diagram before serial number 6290 6 23 Ground Control Panel Wiring Diagram from serial number 6290 to 8354 6 24 Ground Control Panel Wiring Diagram after serial number 8354 6 25 Ground Control Panel Terminal Strip Wiring Diagram after serial number 8354 sssssssssesseseseeeneee nennen nennen entree 6 26 Platform Control Box Wiring Diagram before serial number 6290 6 27 Platform Control Box Wiring Diagram from serial number 6290 to 8354 6 28 Platform Control Box Wiring Diagram after serial number 8354 6 29 LVI BCI Option Wiring Dlagram from serial number 8355 to 9346 6 30 LVI BCI Option Wiring Dlagram after serial number 9346 6 31 Hydraulic SCHEMALIC 6 32 This page
23. 000000 CABLE 1 1 P MANIFOLD HARNESS MH CHASSIS HARNESS CH C49 April 2007 Section 6 Schematics Ground Control Panel Terminal Strip Wiring Diagram after serial number 8354 E D B A TERMINAL BASE TB DESCRIPTION CIRCUIT WIRES FROM CONNECTOR TO CONNECTOR 1 RD WH FLASH BEACON OPT 134 RD C32 1 KEYSWITCH POWER C134PWR WIRES CIRCUIT FROM To DESC RD WH TILT WH C7B 2 134 RD A6 CE OPTION RD KSI 4 KEYSWITCH POWER C134PWR WH J2 11 4 10 2 152 154 JUNCTION BR CB2 BK FLASH BEACON OPT 52 BR MH BR CR4 GROUND BATGND BK Ji C11 3 C52 1 LS1 LS2 JUNCTION BR C8 2 7 3 52 BR BR SP GROUND BATGND OR BK C47JRR C2B 3 SP JIB ROTATE RIGHT OPTION RD WH CR5 M WH BK SP 48 RD WH MH RD WH SP BRAKE RELEASE C48BRK OR C46JRL C2B 2 SP JIB ROTATE LEFT OPTION OR RD CR1 OR RD C2B 4 42 OR RD C49 10 OR RD L3 SWITCHED 48V R42BAT GR BK
24. 5 8 RAB a E 5 OO bt g 6 18 A TEREX COMPANY Z 30 20N Z 30 20N RJ G Part No 106373 gt SWITCH SHOWN WITH BOOM ROTATED PAST EITHER NON STEER WHEEL April 2007 Section 6 Schematics Electrical Schematic CE Models from serial number 8355 to 9346 REVA C29JSH RD WH April 2007 Electrical Schematic after serial number 9346 Section 6 Schematics 1 i 1 1 i i 1 8 1 8 5 imo amp a t lt lt 5 o Sla 8 8 a S z amp 3 amp i 1 1 i i 1 i 1 1 1 1 1 i 1 1 1 1 i 1 1 1 1 1 1 1 1 1 i i 1 1 1 1 1 1 1 1 i 1 1 i 1 1 1 i 1 1 1 1 i i 1 1 1 1 1 1 i 1 1 i i 1 1 1
25. 1 1 i 1 1 1 i 1 1 i 1 1 i 1 1 1 1 1 1 i 1 1 1 i 1 1 i 1 1 i 1 1 1 1 1 i 1 1 i 1 1 i 1 1 1 1 1 1 i 1 1 1 1 i 1 1 i 1 1 i 1 1 i 1 1 i 1 1 1 1 1 1 i 1 1 i 1 1 C2P 4 R42BATOR RD C2B 4 OR RD 1 o 1 8 5 1 88 i 1 RD WH C3B 3 BRN 48V POWER 2 11 RELAY CR2 ole gu BRN 48V POWER gs g RELAY CRI 5 A tree 1 BN 4 Vau 1 41 FLASHING BEACON EAS ha OPTION z 5 aon 1 5 Far i 5 1 2 C28TTA RD BK C1B 2 RD BK WH ers 2 C7B RD RD BRN P23BAT WH 2 TILT SENSOR g gt ere c 1 a S x lt 218 a A 5 a 3 BASE CONTROL 1 BOX GROUND 1 A 1 44 i aol RD C3P 9_ C9HRN BK RD C3B 9 2 1 a 5 AUXILIARY LIFT 49 1 R27AUX RD PUMP ind 1 1 1 d CISSPLABURD C281 e 5 g 1 Y P22BATBK C7B 1 5 L C4 CIOLPEGRWH S 12 8 PRIMARY LIFT PUMP 5 1 o5 a 8 408 5 1 E 1
26. amp 5 ete eee RS m Filia T 58 7 lt 5 Wu als a a o l eee m ey 3 t m cl Xx 3 4 Part No 106373 COMPANY Z 30 20N RJ 2 30 20 G 6 11 DRIVE ENABLE LIMIT SWITCH Shown with boom rotated past either non steer wheel BRN 2 1 DRIVE ENABLE LED TB13 21 22 TB52 BLU RED 3 WHT 5 BRN 5 2 H 52 BLU WHT 3 BLK 5 RED 5 X 5 g Section 6 Schematics Electrical Schematic before serial number 6290 JP1 REMOVE FOR CE MODELS 4 8 9 14 8 13 ORG RED 3 16 DRIVE ENABLE WHT ORG RED BRAKE RELEASE TRAVEL ALARM RED WHT 9 2 A2 7 BRAKE RELEASE N C COIL BRAKE RELEASE JACK d L Ci 11 RED WHT TB48 RED RED WHT 48 RED WHT 48 IBRAKE RELEASE REDWHT 5 0 COIL G BRAKE RELEASE PRESSURE SWITCH 4 BLU 36 STEER LEFT COIL BLU 1 TB36 TB37 BLU BLK 1 BLU BLK 37 STEER RIGHT COIL WHT BLK HOUR METER ORG RED PLATFORM CONTROL BOX GROUND HM AUX POWER RED RED 27 AUXILIARY CONTROL RELAY COIL 85 BC
27. gt SETUP ENABLE USE SET THE BATTERY INDICATOR PROFILES gt SWITCH SHOWN WITH BOOM EXTENDED y F1 g 8 5 BRN C7P 3 BATGND BRN C7B 3 BATGND BRN CISDELBURD C4B 1 C13DELBURD C84 wis 5 eS BANS 4 8 i 12 CI2FTSBL WH C3B 12 C12FTS BLWH 3 Bes 7 RD 5 C8 1 Ts 2 C4P 4 CI6DEOR RD C4B 4 E C16DE OR RD OR RD RD WH 4 TRAVEL ALARM 532 5 4 F48BRK RD WH BRAKE RELEASE t NC COIL i PI 2 F 2 5 BRAKE RELEASE ESEA COIL 5 0 lt gt 05504 6 1 BRAKE RELEASE PRESSURE SWITCH 10 636300 BL C1B 10 BL 5 4 STEER LEFT i CS7SCWBUBK C1B 11 BLIBK n 4 STEER RIGHT 1 1 1 1 i 5 5 IY e x 2 o a 1 ji le Y y 5 gt E Ed 3 zs g E ppt WHIBK 4 HOUR METER 8 8 E 1 1 C27AUX RD 1 1 RD AUX gt 5 i 5 5 538 x ar a 2 gt 8 6 8 rr Nay g amp g OR RD we 1 8 8 AUXILIARY CONTROL t g Z 2 TEE e RD eje 4 RELAY o E4 o o 9 5 2 1 8 E 8 8 5 2 y 1
28. AUXILIARY PUMP 1 A P1 EMERGENCY STOP BUTTON GRN WHT 1 HORN ORG RED 16A IH 4 RED RED WHT 184D SP SWITCH PANEL GIGA PLATFORM LEVEL CUTOUT CE ONLY WHT RED BLK 28D TOR AUXILIARY TOGGHS 8 1 PLATFORM LEVEL CUTOUT CE ONLY TS55 FUNCTION ENABLE TOGGLE SWITCH ORG 14B ORG BLK 15B I BLK BRN CB2 TS57 PLATFORM ROTATE TOGGLE SWITCH OPTION NUMBERS TS58 JIB BOOM UP DOWN TOGGLE SWITCH 1 PLATFORM LEVEL CUTOUT TS59 PLATFORM LEVEL TOGGLE SWITCH 2 FLASHING BEACON ORG 6 2 TS60 SECONDARY BOOM UP DOWN TOGGLE SWITCH 3 DESCENT ALARM TS61 PRIMARY BOOM UP DOWN TOGGLE SWITCH ORG BLK 3 15 oRG BLK CRI08 _ ORG BLK SP PLAT LEVEL DOWN i 14 ORG CR10A ORG SP PLAT LEVEL UP BRN 52D BLK CH TS62 TURNTABLE ROTATE TOGGLE SWITCH ORG 3 CR10 7 TS63 BOOM EXTEND RETRACT TOGGLE SWITCH L NUN UN PR EN Jp 0030 2000 UE WOES etti DA 1 iN Sb TS66 JIB BOOM ROTATE TOGGLE SWITCH OPTION PLATFORM LEVEL CUTOUT CE MODELS ONLY BRN CH ORG RED 42A U33 PLATFORM OVERLOAD MODULE CE MODELS enie A TEREX COMPANY Part No 106373 Z 30 20N Z 30 20N RJ 6 24 April 2007 Section 6 Schematics Lu MH Ground Control Panel Wiring Diagram from serial number 6290 to 8354 Section 6 Schematics April 2007 k k
29. L N TS13 TS11 TS10 ONC O 2 ONC O TS8 UN lt gt yl _ 1 BK RD RD GR Ts2 11234567 819110 1 6 4 O 0 D C B A 1 C9 5 2 C7B a 3 2 N m C47 JIB _ 5 4 C2P 81765432 1 1518 RESET DISCHARGE C3P _ SS SET SET TO 5 x 6 WH RD BL 7 GND BRN 9 7 a B oo CR19 LIFT LOCKOUT RELAY 1 50 89010 01 460 1 8678 460 A TEREX COMPANY Part No 106373 Z 30 20N Z 30 20N RJ 6 30 April 2007 Section 6 Schematics BCI Option Wiring Diagram from serial number 8355 to 9346 April 2007 Section 6 Schematics BCI Option Wiring Diagram after serial number 9346 N M L K J G E D 1 0 0 I C9 FS
30. 3 13 B 6 Check the Oil Level in the Drive Hubs and Mounting Bolt Torque 3 14 B 7 Testthe Ground Control Override 3 14 B 8 Test the Platform Self leveling 2 0 3 15 B 9 Test the SEEREN 3 15 B 10 Test the Drive Speed Stowed 3 16 B 11 Test the Drive Speed Raised or Extended Position 3 16 B 12 Test the Alarm Package if equipped 3 17 B 13 Testthe Turntable Rotation Stop 3 18 B 14 Check the Electrical Contactors 3 18 B 15 Perform Hydraulic Oil 3 19 Checklist C Procedures C 1 Grease the Platform Overload Mechanism if equipped 3 20 C 2 Test the Platform Overload System if equipped 3 20 Section 3 Section 4 Rev D Rev TABLE OF CONTENTS Scheduled Maintenance Procedures continued Checklist D Procedures D 1 Check the Primary Boom Wear 3 23 D 2 Checkthe Free wheel Configuration 2 3 24 D 3 Check the Turntable Rotation Bearing Bolts 3 25 3 26 D 5 Replace the Hydraulic Tank Return Filter Element
31. Fundamentals It is the responsibility of the dealer to perform the Pre delivery Preparation The Pre delivery Preparation is performed prior to each delivery The inspection is designed to discover if anything is apparently wrong with a machine before it is put into service A damaged or modified machine must never be used If damage or any variation from factory delivered condition is discovered the machine must be tagged and removed from service Repairs to the machine may only be made by a qualified service technician according to the manufacturer s specifications Scheduled maintenance inspections shall be performed by qualified service technicians according to the manufacturer s specifications and the requirements listed in the responsibilities manual Genie A TEREX COMPANY Genie UK The Maltings Wharf Road Grantham Lincolnshire NG31 6BH England 44 1476 584333 Genie Industries USA 18340 NE 76th Street PO Box 97030 Redmond WA 98073 9730 425 881 1800 Copyright 2002 by Genie Industries Genie is a registered trademark of Genie Industries RevB Instructions Use the operator s manual on your machine The Pre delivery Preparation consists of completing the Pre operation Inspection the Maintenance items and the Function Tests Use this form to record the results Place a check in the appropriate box after each part is completed Follow the instructions in the operator s manual I
32. OR RD z EG 2209 y h RD 4 RELAY 5 i69 91 5 B ORG gt a 5 een __ a 5 10880 xm 5 i m Xt 4 2 i 2 WH 5 C4P 7 CT9LPE GR WH C4B 7 nja OF gt i e k C19LPE GR WH i 8 2 6 C6MFV WH RD C3B 6 WH RD eje 2 PROPORTIONAL CONTROL VALVE 5 x i 1 E gt 9 8 amp coco R _ __ _________ 1 1 ij 5 eg SE E posee eee cbe ede eee 5 1 i i EG C2P 3 C47JRR OR BK 2 3 m 5 C2P 2 C46JRL OR i 1 1 i i Ln un bacio EEE E E 5 C46JRL YL i gt 1 1 i C2P 5 C47JRR RD PLATFORM ROTATE RIGHT 1 JIB BOOM UP i 1 Mesue condos be usan stel PLATFORM ROTATE LEFT JIB BOOM DOWN 1 FIND 1 1 5 i C2P 5 C43JU GR C2B 5i E SH 2 6 C44JD GRIBK 2 6 t C47 3 C44JD WH t 1 NA i C474 C43JU BK 0 i 8 Sak z 2 B C474 C18PRLOR ow 5 gt 42 ER 8 mo 5 LEFT a 3 z 8 9 9 o 5 5 C47 2 C17PRR BL Ap 3 9 i u E PLATFORM LEVEL 89 RIGHT 6 018088 0086 0486 CUT OUT OPTION E C4P 5 C17PRLGR 0485 5 1
33. Serial Number Information Genie Industries offers the following Service Manuals for these models Title Part No Z 30 20N Service Manual before serial number 5934 35532 Z 30 20N Service Manual after serial number 11499 139378 Copyright 1996 by Genie Industries 106373 Rev C June 2008 Second Edition Third Printing Genie and Z are registered trademarks of Genie Industries in the USA and many other countries 69 Printed on recycled paper Printed in U S A Part No 106373 2008 INTRODUCTION Serial Number Legend Genie A TEREX COMPANY Model Z 30 20N Serial number Z30N05 12345 Model year 2005 Manufacture date 04 12 05 Electrical schematic number ESXXXX Machine unladen weight Rated work load including occupants XXX Ib XXX kg Maximum number of platfrm occupants X Maximum allowable side force Ib XXX N Maximum allowable inclination of the chassis 0 deg 230 05 12345 Maximum wind speed XX mph XX m s Maximum platform height XX ft XX m Moder Maximum platform reach XX ft XX m Sequence Gradeability N A number Y f Country of manufacture USA ear o manufacture This machine complies with Serial label located under cover Serial number stamped on chassis Genie Industries 18340 NE 76th Street Redmond WA 98052
34. is 5 o d Sons v 2 e WH CAP 7 CISLPE Capi 1 e C3P 6 WH RD C3B 61 WH RD eve 4 PROPORTIONAL CONTROL VALVE lt 54 zo 1 5 25352 5 5 COLO E fo a 1 p 1 5 26 1 Sg Ea E C2P 8 C47JRR OR BK i C2P 2 C46JRL OR E C2P 5 YL C2P 5 C47JRR RD n PLATFORM ROTATE RIGHT JIB BOOM UP PLATFORM ROTATE LEFT JIB BOOM DOWN gt 29 ue C2P 5 C43JU GR C2B 5 m le C2P 6 C44JD GR BK C2B 6 E 5 C47 8 C44JD WH 4 4 C43JU BK 0 E 5 38 C474 C18PRL OR fa 2 ge 5 8 E 5 5 46 3 m M 5 Bu C472 C17PRR BL m 9 EE PLATFORM LEVEL 20 C4P 6 CIBPRRGR BK C4B 6 CUT OUT OPTION Z C4P 5 C17PRLGR C4B 5 5 0 E UP P PLATFORM LEVEL 5 UP COIL 5 e PLATFORMLEVEL 8 2 DOWN COIL a4 E o 0 mtem eic n 2 8 5 gt C4P 2 C14PLU OR C4B 2 5 015010 00 86 C4B 3 lt EXTEND at BK ni 4 BOOM EXTEND E 4 2 3 gt m BK WH 5 4 BOOM RETRACT 28 8 8 aa 5 E 5 2 5 7 7 C3B 7 8 C8PBRBK WH _ C3B 8 UP RD PRIMARY 4 gt BOOM UP 8 1
35. lt lt Be 08 g i 2 l lt ai C48 1 P182BAT RD RD 20 lt amp lt E gt g t N iO 48V POWER RELAY CR2 48V POWER RELAY CR1 FLASHING BEACON OPTION TILT SENSOR BASE CONTROL BOX GROUND AUXILIARY LIFT PUMP PR3 PRIMARY LIFT PUMP CONTACTOR RELAY PRIMARY LIFT PUMP PR2 HORN RELAY HORN LS1 EXT RET LS2 PRI UPIDWN LS4 SEC UP DWN CHASSIS GROUND BRAKE RELEASE RELAY CR5 PR1 DRIVE CONTACTOR 1 PRIMARY LIFT PUMP AUXILIARY LIFT PUMP NOTES Part No 106373 TEREX COMPANY Z 30 20N Z 30 20N RJ G 1 ALL LIMIT SWITCHES SHOWN WITH BOOM IN STOWED POSITION EXCEPT AS NOTED gt SWITCH SHOWN WITH BOOM ROTATED PAST EITHER NON STEER WHEEL 4 ALL SOLENOID AND RELAY COILS ARE 24VDC EXCEPT WHERE NOTED gt SWITCH SHOWN WITH BOOM EXTENDED 6 15 Section 6 Schematics Electrical Schematic from serial number 8355 to 9346 C29JSH RD WH C32JSL WH RD April 2007 C29JSH RD WH C32JSL WH RD REVA
36. 43 Remove the mounting fasteners from the counterweight attached to the lower leveling link 44 Attach a lifting strap from an overhead crane to the counterweight Remove the counterweight from the lower leveling link ADANGER Tip over hazard The counterweight is critical to machine stability If the counterweight is not installed during re assembly of the machine the machine will become unstable and tip over AWARNING Crushing hazard The counterweight could become unbalanced and fall when removed from the machine if not properly supported by the overhead crane A TEREX COMPANY Z 30 20N Z 30 20N RJ REV 45 Remove the mounting fasteners from the function manifold and slide the function manifold to the side This will allow access to the secondary boom lift cylinder barrel end pivot pin 46 Remove the mounting fasteners from the auxiliary power unit Do not disconnect the electrical cables or hydraulic hoses 47 Slide the auxiliary power unit to the side to access the other secondary boom lift cylinder barrel end pivot pin 48 Remove the retaining fasteners from the secondary boom lift cylinder barrel end pivot pins 49 Attach a lifting strap from an overhead crane to the lug on the rod end of the secondary boom lift cylinder 50 Tag disconnect and plug the hydraulic hoses from the secondary boom lift cylinder Cap the fittings on the cylinder AWARNING Bodily injury hazard Spraying hydr
37. 54 2 Nm 10 105 ft lbs 142 4 Nm 10 63 ft lbs 85 4 Nm 12 140 ft Ibs 190 Nm 12 90 ft lbs 122 Nm 16 210 ft Ibs 284 7 Nm 16 120 ft lbs 162 7 Nm 20 260 ft lbs 352 5 Nm 20 140 ft Ibs 190 Nm 24 315 ft lbs 427 1 Nm 24 165 ft lbs 223 7 Nm Part No 106373 TEREX COMPANY Z 30 20N Z 30 20N RJ Section 2 Specifications June 2008 SPECIFICATIONS REV E SAE FASTENER TORQUE CHART This chart is to be used as a guide only unless noted elsewhere in this manual A574 High Strength Grade 8 Black Oxide Bolts LUBED DRY LUBED DRY LUBED Wm mies Nm gt 110 140 130 120 T60 140 LUBED DRY LUBED ribs T8 14 20 23 33 26 37 14 7 15 8 LUBED I 20 i 9 0 Ej lt 24 27 1 44 7 50 1 67 8 81 3 108 4 122 162 176 217 244 18 25 27 44 49 70 33 9 28 4 36 6 32 5 59 6 51 5 66 4 58 3 16 14 94 7 82 7 108 4 92 1 149 126 162 142 203 176 250 189 251 244 325 271 515 233 569 474 827 591 37 50 di 64 867 one 12 5 108 4 110 149 120 8 o 15 10 16 130 60 180 280 379 310 220 12 350 430 583 450 60 610 878 60 908 759 480 650 640 867 580 92 90 1233 1044 12 530 718 70 962 750 1016 950 1342 1139 0 1749 1477 8 1952 1654 2
38. ORG BLK 3 PRIMARY BOOM BLK 7 EXTEND COIL BLK WHT 8 PRIMARY BOOM RETRACT COIL COR lk BLK 3 TEXTEND IRETRACT BLK WHT 3 PRIMARY BOOM UP COIL PRIMARY BOOM DOWN COIL RED 1 RED BLK 2 RED 3 PRIMARY BOOM RED BLK 3 SECONDARY BOOM UP COIL SECONDARY BOOM DOWN COIL BLU 10 BLU BLK 11 BLU 3 SECONDARY TS10 Boom DOWN BLU BLK 3 TURNTABLE ROTATE RIGHT COIL TURNTABLE ROTATE LEFT COIL WHT BLK 5 TURN ROT 1785 WHT 4 TS62 TB4 5 WHT BLK 3 5 8 5 WHT 3 TS12 BLU WHT 12 BLK 24V DC zz 9 zc E cis ORG RED 1 RED ORG RED WHT 1 WHT BLK 1 RED RED GND GND BRN 6 12 Z 30 20N Z 30 20N RJ G Part No 106373 April 2007 Section 6 Schematics Electrical Schematic before serial number 6290 Section 6 Schematics April 2007 Electrical Schematic from serial number 6290 to 8354 REV A B H J K L M N BL WH 1
39. Remove the upper cable track mounting fasteners from the platform end of the boom Remove the cable track mounting fasteners then remove the cable track from the boom and lay it flat on the ground Component damage hazard The cable track can be damaged if it is twisted Component damage hazard Cables and hoses can be damaged if they are kinked or pinched Raise the secondary boom until the primary boom lift cylinder rod end pivot pin is accessible above the mid pivot weldment Turn the machine off 9 Disconnect the battery packs from the machine 10 Remove all the hose and cable clamps from the underside of the primary boom and at the pivot end of the primary boom A TEREX COMPANY Z 30 20N Z 30 20N RJ Section 4 Repair Procedures June 2008 PRIMARY BOOM COMPONENTS 11 Attach a lifting strap of ample capacity from an overhead 5 ton 5000 kg crane to the primary boom for support 12 Locate the cables from the primary boom cable track to the platform control box Number each cable and its entry location at the platform control box 13 Open the platform conrol box 14 Tag and disconnect each wire from the cables in the platform control box 15 Pull all the cables out of the platform control box 16 Remove the front counterweight cover 17 Remove the extension boom drive limit switch from the side of the primary boom at the pivot end Do not disconnect the wiring 18 Tag disconnect and p
40. enie A TEREX COMPANY Serial Number Range Z 30 20N 2 30 20 RJ 3 June 2008 Introduction June 2008 Introduction Important Read understand and obey the safety rules and operating instructions in the Genie Z 30 20N Operator s Manualbefore attempting any maintenance or repair procedure This manual provides detailed scheduled maintenance information for the machine owner and user It also provides troubleshooting fault codes and repair procedures for qualified service professionals Basic mechanical hydraulic and electrical skills are required to perform most procedures However several procedures require specialized skills tools lifting equipment and a suitable workshop In these instances we strongly recommend that maintenance and repair be performed at an authorized Genie dealer service center Technical Publications Genie Industries has endeavored to deliver the highest degree of accuracy possible However continuous improvement of our products is a Genie policy Therefore product specifications are subject to change without notice Readers are encouraged to notify Genie of errors and send in suggestions for improvement All communications will be carefully considered for future printings of this and all other manuals Contact Us http Awww genieindustries com e mail techsup genieind com A TEREX CON li Z 30 20N Z 30 20N RJ
41. mo 25 5 lt 3 m o82 9 9 we p 50 7 5 3 5 295 5 E 8 5 e EJ 5 BRN i lt 8 1 BLK 24V DC EE NOTES 1 ALL LIMIT SWITCHES WITH BOOM IN STOWED POSITION EXCEPT AS NOTED lt 5 CE amp PLATFORM LOAD SENSE OPTION lt SWITCH SHOWN WITH BOOM EXTENDED lt 6 ADD D40 ONLY IF UNIT HAS BOTH 14 amp 148 lt REDUNDANT COIL SUPPRESION DIODE FOR 1 IS INSIDE CONTROLLER BETWEEN 1 9 AND 1 17 lt 7 ANSI CSA ONLY Genie TEREX COMPANY 6 13 Z 30 20N Z 30 20N RJ Part No 106373 Section 6 Schematics Electrical Schematic JP1 REMOVE FOR CE VERSION from serial number 6290 to 8354 LVI BCI OPTION April 2007 REV B WHT N
42. s BD BK PRIMARY 9 i 29 DOWN a BOOM DOWN 2 gt 1 2 1 lt i 8 C3P 1 C1PBU RD 0884 _ T z M o 2 2 C3B 2 1 e 5 uP 5 BL SECONDARY 2 8 BOOM UP gt BUBK SECONDARY 5 99 BOOM DOWN 5 8 5 ee o DESCENT ALARM 5 10 010880 BL 03840 1 OPTION g IN 5 AAAA NE as umi 11 CHSBDBLBK C3B M E 1 rA i RIGHT WHIBK TURNTABLE 5 a ROTATE RIGHT 5 i lt WH TURNTABLE 8 55 a ROTATE LEFT 5 a 1 5 P Q RIGHT C3P 5 CSTRR WH BK 088 5 5 EI 2 C3P 4 WH C3B4 23 H 5 z ELE i 8 58 8 AS 25 4 zz BE 26 6 gt T d 1 5 8 5 9 5 6 16 A TEREX COMPANY Z 30 20N Z 30 20N RJ G Part No 106373 gt SWITCH SHOWN WITH BOOM ROTATED PAST EITHER NON STEER WHEEL April 2007 Section 6 Schematics M S Electrical Schematic from serial number 8355 to 9346 April 2007 Section 6 Schematics Electrical Schematic CE Models from serial number 8355 to 9346 REVA C29JSH RD WH
43. 106373 TEREX COMPANY Z 30 20N Z 30 20N RJ G 1 ALL LIMIT SWITCHES SHOWN WITH BOOM IN STOWED POSITION EXCEPT AS NOTED gt lt SWITCH SHOWN WITH BOOM EXTENDED 4 ALL SOLENOID AND RELAY COILS ARE 24VDC EXCEPT WHERE NOTED gt SWITCH SHOWN WITH BOOM ROTATED PAST EITHER NON STEER WHEEL 6 19 Section 6 Schematics Electrical Schematic after serial number 9346 C29JSH RD WH C32JSL WH RD April 2007 C29JSH RD WH C32JSLWH RD REVA gt SETUP ENABLE USE SET THE BATTERY INDICATOR PROFILES gt SWITCH SHOWN WITH BOOM EXTENDED ug 2 S 22 5 BRN C7P 3 BATGND BRN C7B 3 BATGND BRN 5 1 1 019081 4 1 C13DEL BL RD 4 WH 5 S BRN 5 2 7 8 4 12 C12FTS 12 m C12FTS BUWH 3 865 7 RD 5 fa 4 C16DE OR RD 4 01608 OR RD s OR RD 5 RD WH 4 TRAVEL
44. 2 2 9 a _ E gt 5 5 5 3 2 5 2 2 5 6 Fara lt 8 T 5 5 6 5 tr T 8 e E di 353 5 gt gt 5 z 9 2 d 5 3 o E 5 Q 0 lt a a a 5 2 m e O BRN JIB BRN 2 5 C ee 01320 BL WH C1P 12 013301 C2P 1 C28TTA RD BK 2 P23BAT WH C7P 2 12 5 BL WH C3P 12 C16DRE OR RD C4P 4 5 WH BK C3P 5 C4TRL WH C3P 4 C11SBD BL BK C3P 11 C10SBU BL C3P 10 C6MFV WH RD C3P 6 TS15 TS12 BP1 RD BK BK RD RD GRN C18PRR GR BK C4P 6 C17PRL GR 5 TS11 04300 GR C2P 5 Sod c Pal C ec gt C19LPE GR WH 7 8 0440 GR BK C2P 6 C2PBD RD BK C3P 2 C1PBU RD C3P 1 C14PLU OR C4P 2 beeen ae sae eae eae C47JRR OR BK C2P 3 JIB ROTATE O
45. 2 LY 22 454 Models without rotating jib boom 606 AY ee Models with rotating jib boom A TEREX COMPANY Part No 106373 Z 30 20N Z 30 20N RJ 4 39 Section 4 Repair Procedures June 2008 MANIFOLDS 7 4 Valve Coils How to Test a Coil A properly functioning coil provides an electromotive force which operates the solenoid valve Critical to normal operation is continuity within the coil that provides this force field AWARNING Electrocution burn hazard Contact with electrically charged circuits could result in death or serious injury Remove all rings watches and other jewelry 1 Tag and disconnect the wiring from the coil to be tested 2 Test the coil resistance Coils with 2 terminals Connect the leads from the ohmmeter to the valve coil terminals Coils with 1 terminal Connect the positive lead from the ohmmeter to the valve coil terminal then connect the negative lead from the ohmmeter to the internal ring of the valve coil Result The resistance should be within specification plus or minus 30 W Result If the resistance is not within specification plus or minus 30 replace the coil A TEREX CON Z 30 20N Z 30 20N RJ MEANY REVD Valve Coil Resistance Specification Note The following coil resistance specifications are at an ambient temperature of 68 F 20 C As valve coil resistance is sensitive t
46. 8 BK 8 24 S Ls zE 5 RD 5 P22LS BK C10 1 7 e 8 P22BAT 9 J2 BK C10 2 WH 7 5 8 52 1 8 C11 4 WH 6 5 1 pa 5 C52 2 WH 8 C11 3 BK 6 5 77 vys 5 5 RR 22 CONTROLLER STATUS 5 m LED L3 oc 5 E LORD C49 7 CI78CSL 5 g 1 4 4 4 CR5 2 SRS 29 X PRI C182PWR GR 7 il S S jg ES 0499 OFF LIMT SPD INP 4 e 55 uj 5 EH 0498 BLWH INTERLOCK i J dle i CiP 8 4 C29JSH RD WH C1B 3 C49 3 RD WH 46 52 y i amp 56 5 d 1 6 C32JSLWH RD C1B 6 C49 6 WH RD POT LOW 44 lt o m 1 5 C31REV WH BK 1 5 49 5 WH BK REVERSE 9 1 4 C30FWD WH C1B 4 C49 4 WH FORWARD E i DIODE RETURN 9 g R42BAT OR RD 48V INPUT LE 5 8 EL 5 8 2 5 zs 5 8 8 5 BK 4 5 lt 8 2 t 5 ene oe C48 1 P182BAT RD RD 20 lt amp 2 g gt gt Nem a a c X 5 Ne pu 55 N N 48V POWER RELAY CR2 48V POWER RELAY CR1 FLASHING BEACON OPTION TILT SENSOR BASE CONTROL BOX GROUND AUXILIARY LIFT PUMP PR3 PRIMARY LIFT PUMP CONTACTOR RELAY PRIMARY LIFT PUMP PR2 HORN RELAY HORN LS1 EXT RE
47. ______7 2 T C7B omo ol O 157 O 2 O 3 wh MB TS13 TS11 TS10 3 ONC O 2 2 a TS8 8 i ie 5 WH RD eile cap gt NL BP1 BRN BK 6 BK RD WH RD RD GR BL OJO 6 11234567 8 910 i Hd e 6 54 0 8 gt SETUP ENABLE WIRE 5 ENABLE WHEN IS TEMPORARILY CONNECTED 24VDC 3 RELAY 8 Genie TEREX COMPANY Part No 106373 Z 30 20N Z 30 20N RJ 6 31 April 2007 Section 6 Schematics BCI Option Wiring Diagram after serial number 9346 January 2008 Section 6 Schematics Hydraulic Schematic REV N M L K J H G F E D 8 JIB BOOM JIB BOOM ROTATE OPTION PLATFORM ROTATE Bi _ 2 ge de ESL Us ow Hg oes d ROTATE MANIFOLD 3300 psi 3000 psi 93008 ROTATE MANIFOLD JIB BOOM pia PLATFORM 3 JR1 JR2 J1 J2 PR1 PR2 FTW ap H 5 X X PLATFORM LEVELING 20 0 3 gpm
48. battery cables or poor connections Operate machine within specified temperature limits OR check for debris around motor controller preventing proper cooling of the controller OR check for mechanical restrictions causing excessive load on the machine TEREX COMPANY Z 30 20N Z 30 20N RJ Section 5 Fault Codes June 2008 This page intentionally left blank TEREX COMPANY 5 6 Z 30 20N Z 30 20N RJ Part No 106373 June 2008 Section 6 Schematics Observe and Obey Troubleshooting and repair procedures shall 6 completed by a person trained and qualified on the repair of this machine Immediately tag and remove from service damaged or malfunctioning machine Repair any machine damage or malfunction before operating the machine Before Troubleshooting Read understand and obey the safety rules and operating instructions printed in the Genie Z 30 20N Operator s Manualon your machine Schematics About This Section There are two groups of schematics in this section Electrical Schematics AWARNING Electrocution burn hazard Contact with electrically charged circuits could result in death or serious injury Remove all rings watches and other jewelry Hydraulic Schematics AWARNING Bodily injury hazard Spraying hydraulic oil can penetrate and burn skin Loosen hydraulic connections very slowly to allow the oil pressure to dissipate gradually D
49. o x x B 2 a PLATFORM LEVEL 5 L UP COIL gt PLATFORM LEVEL 55 DOWN DOWN COIL Eg QUT 4 8 uU i gt I up C4P 2 C14PLU OR C4B2 5 1 a C4P 3 C15PLDORBK 0488 5 1 a BOOM EXTEND gt n m 25 s BOOMRETRACT 8 1 RETRACT 8 5 4 3 i 1 1 7 0887 1 E 1 C3P 8 7 C3B 8 UP s B PRIMARY gt i BOOM UP 8 PRIMARY 9 O DOWN a BOOM DOWN 5 5 1 d E 5 8 5 8 C3P 1 C1PBU RD 084 T 5 2 C2PBD RD BK 0882 _ o 2 5 E UP zE SECONDARY 2 8 i 5 0 m SECONDARY 5 Q DOWN BOOM DOWN 8 lt 0 5 1 gt 9 DESCENT ALARM 8 C3P 10 CIOSBUBL 10 OPTION ea n C3P H CHSBDBUBK 7 C3B 11 E z RIGHT af WHIBK Pil TURNTABLE 5 lt ROTATE RIGHT 5 i ER WH in 4 TURNTABLE 4 55 EFT a ROTATE LEFT 5 u m 1 Fa 5 RIGHT C3P 5 CSTRR WH BK C3B5 _ 5 E 4 WH C3B4 a lt 1 rc Es 28 TEE om 55 g 58 55 5 2 e i
50. watches and other jewelry 1 Remove the drive chassis cover from the non steer end of the machine and locate the electrical contactors mounted on the electrical component mounting panel 2 Visually inspect the contact points of each contactor for the following items Excessive burns Excessive pitting Note Replace the contactors if any damage is found MEANY Part No 106373 June 2008 Section 3 Scheduled Maintenance Procedures REV E B 15 Perform Hydraulic Oil Analysis Note Genie specifications require that this procedure be performed every 250 hours or quarterly whichever comes first Replacement or testing of the hydraulic oil is essential for good machine performance and service life Dirty oil and suction strainers may cause the machine to perform poorly and continued use may cause component damage Extremely dirty conditions may require oil changes to be performed more often Note Before replacing the hydraulic oil the oil may be tested by an oil distributor for specific levels of contamination to verify that changing the oil is necessary If the hydraulic oil is not replaced at the two year inspection test the oil quarterly Replace the oil when it fails the test See E 1 Test or Replace the Hydraulic Oil PartNo 106373 Z 30 20N Z 30 20N RJ Genie CHECKLIST PROCEDURES Section 3 Scheduled Maintenance Procedures June 2008 Checklist C Procedures C 1 G
51. 2 Remove the plug located at 90 degrees and check the oil level Result The oil level should be even with the bottom of the side plug hole If necessary remove the top plug and add oil until the oil level is even with the bottom of the side plug hole Refer to Section 2 Specifications 4 Install the plugs into the drive hub 5 Checkthe torque of the drive hub bolts Refer to Section 2 Specifications 6 Repeat this procedure for each drive hub A TEREX CON Z 30 20N Z 30 20N RJ Note Genie specifications require that this procedure be performed every 250 hours or quarterly whichever comes first A properly functioning ground control override is essential to safe machine operation The ground control override function is intended to allow ground personnel to operate the machine from the ground controls whether the red Emergency Stop button on the platform controls is in the on or off position This function is particularly useful if the operator at the platform controls cannot return the boom to the stowed position 1 Push in the red Emergency Stop button at the platform controls to the off position 2 Turn the key switch to ground controls and pull out the red Emergency Stop button to the on position 3 Operate each boom function through a partial cycle at the ground controls Result All boom functions should operate MANY Part No 106373 June 2008 Section 3 Scheduled Maintenance
52. 26 to 32 seconds Jib boom down 23 to 29 seconds Jib boom rotate 200 before serial number 8333 12 to 18 seconds Jib boom rotate 180 after serial number 8332 12 to 18 seconds Primary boom up 14 to 22 seconds Primary boom down 12 to 20 seconds Primary boom extend models with rotating jib boom models without rotating jib boom 14 to 24 seconds 9 to 15 seconds Primary boom retract 12 to 18 seconds Secondary boom up 11 to 18 seconds Secondary boom down 7 to 15 seconds Turntable rotate 355 62 to 68 seconds Platform rotate 160 5 to 11 seconds Platform level up 14 to 19 seconds Platform level down 13 to 18 seconds Section 2 Specifications June 2008 SPECIFICATIONS REV E Hydraulic Oil Specifications Hydraulic Oil Specifications Hydraulic oil type Chevron Rykon MV equivalent Viscosity grade Multi viscosity Viscosity index 200 Cleanliness level minimum 15 13 Water content maximum 200 ppm Chevron Rykon MV oil is fully compatible and mixable with Shell Donax TG Dexron oils Genie specifications require hydraulic oils which are designed to give maximum protection to hydraulic systems have the ability to perform over a wide temperature range and the viscosity index should exceed 140 They should provide excellent antiwear oxidation corrosion inhibition seal conditioning and foam and aerati
53. 3 26 0 6 Inspect for Turntable Bearing Wear 3 27 Checklist E Procedures E 1 Testor Replace the Hydraulic 3 29 E 2 Grease the Steer Axle Wheel Bearings 3 31 Repair Procedures 4 1 Platform Controls 1 5 Controllers 4 2 Platform Components 2 1 Platform Leveling Slave 4 4 2 2 Plattorm 4 5 2 3 Platform Overload 4 7 Jib Boom Components 3 1 Jib BOOM wists ne EEE ee aed ee 4 9 32 Jib Boom Bell Crank models without rotating jib boom 4 10 3 3 Jib Boom Rotator models with rotating 4 11 3 4 Jib Boom Lift Cylinder 0 7 4 13 TABLE OF CONTENTS Section 4 Section 5 Rev B Rev Repair Procedures continued Primary Boom Components 4 1 Cable Track 4 14 42 Primary BOOIm 4 14 4 3 Primary Boom Lift 4 18 44 Extension Cylinder 4 19 4 5 Platform Leveling Master 4 20 Secondary Boom Components 5 1 Secondary BOOM 4 23 5 2 Secondary Boom Lift Cylinder 2 2 4 28 Hydraulic Pump 6 1 Auxiliary 4 30 Manifolds 7 1 Function Manifold Components
54. 4 mm The bearing is good W Result The measurement is more than 0 055 inch 1 4 mm The bearing is worn and needs to be replaced 8 Fully retract the primary boom Raise the primary and secondary booms to full height Visually inspect the the dial indicator to be sure the needle returns to the position 9 Remove the dial indicator and rotate the turntable 90 10 Repeat steps 4 through 9 until the rotation bearing has been checked in at least four equally spaced areas 90 apart 11 Lower the primary and secondary booms to the stowed position and turn the machine off 12 Remove the dial indicator from the machine Part No 106373 June 2008 Section 3 Scheduled Maintenance Procedures Checklist E Procedures REV D E 1 Test or Replace the Hydraulic Oil Note Genie specifications require that this procedure be performed every 2000 hours or every two years whichever comes first Perform this procedure more often if dusty conditions exist Replacement or testing of the hydraulic oil is essential for good machine performance and service life Dirty oil and suction strainers may cause the machine to perform poorly and continued use may cause component damage Extremely dirty conditions may require that the oil be changed more often Note 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
55. 45 to 0 5 controller If the motor controller is found to be faulty note which test failed and which fault code F2 B 0 45 to 0 5 if any was present at the time of failure B 1 0 45 to 0 5 1 Turn the key switch to the off position and B F2 0 45 to 0 5 disconnect the battery packs from the machine 2 Tagand disconnect all power cables from the R Bias motor controller Cverse Bias Electrocution burn hazard Contact Test Desired result AWARNING with electrically charged circuits could result in death or serious Positive Lead Negative Lead injury Remove all rings watches Rises to OL V and other jewelry M B Rises to OL V 3 Press the release tab on the motor controller harness connector and remove the motor 1 Rises to OL V sel el harness connector from the motor Bs F2 Rises to OLV 4 Setan ohmmeter to diode test mode il B OPV F2 B Rises to OL V Genie A TEREX COMPANY Z 30 20N Z 30 20N RJ Part No 106373 June 2008 Section 5 Fault Codes Observe and Obey Troubleshooting and repair procedures shall be completed by a person trained and qualified on the repair of this machine Immediately tag and remove from service a damaged or malfunctioning machine Repair any machine damage or malfunction before operating the machine Unless otherwise specified perform each repair procedure with the machine in the following configuration Machine parked on a firm le
56. 5 E z 8 3 8 8 o Ei lt 508 o E m gt a acu cara T ue e lt lt Xe es Bo 8 eae 1 3 lt gt 8 gg e 48 1 P182BAT RD RD 20 amp amp lt 12 5 10 i 1G N 1O 48 POWER RELAY CR2 48V POWER RELAY CR1 FLASHING BEACON OPTION TILT SENSOR BASE CONTROL BOX GROUND AUXILIARY LIFT PUMP PR3 PRIMARY LIFT PUMP CONTACTOR RELAY PRIMARY PUMP PR2 HORN RELAY HORN LS1 EXT RET LS2 PRI UPIDWN LS4 SEC UP DWN CHASSIS GROUND BRAKE RELEASE RELAY 5 DRIVE CONTACTOR gt CE 8 PLATFORM LOAD SENSE OPT PRIMARY LIFT PUMP AUXILIARY LIFT PUMP NOTES Part No 106373 e ADD D40 ONLY IF UNIT HAS L4 AND L48 TEREX COMPANY Z 30 20N Z 30 20N RJ G 1 ALL LIMIT SWITCHES SHOWN WITH BOOM IN STOWED POSITION EXCEPT AS NOTED gt SWITCH SHOWN WITH BOOM EXTENDED 4 ALL SOLENOID AND RELAY COILS ARE 24 00 EXCEPT WHERE NOTED gt SWITCH SHOWN WITH BOOM ROTATED PAST EITHER NON STEER WHEEL 6 17 Section 6 Schematics Electrical Schematic CE Models from serial number 8355 to 9346 C29JSH RD WH 03291 WH RD April 2007 C29JSH RD WH 03291 WH RD REVA
57. 9V DC or more when measured across the terminals Resistor 10Q Genie part number 27287 Part No 106373 A TEREX COMI Z 30 20N Z 30 20N RJ MANIFOLDS b 100 9V RESISTOR BATTERY isa quy multimeter 9V DC battery 100 resistor coil ao om Note Dotted lines in illustration indicate a reversed connection as specified in step 6 3 Seta multimeter to read DC current Note The multimeter when set to read DC current should be capable of reading up to 800 mA 4 Connect the negative lead to the other terminal on the coil Note If testing a single terminal coil connect the negative lead to the internal metallic ring at either end of the coil 5 Momentarily connect the positive lead from the multimeter to the positive terminal on the 9V DC battery Note and record the amperage reading 6 Atthe battery or coil terminals reverse the connections Note and record the current reading Result Both current readings are greater than 0 mA and are different by a minimum of 20 The coil is good W Result If one or both of the current readings are 0 mA or if the two current readings do not differ by a minimum of 20 the coil and or its internal diode are faulty and the coil should be replaced Section 4 Repair Procedures June 2008 Turntable Rotation Components 8 1 Turntable Rotation Hydrau
58. A CAUTION situation which if not avoided may cause minor or moderate injury Indicates a potentially hazardous situation which if not avoided may result in property damage Indicates that a specific result is expected after performing a series of steps W Indicates that an incorrect result has occurred after performing a series of steps MANY Section 4 Repair Procedures June 2008 Platform Controls 1 1 Controllers The drive joystick is connected to the drive motor controller located under the drive chassis cover at the non steer end of the machine Maintaining the boom function speed controller at the proper settings is essential to safe machine operation The boom function speed controller should operate smoothly and provide proportional speed control through its entire range of motion For further information or assistance contact the Genie Industries Service Department boom function speed controller drive and brake printed circuit board drive joystick A TEREX CON Z 30 20N Z 30 20N RJ MEANY REV B Boom Function Speed Controller Adjustments AWARNING Electrocution burn hazard Contact with electrically charged circuits could result in death or serious injury Remove all rings watches andother jewelry Note Do not adjust the boom function speed controller unless the static battery supply voltage is above 2
59. ALARM lt 552 4 6 R48BRK RD WH lt BRAKE RELEASE 87 5 g COIL a TI wo ese Y 3 E 220 1 4 PSi 4 BRAKE RELEASE 4 PRESSURE SWITCH 8 ius CIP 0 C36SCC BL C1B 10 BL 4 STEER LEFT 1 eje 8 1 01 11 C37SCW 81 86 C1B 11 BL BK n 4 STEER RIGHT 3 e k gt Q a 5 Toc 5 2 WH BK 8 5 amp al 4 HOUR METER 1 1 C27AUX RD 1 1 RD AUX gt I B H 5 gt 2 9 555 8 5 m s lt 5 um 8 5 5 Ae Num 1 is g 522 AUXILIARY CONTROL 5 SEP py 4 RELAY 8 OR RD 8 8 5 2 2 ge eg ain 8 WH e T x 7 CISLPE GR WH C4B 2 8 C19LPE GR WH 2 a d 5 6 WH RD C3B 6 E WH RD 4 PROPORTIONAL a CONTROL VALVE oc 255 1 m 5 E 5 z 5855 9 5 COLO 1 i 1 5a aS 1 1 EC
60. BOOM DOWN E 8 2 2 5 AP gt OR 4 DESCENT ALARM 8 10 C10SBU BL C3B 10 yg OPTION 8 11 C11SBD BUBK T 2 5 RIGHT _ WH BK TURNTABLE 5 a 4 E ROTATE RIGHT 5 ER m WH n TURNTABLE M 55 i ROTATE LEFT 5 4 m 1 Fa RIGHT 5 5 WH BK 0885 5 1 e 4 CATRL WH C3B 4 1 p 9 s z o z Z 3 8 Sa a 25 z E EC imo 28 g 5 NIE 5 5 S RINS aj E 5 9 1 6 20 a Z 30 20N Z 30 20N RJ G Part No 106373 gt SWITCH SHOWN WITH BOOM ROTATED PAST EITHER NON STEER WHEEL April 2007 Section 6 Schematics a JOOY ________L___________ ____ _____ __ __ Electrical Schematic after serial number 9346 REVA C29JSH RD WH April 2007 Electrical Schematic CE Models after serial number 9346 Section 6 Schematics
61. CI2FTS BLWH C3B 12 CI2FTS 3 Bks 7 RD 5 cet e lt C4P 4 Ci6DEOR RD 77 C4B 4 C16DE OR RD E It OR RD B 3 y RD WH 4 520 2 20 5 RD WH 4 lt lt g m i i 5 1 EUT 3 5 5 05 3 58 1 4 6838 51 i Ca6SCCBL 0 BL 4 Soo 8 C1P 11 75 C1B 11 BLBK ie gt gt lt t n i 1 4 amp z x 2 5 c qb 5 1 lt Z a gt i 5 Serw 214 5 g 55 o WHBK 8558 B 8 e t 4 i a C27AUX RD C1B 1 RD AUX 4 5 I 55 e 220 1 6 5 lt al E 8 a iw 4 5 8 5 1 285 558 5 4 222 gg PD y RD 4 S OR RD 8 5 V Be 5 1 EIE g i e I m wH ale 5 2 m mmm 7 C19LPE GR WH 4 7 gt 5 C19LPE GR WH 8 8 5 C3P 6 WH RD C3B 6 WH RD 5 4 a cA 1 o e 5 6 1 1 E WH 8 8 2 258 1 amp roro quse a ai E RIGHT E 1 lt EFT 5
62. Crushing hazard The cylinder could fall if not properly supported when it is pulled out of the extension tube Note To make installation of the extension cylinder easier be sure that the cylinder rod is extended 3 to 4 feet 1 m Note During removal the overhead crane strap will need to be carefully adjusted for proper balancing A TEREX CON Z 30 20N Z 30 20N RJ MPANY REV 4 5 Platform Leveling Master Cylinder The platform leveling master cylinder acts as a pump for the slave cylinder It is part of the closed loop hydraulic circuit that keeps the platform level through the entire range of primary boom motion The platform leveling master cylinder is located inside the upper mid pivot at the pivot end of the primary boom How to Remove the Platform Leveling Master Cylinder AWARNING 9 injury hazard This procedure requires specific repair skills lifting equipment and a suitable workshop Attempting this procedure without these skills and tools could result in death or serious injury and significant component damage Dealer service is strongly recommended Note When removing a hose assembly or fitting the O ring on the fitting and or hose end must be replaced and then torqued to specification during installation Refer to Section 2 Hydraulic Hose and Fitting Torque Specifications Note Before cylinder removal is considered bleed the cylinder to be sure that there is no air in the clos
63. Diagram before serial number 6290 A B G H 1 BRN CB2 BLK OPTION 2 52 BRN CH BRN CR4 GROUND ORG RED CH RED 27D amwen M BRN 5 BRN 2 52 BRN MH BRN SP GROUND E WHT 6 WHT 8 50 LS2 LS4 JUNCTION 4 H 7 BLK 6 49 LS1 LS2 JUNCTION REDWHT TBSD 1 WHT BLK SP RED WHT CR5 48 RED WHT MH_ RED WHT SP BRAKE RELEASE T TE TZ BLKRED HORN ORG BLK 1 47 ORG BLK SP JIB BOOM ROTATE RIGHT ORG RED 42D RED CH BLK RED 9D ORG 1 46 ORG SP JIB BOOM ROTATE LEFT GRN BLK 1 44 GRN BLK SP JIB BOOM DOWN RED WHT 48C ORG MH ORG BLK MH 2 GRN 1 43 GRN SP JIB BOOM UP 5 L fa TB ORG RED CR1 ORG RED 1 42 ORG RED CH ORG RED L3 SWITCHED 48V DC A SUL p BLK 8 40 ORG CH OFF LIMIT SPEED ORGIRED 18A h BLU BLK 19D 1 37 BLU BLK MH STEER RIGHT BLU 19D BLU 1 36 BLU MH STEER LEFT WHT RED 1 32 WHT RED CH JOYSTIC
64. Ground Control Panel Wiring Diagram after serial number 8354 Section 6 Schematics April 2007 Ground Control Panel Wiring Diagram after serial number 8354 A B D E F TILT SENSOR RD A RD WH 134D 2 WH 6 RD BK C1B 2 pk sP BR CB2 L3 T f BK C49 7 Q BR C48 3 OR RD 42A HM P1 O 0 E 4 Onc O TS51 KS1 olo O NO 5 6 LABEL DESCRIPTION P1 EMERGENCY STOP BUTTON KS1 KEY SWITCH TS51 AUXILIARY SWITCH TS55 FUNCTION ENABLE SWITCH TS66 TS63 TS59 TS57 PLATFORM ROTATE SWITCH 6 6 6 TS58 JIB UP DOWN SWITCH TS59 PLATFORM LEVEL SWITCH TS60 SECONDARY BOOM UP DOWN SWITCH eo TS61 PRIMARY BOOM UP DOWN SWITCH TS58 1 TS62 TURNTABLE ROTATE SWITCH 7887 OR 0 TS63 BOOM EXTEND RETRACT SWITCH 6 JIB ROTATE SWITCH OPTION CBI CIRCUIT BREAKER CONTROLS 10A 7 ch CIRCUIT BRKR CONTROLS RETURN 104 x Ji BRAKE RELEASE JACK 1560 TA T Sem HM HOURMETER CHASSIS HARNESS MH MANIFOLD HARNESS 5 SWITCH PANEL CONTROL RELAY A2 TRAVEL ALARM 8 DESCENT ALARM OPTION DESCENTAVARM WIRING OPTION A6 PLATFORM OVERLOAD CE OPTION Q Q L3 CONTROLLER STATUS LED P L45 PLATFORM OV
65. June 2008 EE REV B How to Remove the Primary Boom AWARNING P dily injury hazard This procedure requires specific repair skills lifting equipment and a suitable workshop Attempting this procedure without these skills and tools could result in death or serious injury and significant component damage Dealer service is strongly recommended Note Perform this procedure with the boom in the stowed position Note When removing a hose assembly or fitting the O ring on the fitting and or hose end must be replaced and then torqued to specification during installation Refer to Section 2 Hydraulic Hose and Fitting Torque Specifications 1 2 Remove the platform Remove the platform rotator See 2 3 How to Remove the Platform Rotator Remove the jib boom See 3 1 How to Remove the Jib Boom Models without rotating jib boom Remove the jib boom bellcrank See 3 2 How to Remove the Jib Boom Bellcrank Models with rotating jib boom Remove the jib boom rotator See 3 3 How to Remove the Jib Boom Rotator Part No 106373 Section 4 Repair Procedures PRIMARY BOOM COMPONENTS 5 Tag disconnect and cap the slave cylinder hydraulic hoses at the union Plug the hoses from the slave cylinder AWARNING Bodily injury hazard Spraying hydraulic oil can penetrate and burn skin Loosen hydraulic connections very slowly to allow the oil pressure to dissipate gradually Do not allow oil to squirt or spray
66. RED WHT CRi RED WHT 3 3 48V DC RELAY COIL POWER RED BLK 3 2 RED BLK MH RED BLK SP PRIMARY BOOM DOWN DESCRIPTION P1 EMERGENCY STOP BUTTON RED 3 1 RED MH RED SP PRIMARY BOOM UP KS1 KEY SWITCH TS51 AUXILIARY TOGGLE SWITCH D C B A TS55 FUNCTION ENABLE TOGGLE SWITCH TS57 PLATFORM ROTATE TOGGLE SWITCH TS58 JIB BOOM UP DOWN TOGGLE SWITCH 7 TS59 PLATFORM LEVEL TOGGLE SWITCH TS60 SECONDARY BOOM UP DOWN TOGGLE SWITCH TS61 PRIMARY BOOM UP DOWN TOGGLE SWITCH SEE OPTIONAL WIRING TS62 TURNTABLE ROTATE TOGGLE SWITCH TS63 BOOM EXTEND RETRACT TOGGLE SWITCH JIB BOOM ROTATE OPTION TS66 JIB BOOM ROTATE TOGGLE SWITCH OPTION 1 CIRCUIT BREAKER CONTROLS 10 082 CIRCUIT BREAKER CONTROLS RETURN 10 1 BRAKE RELEASE JACK 8 CONTROL RELAY 1 0 SPARE WIRE LIST OPTION NUMBERS HM HOURMETER SECONDARY 48V DC POWER BLK 1 1 PLATFORM LEVEL CUTOUT CH CHASSIS HARNESS CR2 PRIMARY 48V DC POWER BLK WHT 1 2 FLASHING BEACON MH MANIFOLD HARNESS AUXILIARY PUMP BLK RED 1 3 DESCENT ALARM SP SWITCH PANEL CR4 HORN BLU WHT 1 CR CONTROL RELAY CR5 BRAKE RELEASE BLU RED 1 A2 BRAKE RELEASE TRAVEL ALARM CR10A PLATFORM LEVEL CUTOUT CE ONLY GRN WHT 1 DESCENT ALARM OPTION CR10B PLATFORM LEVEL CUTOUT CE ONLY L3 CONTROLLER STATUS LED Z 30 20N Z 30 20N RJ A TEREX COMPANY Part No 106373 J K L M ibo RED WHT BRN A2 Q SWITCH PANEL Q WHT BLK 19D 48D BRN 52A HM 1
67. Section 3 Scheduled Maintenance Procedures REV E 12 Check the ambient air temperature and adjust the specific gravity reading for each cell as follows Add 0 004 to the reading of each cell for every 10 5 5 C above 80 F 26 7 C e Subtract 0 004 from the reading of each cell for every 10 5 5 C below 80 26 7 C O Result All battery cells display a specific gravity of 1 277 or greater The battery is fully charged Proceed to step 13 Result The difference in specific gravity readings between cells is greater than 0 1 OR the specific gravity of one or more cells is less than 1 217 Replace the battery 13 Check the battery acid level If needed replenish with distilled water to 1 8 inch 3 mm below the bottom of the battery fill tube Do not overfill 14 Install the vent caps and neutralize any electrolyte that may have spilled PartNo 106373 Z 30 20N Z 30 20N RJ CHECKLIST B PROCEDURES B 2 Inspect the Electrical Wiring Note Genie specifications require that this procedure be performed every 250 hours or quarterly whichever comes first 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 AWARNING Electrocution burn hazard Contact with hot or live circuits could result
68. boom compression arm 58 Remove the pin retaining fastener from the lower secondary boom compression arm to turntable riser pivot pin 59 Use a slide hammer and remove the pin Remove the compression arm from the machine Repeat for the hydraulic tank side lower secondary boom compression arm AWARNING Crushing hazard The lower secondary compression arm could become unbalanced and fall when removed from the machine if not properly supported by the overhead crane Part No 106373 A TEREX CON Z 30 20N Z 30 20N RJ MEANY SECONDARY BOOM COMPONENTS 60 Attach a lifting strap from an overhead crane to the lower secondary boom 61 Remove the pin retaining fastener from the lower secondary boom to turntable riser pivot pin Use a soft metal drift to remove the pin 62 Remove the lower secondary boom from the machine AWARNING Crushing hazard The lower secondary boom could become unbalanced and fall when removed from the machine if not properly supported by the overhead crane Section 4 Repair Procedures June 2008 SECONDARY BOOM COMPONENTS 5 2 Secondary Boom Lift Cylinder The secondary boom lift cylinder raises and lowers the secondary boom The secondary boom lift cylinder is equipped with counterbalance valves to prevent movement in the event of a hydraulic line failure How to Remove the Secondary Boom Lift Cylinder AWARNING 2 lly injury hazard This procedure requires specific r
69. device lift the additional test weight from the platform Result The platform overload indicator lights should turn off at both the ground and platform controls and the alarm should not sound Note There may be an 2 second delay before the overload indicator lights and alarm turn off 13 Start the engine and test all machine functions from the ground controls Result All ground control functions should operate normally 14 Turn the key switch to platform control 15 Test all machine functions from the platform controls Result All platform control functions should operate Note If the platform overload system is not operating properly Refer to Repair Procedure 2 3 How to Calibrate the Platform Overload System if equipped 16 Using a suitable lifting device remove the remaining test weights from the platform Part No 106373 June 2008 Section 3 Scheduled Maintenance Procedures Checklist D Procedures REV D D 1 Check the Primary Boom Wear Pads Note Genie specifications require that this procedure be performed every 1000 hours or annually whichever comes first 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 op
70. kinked or pinched A TEREX CON Z 30 20N Z 30 20N RJ MEANY REV B 21 Position a lifting strap from the overhead crane approximately 2 feet 60 cm from the platform end of the primary boom Measure from the platform end of the primary boom tube 22 Remove the pin retaining fasteners from the upper pivot to upper secondary compression arm pivot pins Use a soft metal drift to remove the pins 23 Swing the compression arms down and out of the way Secure them from moving 24 Remove the pin retaining fasteners from the upper pivot to the upper secondary boom pivot pin Use a soft metal drift to remove the pin 25 Carefully remove the entire primary boom assembly from the machine primary boom assembly jib boom assembly platform master cylinder primary lift cylinder and upper pivot AWARNING Crushing hazard The primary boom assembly could become unbalanced and fall when removed from the machine if not properly supported by the overhead crane Do not remove the assembly from the machine until it is properly balanced Note During removal the overhead crane strap will need to be carefully adjusted for proper balancing 26 Place the entire assembly onto a structure capable of supporting it Part No 106373 June 2008 Section 4 Repair Procedures REV 27 Remove the pin retaining fasteners from the upper secondary compression arm pivot pins Do not remove the pins 28 Position a lifting s
71. normally when they are actually not fully operational AWARNING Collision hazard Be sure that the machine is not in free wheel or partial free wheel configuration Refer to B 5 Confirm the Proper Brake Configuration 1 Select test area that is firm level and free of obstructions Mark a test line on the ground for reference Lower the boom to the stowed position Turn the key switch to platform controls Choose a reference point on the machine i e contact patch of a tire as a visual reference for use when crossing the test line 6 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 7 Measure the distance between the test line and your machine reference point Refer to Section 2 Specifications Note The brakes must be able to hold the machine on any slope it is able to climb Section 3 Scheduled Maintenance Procedures June 2008 CHECKLIST B PROCEDURES B 10 Test the Drive Speed Stowed Position Note Genie specifications require that this procedure be performed every 250 hours or quarterly whichever comes first 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 control
72. procedure be performed every 250 hours or quarterly whichever comes first 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 result in a hazardous operating situation 1 Pull out the red Emergency Stop button to the on position at both the ground and platform controls 2 Turn the key switch to platform controls 3 Check the machine functions from the ground controls Result The machine functions should not operate 4 Turn the key switch to ground controls 5 Check the machine functions from the platform controls Result The machine functions should not operate 6 Turn the key switch to the off position Result No function should operate Part No 106373 June 2008 Section 3 Scheduled Maintenance Procedures REV CHECKLIST B PROCEDURES B 4 B 5 Check the Tires Wheels and Lug Nut Torque Note Genie specifications require that this procedure be performed every 250 hours or quarterly whichever comes first Maintaining the tires and wheels including proper wheel fastener torque is essential to safe operation and good performance Tire and or wheel failure could result in a machine tip over Component damage may also result if problems ar
73. the key removed Wheels chocked All external AC power supply disconnected from the machine Part No 106373 A TEREX Z 30 20N Z 30 20N RJ 3 1 About This Section This section contains detailed procedures for each scheduled maintenance inspection Each procedure includes a description safety warnings and step by step instructions Symbols Legend Safety alert symbol used to alert personnel to potential personal injury hazards Obey all safety messages that follow this symbol to avoid possible injury or death Indicates an imminently hazardous situation which if not avoided will result in death or serious injury ADANGER AWARNING Indicates a potentially hazardous situation which if not avoided could result in death or serious injury Indicates a potentially hazardous ACAUTION situation which if not avoided may cause minor or moderate injury Indicates a potentially hazardous situation which if not avoided may result in property damage Indicates that a specific result is expected after performing a series of steps W Indicates that an incorrect result has occurred after performing a series of steps Section 3 Scheduled Maintenance Procedures June 2008 SCHEDULED MAINTENANCE PROCEDURES Maintenance Symbols Legend The following symbols have been used in this manual to help communicate the intent of the instructions When one or more of the symbols appear
74. the key switch to platform control and pull out the red Emergency Stop button to the on position at both the ground and platform controls 4 Raise the primary boom more than 5 feet 1 5 m 5 Choose a reference point on the machine i e contact patch of a tire as a visual reference for use when crossing the start and finish lines 6 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 7 Continue at full speed and note the time when your machine reference point passes over the finish line Refer to Section 2 Specifications Part No 106373 June 2008 Section 3 Scheduled Maintenance Procedures REV E B 12 Test the Alarm Package if equipped Note Genie specifications require that this procedure be performed every 250 hours or quarterly whichever comes first The alarm package includes Travel alarm Descentalarm Flashing beacon Alarms and a beacon are installed to alert operators and ground personnel of machine proximity and motion The alarm package is installed on the ground controls side turntable cover 1 Turn the key switch to ground controls and pull out the red Emergency Stop buttons to the on position at both ground and platform controls Result The flashing beacon should be on and flashing 2 Hold the function enable toggle switch to either side then move the primary bo
75. the platform Note Failure to remove all weight tools and accessories from the platform will result in an inaccurate test 4 Using a suitable lifting device place a test weight equal to that of the available capacity one of the locations shown Refer to Illustration 1 Result The platform overload indicator lights should be off at both the ground and platform controls and the alarm should not sound Result The platform overload indicator lights are on and the alarm is sounding Calibrate the platform overload system Refer to Repair Proceedure 2 3 How to Calibrate the Platform Overload System if equipped Part No 106373 Z 30 20N Z 30 20N RJ CHECKLIST C PROCEDURES 5 Carefully move the test weight to each remaining location Refer to Illustration 1 Result The platform overload indicator lights should be off at both the ground and platform controls and the alarm should not sound Result The platform overload indicator lights are on and the alarm is sounding Calibrate the platform overload system Refer to Repair Proceedure 2 3 How to Calibrate the Platform Overload System if equipped Illustration 1 6 Using a suitable lifting device place an additional 10 16 4 5 kg of weight onto the platform Result The alarm should sound The platform overload indicator lights should be flashing at both the ground and platform controls W Result The alarm does not sound and the plat
76. way Primary boom up down 22 Flow regulator valve 1 5 5 7 L min before serial number 10808 Flow regulator valve 1 8 6 8 L min after serial number 10807 Turntable rotate 23 Flow regulator valve 0 8 3 cp Jib boom platform rotate circuit 24 Solenoid valve 3 position 4 way Turntable rotate left right REV D Torque 20 25 ft lbs 27 34 Nm 30 35 ft lbs 41 47 Nm 20 25 ft lbs 27 34 Nm 20 25 ft lbs 27 34 Nm 20 25 ft lbs 27 34 Nm 20 25 ft lbs 27 34 Nm 20 25 ft lbs 27 34 Nm 20 25 ft lbs 27 34 Nm A TEREX COMPANY 4 34 Z 30 20N Z 30 20N RJ Part No 106373 MANIFOLDS Section 4 Repair Procedures June 2008 REV D 966 9 E gt SER 727 22 _ JS y WS Z 30 20N RJ 2 30 20 mod Vg 7 in 0O00 5 we Part No 106373 0 Section 4 Repair Procedures June 2008 MANIFOLDS 7 2 Valve Adjustments Function Manifold How to Adjust the System Relief Valve 1 Connect 8 0 to 5000 psi 0 to 350 bar pressure gauge to the test port on the function manifold 2 the key switch to ground cont
77. 0 Fax 425 883 3475 Genie Australia Pty Ltd Phone 61 7 3375 1660 Fax 61 7 3375 1002 Genie China Phone 86 21 53852570 Fax 86 21 53852569 Genie Malaysia Phone 65 98 480 775 Fax 65 67 533 544 Genie Japan Phone 81 3 3453 6082 Fax 81 3 3453 6083 Genie Korea Phone 82 25 587 267 Fax 82 25 583 910 Genie U K Phone 44 0 1476 584333 Fax 44 0 1476 584334 Genie Brasil Phone 55 11 41 665 755 Fax 55 11 41 665 754 Genie Mexico City Phone 52 55 5666 5242 Fax 52 55 5666 3241 Genie Holland Phone 31 183 581 102 Fax 31 183 581 566
78. 0 bar pressure gauge to the test port on the function manifold 2 Turn the key switch to ground control and pull out the red Emergency Stop button to the on position 3 Move and hold the function enable toggle switch to either side and move and hold the primary boom extend retract toggle switch in the extend direction with the primary boom fully extended Observe the pressure reading on the pressure gauge Refer to Section 2 Specifications 4 Turn the machine off Hold the primary booom extend relief valve with a wrench and remove the cap item G 5 Adjust the internal hex socket Turn it clockwise to increase the pressure or counterclockwise to decrease the pressure Install the relief valve cap AWARNING Tip over hazard Do not adjust the relief valves higher than specified 6 Repeat steps 2 and to confirm the relief valve pressure setting Part No 106373 Z 30 20N Z 30 20N RJ 4 37 Section 4 Repair Procedures MANIFOLDS How to Adjust the Turntable Rotate Relief Valve 1 Connect 0 to 3000 psi 0 to 200 bar pressure gauge to the test port on the function manifold Turn the key switch to ground control and pull out the red Emergency Stop button to the on position Move and hold the function enable toggle switch to either side and move and hold the turntable rotate toggle switch in the right direction until turntable stops against the rotation stop Observe the pressure reading on the p
79. 008 SPECIFICATIONS Machine Torque Specifications Platform rotator and jib boom rotator Z 30 20N RJ 1 8 center bolt GR 5 lubricated Jib boom rotator 480 ft lbs 650 Nm 3 4 10 bolt GR 8 lubricated Platform rotator 280 ft lbs 379 Nm 3 8 16 bolts GR 5 lubricated Platform rotator 23 ft lbs 31 Nm 1 2 13 bolts GR 5 lubricated Jib boom rotator Platform rotator Z 30 20N 57 ft lbs 77Nm 3 4 10 bolt GR 8 lubricated 280 ft lbs 379 Nm 3 8 16 bolts GR 5 lubricated Turntable rotate bearing 23 ft lbs 31 Nm Rotate bearing mounting bolts lubricated Drive hubs brakes and motors 180 ft Ibs 244 Nm Drive hub mounting bolts lubricated 180 ft lbs 244 Nm Brake mounting bolts lubricated 93 ft lbs 126 Nm Drive motor mounting bolts 31 ft lbs 42 Nm Continuous improvement of our products is a Genie policy Product specifications are subject to change without notice Genie SAN REV E Z 30 20N Z 30 20N RJ Part No 106373 June 2008 Section 2 Specifications REV Hydraulic Hose and Fitting Torque Specifications Your machine is equipped with Parker Seal Lok SPECIFICATIONS Seal Lok fittings 1 fittings and hose ends Genie specifications require that fittings and hose ends be torqued to specification when they are removed and installed or when new hoses or fittings are installed SAE O
80. 074 1 2304 3620 2 7640 2067 METRIC FASTENER TORQUE CHART This chart is to be used as a guide only unless noted elsewhere in this manual Size 6 69 Class 8 8 Class 10 9 03 Class 12 9 mm Y 5 6 7 pd 110 120 150 170 210 240 380 420 m 8 A DR DRY 854 58 775 91 105 132 DRY DRY 600 458 622 612 830 536 727 715 970 570 562 762 583 791 778 1055 682 925 909 1285 Genie TEREX COMPAN 2 6 Z 30 20N Z 30 20N RJ Part No 106373 1 ile c 5 i c 5 5 1 P gt ol CO No O O1 ala age E j m o gt SI NI zi a B gt 0 le ER 0 pp c 0 Poy PIS N SJA iol kaa ESDS A N T zi z 0 P eS zv Nin j 1 gt pol con Copco OF CO o EF BEN 0
81. 08 FAULT CODE CHART Fault Code Programmer Condition Possible Causes Diagnostic Display THROTTLE FAULT 1 THROTTLE FAULT 2 CONT DRVR OC MAIN CONT WELDED PRECHARGE FAULT Machine will not drive Machine will not drive Machine will not drive Machine will not drive Machine will not drive Open in wht red wire 32 at pin 14 or red wht wire 29 at pin 16 on the motor controller going from drive joystick to pins 14 and 16 at the motor controller OR pin 14 is internally shorted to power or ground OR the potentiometer on the drive joystick is defective Pin 14 wht red 32 is shorted to power or ground OR the potentiometer on the drive joystick is defective Main contactor PR1 coil defective OR brake release relay CR5 defective Main contactor PR1 contacts stuck closed OR grn wire at pin 17 on motor controller shorted to ground OR open in motor armature wiring OR motor controller has an internal short to ground External short between B terminal on motor controller and ground OR motor controller is defective REVA Consult Genie Industries Service Department Consult Genie Industries Service Department Replace main contactor PR1 or brake release relay CR5 OR replace the motor controller Consult Genie Industries Service Department Repair short between B terminal on motor controller and ground OR replace motor controller Note Short can be on any part o
82. 4 13 Section 4 Repair Procedures June 2008 Primary Boom Components 4 1 Cable Track The primary boom cable track guides the cables and hoses running up the boom It can be repaired link by link without removing the cables and hoses that run through it Removing the entire primary boom cable track is only necessary when performing major repairs that involve removing the primary boom How to Repair the Plastic Cable Track Component damage hazard The primary boom cable track can be damaged if it is twisted Note A 7 link repair section of cable track is available through the Genie Industries Service Parts Genie part no 58919 a link separation point b lower clip 1 Use slotted screwdriver to pry down on the lower clip 2 Repeat step 1 for each link To remove a single link open the lower clip Use a screwdriver to pry the link to the side A TEREX CON Z 30 20N Z 30 20N RJ REV 4 2 How to Shim the Primary 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 Extend and retract the boom through an entire cycle Check for tight spots that could cause scraping or binding Note Always maintain squareness between the outer and inner boom tubes Part No 106373
83. 41 47 Nm 20 25 ft lbs 27 34 Nm 20 25 ft lbs 27 34 Nm 30 35 ft lbs 41 47 Nm 10 12 ft lbs 14 16 Nm 20 25 ft lbs 27 34 Nm 20 25 ft lbs 27 34 Nm 20 25 ft lbs 27 34 Nm A TEREX COMPANY 4 32 Z 30 20N Z 30 20N RJ Part No 106373 MANIFOLDS Section 4 Repair Procedures June 2008 REV D 966 9 2 gt SER 727 22 _ JS y WS Z 30 20N RJ 2 30 20 mod Vg 7 in 0O00 5 we Part No 106373 0 Section 4 Repair Procedures June 2008 MANIFOLDS Function Manifold Components continued The function manifold is locate behind the ground controls turntable cover Index Schematic No Description Item Function 14 Orifice 0 045 inch 1 14 mm Brake and steer circuit 15 Solenoid valve Brake seoses 16 Differential sensing valve Differential sensing circuit 17 Relief valve 2800 psi 193 uus System 18 Orifice 0 035 inch 0 89 mm S uas Tank return circuit 19 Diagnostic fitting qd Testing 20 Solenoid valve 3 position 4 way Us Secondary boom up down 21 Solenoid valve 3 position 4
84. 4V DC 1 Turn the key switch to platform controls and pull out the red Emergency Stop button to the on position at both the ground and platform controls 2 Open the platform control box lid and locate the boom function speed controller a black red wire b diode c white red wire d boom function speed controller e ramp rate trimpot f threshold trimpot g max out trimpot Part No 106373 June 2008 Section 4 Repair Procedures REV 3 Locate the diode between the black red wire from the boom function speed controller and the white red wire Disconnect the white red wire from the diode on the black red wire 4 Connect the negative lead from a multi meter set to measure amperage to the wire connector of the white red wire Connect the positive lead of the multi meter to the diode on the black red wire 5 Turn the boom function speed controller to the CREEP position 6 Set the threshold Press down the foot switch and move the primary boom toggle switch to the up position Adjust the amperage to 0 28A Turn the threshold trimpot adjustment screw clockwise to increase the amperage or counterclockwise to decrease the amperage 7 Turn the boom function speed controller to the 9 position 8 Set the max out Press down the foot switch and move the primary boom toggle switch to the down position Adjust the amperage to 0 65A Turn the max out trimpot adjustment screw clockwise to increase the amperage or c
85. 7 Section 6 Schematics Power Cable Diagram before serial number 6290 Section 6 Schematics April 2007 Power Cable Diagram before serial number 6290 e9 2 wid 8 G H 1 GROUND CONTROLS SIDE TANK SIDE BATTERY PACK AMMETER BLK 10 Ga WHT 10 Ga 2 AC BATTERY CHARGER 3 PRIMARY LIFT PUMP Ai 01 BLK 4 Q p D1 UJ I AUXILIARY 4 2 m LIFT PUMP lt 8 9 RD Q v gt om RED Je 24V DC 5 RED 2 BLK DRIVE i 2 Ga 5 5 2 IN AUXILIARY PR1 F3 300A LIFT PUMP dh Fe NO CONTACTOR 6 PRIMARY 100 3 DIODES PR3 LIFT PUMP CONTACTOR PR2 CONTROLLER 7 RED 10 Ga 2 B 2 2 8 D 0 D F1 F2 A2 A1 LEFT SIDE BLK 2 Ga BLK 2 2 RIGHT SIDE DRIVE MOTOR Fip 9 DRIVE MOTOR 1 2 RED 10 Ga 6 5 Z 30 20N Z 30 20N RJ Part No 106373 REVA REV April 2007 Section 6 Schematics Power Cable Diagram from se
86. 73 Z 30 20N Z 30 20N RJ CHECKLIST A PROCEDURES A 3 Perform Function Tests Note Genie specifications require that this procedure be performed daily or every 8 hours whichever comes first Completing the function tests is essential to safe machine operation Function tests are designed to discover any malfunctions before the machine is put into service A malfunctioning machine must never be used If malfunctions are discovered the machine must be tagged and removed from service Complete information to perform this procedure is available in the appropriate Genie Z 30 20N Operator s Manual Refer to the Operator s Manual on your machine Section 3 Scheduled Maintenance Procedures June 2008 CHECKLIST A PROCEDURES A 4 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 40 hours of usage After this interval refer to the maintenance checklists for continued scheduled maintenance 1 Perform the following maintenance procedures 5 Grease the Turntable Rotation Bearing and Worm Drive Gear B 4 Check the Tires Wheels and Lug Nut Torque e 3 Check the Turnable Rotation Bearing Bolts D 5 Replace the Hydraulic Tank Return Filter Element A TEREX CON 3 8 Z 30 20N Z 30 20N RJ REV D A 5 Grease the Turntable Rotation Bearing and Worm Drive Gear Note Genie specifications require that this p
87. 7AUX DA a a 2 C133PLABLRD C2B i TEM E E 15 5 5 251 NEM E 8_1 Y P22BAT BK C7B 1 5 C49 11 0191 5 GR WH 4 25 Mii a 8 a c 5 o S 2 5 R19LPE GR WH o a o gg 2 WT wo 21 gt o o o C9HRN BK RD 85 8 BRN ed i amp d 2 a 9 8 2 5 d WE 4 5 RD 5 P22LS C104 BK 7 2 e Bm P22BAT J2 BK 2 co2wi7 92 I i gt 8 C52 1 BK 8 5 11 4 WH 6 5 g 8 C522WH8 11 3 BK 6 3 5 Bc CONTROLLER STATUS 58 LED L3 V ORD 2 49 7 0178081 BK a 2 a AA 49 2 5 i5 X PRI C182PWR GR efOR RD T 2 amp 1 T 5 5 l SES C499 OFF LIMT SPD INP eI uj ln Jae 0498 1 INTERLOCK 2 4 5 1 3 C29JSH RD WH C1B 3 49 3 RD WH POT HI 45 uz 16 55 z 8 o C1P 6_ C32JSL WH RD C1B 6 C49 6 WH RD POT LOW Ji 3 o a C1P 5_ 1 1 5 C49 5 WH BK REVERSE 9 1 4 C30FWD WH 4 C494 WH FORWARD S 5 1 i DIODE 9 5 R42BAT OR RD V INP g 2 48 UT 1 ESS g 5 5 EI
88. 90 Section 6 Schematics SPARE WIRES BLK 1 BLK RED 1 BLU WHT 1 BLU RED 1 GRN WHT 1 BLK WHT 1 DESCRIPTION EMERGENCY STOP BUTTON HORN BUTTON 1 DRIVE CONTROLLER DRIVE ENABLE LIGHT BATTERY CHARGE INDICATOR OPTION TILT ALARM TS10 SECONDARY BOOM UP DOWN TOGGLE SWITCH TS11 PRIMARY BOOM UP DOWN TOGGLE SWITCH TS12 TURNTABLE ROTATE TOGGLE SWITCH 1 BOOM FUNCTION SPEED CONTROLLER AUXILIARY POWER TOGGLE SWITCH TS7_ PLATFORM ROTATE TOGGLE SWITCH TS8 JIB BOOM UP DOWN TOGGLE SWITCH TS9 PLATFORM LEVEL TOGGLE SWITCH 513 BOOM EXTEND RETRACT TOGGLE SWITCH TS16 JIB BOOM ROTATE TOGGLE SWITCH OPTION TS15 DRIVE ENABLE TOGGLE SWITCH LABEL P2 P3 Al L1 LOAD SENSE _ ACCESSORY O re O BRN JIB BRN 2 A1 RED BLK 1 BLU WHT 3 ORG RED 3 WHT BLK 3 WHT 3 BLU BLK 3 BLU 3 WHT RED 3 TS12 TS10 BP1 BOOM FUNCTION SPEED CONTROL TS15 2E 2 GRN BLK 3 GRN 3 TS11 GRN 1 GRN WHT 3 WHT GRN BLK 1 RED BLK 3 RED 3 Pos GES ERIE pe piene rm iem
89. AKE PS 2 1 12 TRI TR2 sci 5 2 1 2 PUMP PUMP Rx _ 0 2 0 5 gpm 2 1 gpm 2800 psi Pm ii r rus i 1 1 51 1 89 L min 7 95 Lmin P 4 wo t s OT OT 124 bar 7 2 eu ete H wn ime m 3000 psi 1100 psi Ei Uo 207 8 75 8 bar 3 1 ee T 1 HAIX 10 MICRON A X ir 0 8 B min i 1 X Ens before serial 8 number 10808 HYDRAULIC RESERVOIR 4 ee 6 4 6 8 Limi after 5 1 number 10807 1 1 2 851 Note FUNCTION MANIFOLD d Orifice added after serial number 5396 Genie A TEREX COMPANY Part No 106373 Z 30 20N Z 30 20N RJ 6 32 January 2008 Section 6 Schematics SSS SSS SS Hydraulic Schematic Genie Scandinavia Phone 46 31 575100 Fax 46 31 579020 Genie France Phone 33 0 2 37 26 09 99 Fax 33 0 2 37 26 09 98 Genie Phone 34 93 579 5042 Fax 34 93 579 5059 Genie Germany Phone 0800 180 9017 Phone 49 422 149 1818 Fax 49 422 149 1820 Genie North America Phone 425 881 1800 Toll Free USA and Canada 800 536 180
90. BCI TS1 WHT WHT 1 WHT BLK 1 WHT RED 1 RED WHT 1 12345678910 P2 RED WHT 3 ORG RED 1 BLK FS BLK 2 WHT BLK RED 3 RED 1 BLUE JIB ORG JIB WHT JIB BLK JIB YEL JIB RED JIB COMPANY Z 30 20N RJ 2 30 20 G Part No 106373 OPTION REMOVE JUMPER JP1 FOR CE VERSION NOTE April 2007 Section 6 Schematics EE Platform Control Box Wiring Diagram from serial number 6290 to 8354 Section 6 Schematics April 2007 2 Platform Control Box Wiring Diagram after serial number 8354 REVA April 2007 Platform Control Box Wiring Diagram after serial number 8354 Section 6 Schematics g Bg ui 5 9 z d g ole PT 565 S 6 2 ale 5 9 6 5 8 2 8 les X 5 S 5 4828 LE 2 9 sia lt 1225562 55 9 5 2 218 5 al 4828 gt 6 gt a E BIETSEEEEEBEHEHPBEFEFPEEPE o A 553 lt o a 0 E I
91. BOOM UP DOWN TOGGLE SWITCH HORN BUTTON AUXILIARY TOGGLE SWITCH TILT ALARM DRIVE ENABLE LIGHT TILT ALARM LED PLATFORM OVERLOAD LED 6 28 7510 SECONDARY BOOM UP DOWN TOGGLE SWITCH TS12 TURNTABLE ROTATE TOGGLE SWITCH 1513 EXTEND RETRACT TOGGLE SWITCH TS15 DRIVE ENABLE TOGGLE SWITCH TS16 JIB ROTATE TOGGLE SWITCH OPTION LABEL DESCRIPTION Al BCI DP1 L1 L4 L48 P2 P3 TS1 TS7 TS8 TS9 7511 di RR 1 BLU WHT 1 BLU RED 1 RED BLK 1 WHT 2 BLU WHT 3 ORG RED 3 WHT BLK 3 WHT 3 BLU BLK 3 BLU 3 WHT RED 3 7512 TS10 PO E 4 2 J TS15 TS11 BRN RED BLK GRN BLK GRN BLK 3 GRN 1 GRN WHT 3 WHT ex GRN BLK 1 RED BLK 3 3 GRN 3 robes ead Ion eae JIB ROTATE ORG BLK 3 BLK WHT 3 BLK 3 BLU RED 3 BLU BLK 1 BLU 1 A WHT FS RED R RED RED ORG RED RED 229 Y NO NC NC L
92. Bem Muss sec E Y XY 22 2 7 1 5 49 11 C19LPE GR WH 8 4 5 lt 55 E 5 L R19LPE GRWH P 729 s 5 5 6 BRN e 5 C9HRN BK RD 1 a ay 3 g il 5 2 RD P22LS BK C10 1 ae 2 Bm P22BAT BK o J2 BK C10 2WH7 2DF 5 508 i 8 52 1 8 C11 4 WH 6 5 5 C52 2 WH 8 C11 3 6 5 8 3 5 MES 8 4 ole CONTROLLER STATUS 2 _ _ LEDL3 zo Va I y 0497 CI78CSL g 1 4 4 4 a OR RD CRS C49 2 55 o 8 8 E X Pat C182PWR GR 4802 5 0499 OFF LIMT SPD E gE u PECES EM 0498 1 BLWH INTERLOCK r gt E 5 E C1P 3 C29JSH RD WH 04 49 3 RD WH POT HI zE ez lt 16 8 lt 5 1 6 C32JSLWH RD 6 C49 6 WH RD POT LOW 2 s 5 1 5 C31REV WH BK 1 5 49 5 WH BK REVERSE 9 1 4 C30FWD WH 1 4 C494 WH FORWARD 10 Hg zx T E DIODE RETURN 9 1 5 R42BAT OR RD INI 8 n j 48V BA g 5 5 E amp a lt E 9 3 8 BK a lt 20 5 4 5 m gt p a 0 5 EN e o one 5
93. C Se8m ORG RED 42 BLK amp 55 E 0 1 lt 8 52 CONTROLLER ig gt wy l 208 320 6 FAULT LIGHT 21 AZOA 2 810 Xo 080 8 jo 1412 ORG RED GRN 11865 10m DAVE i y a CONTACTOR pvo dE x 2 5 COIL 8 IQ a Ea E Bik 1 a lt A PEN g io x _RED BLK BRAKEMREL 5 5 5 8 8 OFFLIMIT SPEED INPUT 8 a 1 IE 1 POT LOW 4 gt qu 2 WIREPOT 6 1 els bi lt BLUWHT 2 INTERLOCK 2 9 t BE 8 a _ 8 REVERSE 5 4 XC g LOA FORWARD 49 i 5 DIODE RETURN 5 aes 4 4 ORG RED gt 48V DC INPUT 1 a 1 DRIVE 141 BLK CONTACTOR amp lt bn LE BOLA E m BLK 48 DC BATTERY gt g CHARGER ec a Q Q 5 5 E 0 rep PRIMARY ut ste as 5 we e MC EAE A Ear re d a cem wr mr e ee eed Q AUXILIARY 9 2 PUMP a 5 5 2 8 RED CB1
94. C2B 6 SP JIB DOWN Hq 19 BL BK 1 11 37 BL BK MH STEER RIGHT C378CW ne SE SUE 90 81 BLC1B 10 36 BL MH STEER LEFT C368CC 2 OR C40LS 52 2 CH OFF LIMIT SPEED RD CR3 RD C1B 1 27 RD SP AUXILIARY PUMP SELECT C27AUX WH RD C32JSL 1 6 CH JOYSTICK POT LOW WH 10 2 BK C23 4 22 BK SP BK CR4 24 TO PLATFORM P22BAT WHIBK CSIREV SEs eh REVERSE TB36 TB37 GR WH CR3 19 GR WH MH LIFT PUMP C19LPE WH C30FWD C1B 4 CH FORWARD WH BK SP GR WH C4B 7 19 GR WH SP LIFT PUMP C19LPE RD WH C29JSH C1B 3 CH 2 WIRE POT OR RD C8 1 4 16 OR RD CR5 DRIVE ENABLE C16DE RD BK C28TTA TILT C C1B 2 TILT ALARM CE OPTION OR BK C4B 3 15 OR BK MH OR BK SP PLAT LEVEL DOWN C15PLD DET LOCKOUT CE OPTION OR 2 14 OR MH OR SP PLAT LEVEL UP C14PLU a 8 3 12 BL WH CH FOOTSWITCH 12 5 24 TRACTION CONTROL 3 BL BK C3B 11 11 BL BK MH BL BK SP SEC BOOM DOWN C11SBD GR BK C18PRR C4B 6 SP PLAT ROTATE RIGHT BL C3B 10 10 BL MH BL SP SEC BOOM UP C10SBU GR C17PRL C4B 5 5 PLAT ROTATE LEFT BK WH C3B 8 8 BK WH MH BK WH SP BOOM RETRACT C8PBR BL RD C13DEL C8 4 C4B 1 DRIVE ENABLE LIGHT BK C3B 7 7 BK MH BK SP BOOM EXTEND C7PBE BK RD COHRN C3B 9 HORN 6 WH RD 6 WH RD MH WH RD SP BOOM FUNCTION F C C6MFV RD WH C3BAT CRI C3B 3 48V RELAY COIL PWR WH BK C3B 5 5 WH BK MH WH BK SP TURN ROTATE RIGHT C5TRR BL WH C132PLI C1B 12 32 3 PLAT OVERLOAD INPUT WH C3B 4 4 WH MH WH SP TUR
95. CATRL WH 0884 g Ek Eu x Sg 8 519 22 4 5 z r 5555 HEB a a 8 uu Sa 5 SIS 8 8 of 8 6 8 6 Oo S CR3 TRAVEL ALARM BRAKE RELEASE NC COIL BRAKE RELEASE NO COIL BRAKE RELEASE PRESSURE SWITCH STEER LEFT STEER RIGHT HOUR METER AUXILIARY CONTROL RELAY PROPORTIONAL CONTROL VALVE PLATFORM ROTATE RIGHT JIB BOOM UP PLATFORM ROTATE LEFT JIB BOOM DOWN PLATFORM LEVEL CUT OUT OPTION PLATFORM LEVEL UP COIL PLATFORM LEVEL DOWN COIL BOOM EXTEND BOOM RETRACT ALL SOLENOID AND RELAY COILS ARE 24VDC EXCEPT WHERE NOTED 4 gt SETUP ENABLE USE TO SET THE BATTERY INDICATOR PROFILES PRIMARY BOOM UP PRIMARY BOOM DOWN SECONDARY BOOM UP SECONDARY BOOM DOWN DESCENT ALARM TURNTABLE ROTATE RIGHT TURNTABLE ROTATE LEFT ALL LIMIT SWITCHES SHOWN WITH BOOM IN STOWED POSITION EXCEPT AS NOTED NOTES 1 gt lt SWITCH SHOWN WITH BOOM EXTENDED gt SWITCH SHOWN WITH BOOM ROTATED PAST EITHER NON STEER WHEEL a A TEREX COMPANY Z 30 20N Z 30 20N RJ G 6 22 Part No 106373 April 2007 Section 6 Schematics Electrical Schematic CE Models after serial number 9346 Section 6 Schematics April 2007 Ground Control Panel Wiring Diagram before serial number 6290 Section 6 Schematics April 2007 Ground Control Panel Wiring
96. ERLOAD LED Genie TEREX COMPANY Z 30 20N Z 30 20N RJ Part No 106373 RD 23 1 SWITCH PANEL RD WH 48A BR 52A REV A TO TERMINAL BASE AND CONNECTORS RD 1348 BL RD C2B 1 WH BK 19D 48D GN BK BR 52A BR C32 12 RD C48 1 P1 O nc O RD 134A BK 22A 081 145 O nc O Pam HI 5 TS51 RD C23 6 JIB ROTATE OPTION BL WH C1 12 220 7 1 9 18060 9 20 9V BR HM RD 27A 15 7 BK WH 8A WH RD 6A OR BK C2 3 i 1 2 OR 14A GN BK 18A 559 GN WH 19A GN BK 44A GN 43A TS58 RD BK 2A RD 1A GN 17A TS57 WH BK 5A WH 4A BL BK 11A RD C32 7 C32 U33 PLATFORM OVERLOAD OPTION BL 10A REVA C52 0 LS4 SECONDARY UP DOWN o C8 Oo LS3 DRIVE ENABLE C11 LS2 PRIMARY UP DOWN 10 LS1 PRIMARY EXTEND RETRACT CABLE 2 C4B 000000 C3B 000000
97. EV 3 3 Jib Boom Rotator models with rotating jib boom The platform rotator is a hydraulically activated helical gear assembly used to rotate the jib boom 160 degrees How to Remove the Jib Boom Rotator Note When removing a hose assembly or fitting the O ring on the fitting and or hose end must be replaced and then torqued to specification during installation Refer to Section 2 Hydraulic Hose and Fitting Torque Specifications 1 Remove the jib boom See 3 1 How to Remove the Jib Boom 2 Support and secure the jib boom rotator to an appropriate lifting device 3 Remove the eight mounting bolts from the jib boom rotator mount 4 Remove the center bolt Carefully remove the jib boom rotator from the machine AWARNING Crushing hazard The jib boom rotator could become unbalanced and fall when removed from the machine if not properly supported and secured to the lifting device Note When installing the jib boom rotator be sure to torque the fasteners to specification Refer to Section 2 Specifications 5 Support and secure the jib boom bell crank to an appropriate lifting device 6 Remove the pin retaining fasteners from the slave cylinder rod end pivot pin Do not remove the pin Part No 106373 JIB BOOM COMPONENTS Place a block of wood under the platform leveling slave cylinder for support Protect the cylinder rod from damage Remove the pin retaining fasteners from the
98. Hose and Fitting Torque Specifications 1 Raise the jib boom slightly and place blocks under the platform mounting weldment for support Lower the jib boom until the platform is resting on the blocks 2 Tag disconnect and plug the jib boom lift cylinder hydraulic hoses Cap the fittings on the cylinder AWARNING Bodily injury hazard Spraying hydraulic oil can penetrate and burn skin Loosen hydraulic connections very slowly to allow the oil pressure to dissipate gradually Do not allow oil to squirt or spray 3 Remove the pin retaining fasteners from the jib boom lift cylinder rod end pivot pin Do not remove the pin TEREX COMPANY JIB BOOM COMPONENTS Use a soft metal drift to tap the rod end pivot pin half way out and lower one of the leveling links to the ground Tap the pin the other direction and lower the opposite leveling link Do not remove the pin Attach a lifting strap from an overhead crane to the rod end of the jib boom lift cylinder Remove the pin retaining fasteners from the jib boom lift cylinder barrel end pivot pin Use a soft metal drift to remove the barrel end pivot pin Use a soft metal drift to remove the jib boom lift cylinder rod end pivot pin Remove the jib boom lift cylinder from the machine AWARNING Crushing hazard The jib boom lift cylinder could fall when the pins are removed if not properly supported by the overhead crane Part No 106373 2 30 20 Z 30 20N RJ
99. I OPTION TS51 GRN WHT 19 H TB27 86 LVI BCI OPTION p MEE April 2007 GBN WHT CONTACTOR RELAY i i CR20 LIFT PUMP ORG RED 48V e CONTACTOR COIL PR2 AUXILIARY PUMP CONTACTOR COIL 19 87 3 17 GRN WHT 8 T 4 RED WHT RED 3 WHT RED 6 n PROP FLOW DISCHARGE SET BRN Ves REV WHT CONTROL COIL Lleill RESET RED RED 4 GRN JIB BOOM ROTATE BRN JIB CONTROL BLK RED 1 ROTARY OEM FLOW TS66 ORG BLK 1 ORG 1 TB46 JIB BOOM ROTATE OPTION 4 RED JIB YEL JIB WHT RED 6 GRN 1 PLATFORM LEVEL CUTOUT CE VERSION ONLY GRN BLK 1 FOS Sage 7 PLATFORM LEVEL CUTOUT RELAY COIL PLAT ROT TB18 BLK JIB ORG 6 GRN BLK 3 PLATFORM ROTATE RIGHT GRN 3 5 PLATFORM LEVEL UP COIL PLATFORM LEVEL DOWN COIL UP TS7 PLAT LVL 81 14 ORG JIB E MANIFOLD GROUND E BLU JIB JIB MANIFOLD FUNCTION GROUND ORG 3 PLATFORM LEVEL DOWN AN
100. IL T a E 5 c 2 TH 8 m g gt 9 5 2 i ZSoz 2 5 2628 5 1 a Ge gk 58 j ORGIBLK 1 9 m ORG 1 6 INE e g 4 4 r r E a 1 Lu i 1 E 368 559 GRN 1 55 2 GRN BLK 1 We ace PLATFORM LEVEL o a E i a 5 55 RED 6 CUTOUT X t EE PSI TM E 5 RELAY COIL TENIS 0 X wg bog GRN BLK 3 T i GRN 3 PEN 5 425 14 PLATFORM LEVEL S 8 1 B 4 UP COIL i 815 ORG BLK 1512 PLATFORM LEVEL m T 1 E 2a DOWN COIL 1 4 oz i 22 i 5 20 5 1 gt tuc 220 55 ORG 3 0 ORG BLK 3 gt midi z8 BLK 7 PRIMARY BOOM H EXTEND COIL ji 1 BLKWHT 8 PRIMARY BOOM 3 RETRACT COIL 1 12 8 gt m lt gt gt 29 BLK 3 BLK WHT 3 RED 1 PRIMARY BOOM l UP COIL REDBLK 2 71
101. K POT LOW WHT BLK 1 31 WHT BLK CH DRIVE REVERSE Pas 3 WHT 1 30 WHT CH DRIVE FORWARD ORG BLK 3 15 ORG BLK CR10B ORG BLK SP PLAT LEVEL DOWN RED WHT 1 29 RED WHT CH 2 WIRE POT ORG 3 14 ORG CR10A ORG SP PLAT LEVEL UP WHT TILT RED BLK 1 28 TILT ALARM 7 2 RED CR3 RED 1 27 RED SP AUXILIARY PUMP SELECT PLATFORM LEVEL CUTOUT CE VERSION ONLY OPTION 2 23 KEY SWITCH POWER RED TILT WHT 2 23 WHT SP KEY SWITCH POWER WHT 7 BLK 2 22 BLK CR4 BLK SP 24V DC TO PLATFORM NEN TB36 TB37 GRN WHT CR3 9 GRN WHT MH LIFT PUMP 4 WHT BLK SP GRN WHT 3 19 GRN WHT SP LIFT PUMP GRN BLK 3 18 GRN BLK SP PLATFORM ROTATE RIGHT GRN 3 17 GRN SP PLATFORM ROTATE LEFT RED 5 ORG RED 3 16 ORG RED CR5 DRIVE ENABLE TILT SENSOR ORG BLK 3 15 ORG BLK MH ORG BLK SP PLATFORM LEVEL DOWN wien ORG 3 14 ORG MH ORG SP PLATFORM LEVEL UP 5 BLU RED 3 13 DRIVE ENABLE LIGHT 5 BLK 5 BLU WHT 3 12 BLU WHT CH FOOTSWITCH BLU BLK 3 11 BLU BLK MH BLU BLK SP SECONDARY BOOM DOWN CB2 L3 BLU 3 10 BLU MH BLU SP SECONDARY BOOM UP C 0 ap BLK CH BLK RED CR4 BLK RED 3 9 HORN ey BLK WHT 3 8 BLK WHT MH BLK WHT SP BOOM RETRACT BANCHI ORG REDH2A BLK 3 7 BLK MH BLK SP BOOM EXTEND WHT RED 3 6 WHT RED MH WHT RED SP BOOM FUNCTION FLOW CONTROL JIB ROTATE WHT BLK 3 5 WHT BLK MH WHT BLK SP TURNTABLE ROTATE RIGHT OPTION 6 WHT 3 4 WHT MH WHT SP TURNTABLE ROTATE LEFT
102. N ROTATE LEFT C4TRL BL RD C133PLA C2B 1 A6 PLAT OVERLOAD ALARM RD BK C3B 2 2 RD BK MH RD BK SP PRIMARY BOOM DOWN C2PBD RD C3B 1 1 RD MH RD SP PRIMARY BOOM UP 1 4 D 0 8 TO TERMINAL BASE 5 RD 27D GR WH 19C OR RD C48 2 GR WH C49 11 BK 22A OR RELAY BLOCK CONTROL RELAY 1 0 cre 1 SECONDARY 48V POWER CR2 PRIMARY 48V POWER BR 52A AUXILIARY PUMP RD WH C3B 3 CR4 HORN CR5 BRAKE RELEASE ice BK RD MH HORN CR9 PLAT LEVEL CUTOUT CE ONLY 6 CR10 PLAT LEVEL CUTOUT CE ONLY OR RD 42D BK RD C3B 9 RD WH 48D OR MH OR BK MH 5 CR10A CR10B 7 RD BK C49 2 RD C11 1 OR RD 16A H i BR 52D 14 OR BK 15A eer re 8 OR BK 11 2 i OR BK C4B 3 15 OR BK CR10 OR BK SP PLAT LEVEL DOWN ct OR C4B 2 14 OR CRO OR SP PLAT LEVEL UP i PLATFORM LEVEL CUTOUT CE VERSION ONLY Part No 106373 TEREX COMPANY enie Z 30 20N Z 30 20N RJ April 2007 Section 6 Schematics 4 Ground Control Panel Terminal Strip Wiring Diagram after serial number 8354 Section 6 Schematics April 2007 5 Platform Control Box Wiring Diagram before serial number 6290 REVA April 2007 Platform Control Box Wiring Diagram before serial number 62
103. Note Always use a new cotter pin when installing a castle nut 6 Pullthe hub off the yoke spindle The washer and outer bearing should fall loose from the hub 7 Place the hub on a flat surface and gently pry the grease seal out of the hub Remove the inner bearing Note When removing a bearing always use a new inner bearing seal Part No 106373 A TEREX COMI Z 30 20N Z 30 20N RJ Steer Axle Components How to Install the Hub and Bearings Note When replacing a wheel bearing both the inner and outer bearings including the pressed in races must be replaced 1 Be sure that both bearings are packed with clean fresh grease 2 Place the large inner bearing into the rear of the hub 3 Install a new bearing grease seal into the hub by pressing it evenly into the hub until it is flush Note Always replace the bearing grease seal when removing the hub 4 Slide the hub onto the yoke spindle Component damage hazard Do not apply excessive force or damage to the lip of the seal may Fill the hub cavity with clean fresh grease Place the outer bearing into the hub Install the washer and castle nut Tighten the castle nut to 158 ft lbs 214 Nm to seat the bearings oN O Note Rotate the hub by hand while torquing the castle nut to make sure the bearings seat properly 9 Loosen the castle nut one full turn and then torque to 35 ft lbs 47 Nm 10 Install a new cotter pin Bend th
104. OWN TOGGLE SWITCH 5 lo TS9 PLATFORM LEVEL TOGGLE SWITCH TS10 SECONDARY BOOM TOGGLE SWITCH 9 NO NC NC 9 TS11 PRIMARY BOOM TOGGLE SWITCH 8 TS12 TURNTABLE ROTATE TOGGLE SWITCH TS1 P3 P2 DP1 TS13 BOOM EXTEND TOGGLE SWITCH TS15 DRIVE ENABLE TOGGLE SWITCH TS16 JIB ROTATE TOGGLE SWITCH OPTION L1 DRIVE ENABLE LIGHT L2 OVERLOAD LIGHT OPTION Genie A TEREX COMPANY Z 30 20N Z 30 20N RJ Part No 106373 June 2008 Section 6 Schematics Electrical Symbols Legend REV B 9 a 5 Stop button HORN normaly closed LED Horn button Wire color 6V DC normally open with cable 8171 Battery number 8 BLK Flashing Foot switch chk beacon Terminal Tilt sensor PSH zer Pressure Ground em switch API supression circuit Hour meter Quick disconnect terminal P Circuit breaker Bao f relion speed controller Horn BLK 21 J1 T circuit 8 connects at terminal T circuit connected Connection no terminal Circuits crossing no connection Diode Relay contact normaly open Relay contact normally closed Drive motor Auxiliary Primary lift pump Brake release before serial number 6290 3 Toggle switch SPDT 15
105. P SELECT ONCO ONCO ae 26 LIFT LOCKOUT 3 25 BATTERY LIGHT ONCO INCO 24 TRACTION CONTROL 23 i WHT 7 BLK C23 4 22 BLK CR4 BLK SP 24V TO PLATFORM CB1 TB36 TB37 GRN WHT CR3 19 GRN WHT MH _ LIFT PUMP CBT 1 HE WHT BLK SP_ GRN WHT 3 19 GRNAWHT SP LIFT PUMP RED CH Ke SWITCH PANEL TS51 GRN BLK 3 18 GRN BLK SP PLAT ROTATE RIGHT 51 GRN 3 17 GRN SP PLAT ROTATE LEFT RED 5 ORG RED 3 16 ORG RED CR5 DRIVE ENABLE 1 ORG BLK 3 15 ORG BLK MH ORG BLK SP PLAT LEVEL DOWN L45 4 olo ORG 3 14 ORG MH ORG SP PLAT LEVEL UP C WHT 5 BLU RED 3 13 DRIVE ENABLE LIGHT REDA S BLK 5 BLU WHT 3 12 BLU WHT CH _ FOOTSWITCH BKZ A BLU BLK 3 11 BLU BLK MH BLU BLK SP SEC BOOM DOWN RED 27A BLU 3 10 BLU MH BLU SP SEC BOOM UP ORG BLK 15A BLK RED CR4 BLK RED 3 9 HORN BLK 7A BLK WHT 3 8 BLK WHT MH BLK WHT SP BOOM RETRACT BLK WHT 8A TS66 83 TS59 BLK 3 7 BLK MH BLK SP BOOM EXTEND 4 6 WHT RED 3 6 WHT RED MH WHT RED SP BOOM FUNCTION F C JIB ROTATE OBG BLK47A _ WHT BLK 3 5 WHT BLK MH WHT BLK SP TURN ROTATE RIGHT OPTION ORG 46A LO WHT 3 4 WHT MH WHT SP TURN ROTATE LEFT 506 RAE 5 RED WHT CR1 RED WHT 3 3 48V RELAY COIL PWR ons RED BLK 3 2 RED BLK MH RED BLK SP PRIMARY BOOM DOWN ORG 14A
106. PRIMARY BOOM DOWN COIL ik 1 1 2 5 RED 3 RED BLK 3 BE SECONDARY K BEU 10 BOOM UP COIL een SECONDARY BLU BLK 11 BOOM DOWN COIL lt IW 4 455 2 1 Q 1 2 1 1 e i 5 2 DESCENT 88 116 1 ALARM 88 5 OPTION dese E zo sues BLU BLK 3 218 E TURNTABLE 2 55 WHT BLK 5 ROTATE RIGHT m 0 COIL WHT 4 TURNTABLE Te 0 ROTATE LEFT COIL 55 WHT BLK 3 Fal WHT 3 x 5 Ex 9 a 5 Ela 5 5 5 a 5 5 a tc Sa a z I I 4 5 5 ale 5 5 lt SWITCH SHOWN WITH BOOM ROTATED PAST EITHER NON STEER WHEEL PR3 AUXILIARY PUMP CONTACTOR COIL 6 14 Z 30 20N Z 30 20N RJ G Part No 106373 April 2007 Section 6 Schematics Electrical Schematic from serial number 6290 to 8354 REVA C29JSH RD WH April 2007
107. PTION C46JRL OR C2P 2 44 A C15PLD OR BK C4P 3 C8PBR BK WH C3P 8 m L WH C7PBE BK C3P 7 C13DEL BL RD 1 RD C37SCW BUBK C1P 11 036800 C1P 10 RD BRN ORG RD P24BAT WH C9P 2 RD C30FWD WH C1P 4 C31REV WH BK C1P 5 C32JSL WH RD C1P 6 9 Q C29JSH RD WH C1P 3 2134567819110 09 4 NC CY BCI 1 1 1 RD WH 3 R42BAT OR RD C2P 4 P26BAT BK C9P 1 P22BAT BK C7P 1 C9HRN BK RD C3P 9 C27AUX RD C1P 1 C17PRR BL C47 2 C18PRL OR C47 1 C44JD WH C47 3 C43JU BK C47 4 C46JRL YL C47 5 C47JRR RD C47 6 Part No 106373 Z 30 20N Z 30 20N RJ G 6 29 REVA April 2007 Section 6 Schematics LVI BCI Option Wiring Diagram from serial number 8355 to 9346 OO 17515 Bs TS9 TS7 ONO O O O 2
108. Procedures REV E B 8 Test the Platform Self leveling Note Genie specifications require that this procedure be performed every 250 hours or quarterly whichever comes first Automatic platform self leveling throughout the full cycle of boom raising and lowering is essential for safe machine operation The platform is maintained level by the platform leveling slave cylinder which is controlled by the platform leveling master cylinder located at the base of the primary boom A platform self leveling failure creates an unsafe working condition for platform and ground personnel 1 Turn the key switch to ground controls and pull out the red Emergency Stop button to the on position at both the ground and platform controls 2 Lower the boom to the stowed position 3 Adjust the platform to a level position using the platform leveling toggle switch 4 Raise and lower the primary boom through a full cycle Result The platform should remain level at all times to within 5 degrees Part No 106373 Z 30 20N Z 30 20N RJ CHECKLIST B PROCEDURES B 9 Test the Drive Brakes Note Genie specifications require that this procedure be performed every 250 hours or quarterly whichever comes first 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
109. R19LPE GR WH PRIMARY LIFT 5 gi PUMP PR2 2 g 5 ai 5 gt 5 5 C9HRN BK RD BRN 1 HORN amp 1 RELAY T 3 T Jj BK 4 HORN 56 1 4 5 P22LS C10 1 BK 7 LS1 EXT RET E Be 22 o J2 BK 87 sc lt sca 8 52 1 8 5 8 it 9 5 52 2 WH 8 11 3 6 9 LS2 PRI UP DWN 5 9 1 3 LS4 SEC UP DWN 2 CONTROLLER STATUS 28 LED L3 56 OR RD 49 7 C178CSLBK n CHASSIS GROUND 2 2 OR RD 085 gt 649 2 CABBRK RDIBK BRAKE RELEASE 5 T RELAY X PRI C182PWR PR1 DRIVE p gom CONTACTOR d amp 5 8 6 5 5 0499 1 OFF LIMT SPD INP g 55 10 BLWH INTERLOCK d Buy 2 o C1P 3_ C29JSH C1B 3 C49 3 POLH 6 5 gs 85 8 1 6 C32JSLWH RD 6 C49 6 00 8 C1P 5_ C31REV WH BK 1 5 C49 5 WHIBK REVERSE 1 4 C30FWD WH C1B 4 C49 4 WH FORWARD j i HI L DIODE RETURN 9 Liz 4 42 OR RD j 48 1 1 3 m 5 5 n 2 2 5 a 5 8 ige BK lt 208 9 8 3 amp PRIMARY LIFT PUMP oz 25 AUXILIARY LIFT PUMP 048 1 P182BAT RD amp lt 8 2 Part No
110. Rotation Stop Note Genie specifications require that this procedure be performed every 250 hours or quarterly whichever comes first The turntable is capable of rotating the boom 359 degrees and is stopped midpoint between the steer wheels by the rotation stop Detecting a rotation stop malfunction is essential to safe operation and good machine performance If the turntable rotates past the rotation stop component damage may result 1 Turn the key switch to platform controls and pull out the red Emergency Stop buttons to the on position at both ground and platform controls 2 Rotate the turntable to the left as far as it will go Result Movement should stop when the primary boom reaches midpoint between the steer tires 3 Rotate the turntable to the right as far as it will go Result Movement should stop when the primary boom reaches mid point between the steer tires A TEREX CON Z 30 20N Z 30 20N RJ REV E B 14 Check the Electrical Contactors Note Genie specifications require that this procedure be performed every 250 hours or quarterly whichever comes first 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 AWARNING Electrocution burn hazard Contact with hot or live circuits could result in death or serious injury Remove all rings
111. T LS2 PRI UP DWN LS4 SEC UP DWN CHASSIS GROUND BRAKE RELEASE RELAY CR5 PR1 DRIVE CONTACTOR E gt CE amp PLATFORM LOAD SENSE OPT PRIMARY LIFT PUMP AUXILIARY LIFT PUMP NOTES Part No 106373 E ADD D40 ONLY IF UNIT HAS L4 AND L48 TEREX COMPANY Z 30 20N Z 30 20N RJ G 1 ALLLIMIT SWITCHES SHOWN WITH BOOM IN STOWED POSITION EXCEPT AS NOTED gt SWITCH SHOWN WITH BOOM ROTATED PAST EITHER NON STEER WHEEL 4 ALL SOLENOID AND RELAY COILS ARE 24VDC EXCEPT WHERE NOTED gt SWITCH SHOWN WITH BOOM EXTENDED 6 21 Section 6 Schematics April 2007 Electrical Schematic CE Models after serial number 9346 REVA N u z22z 5855 5 BRN C7P 3 BATGND BRN C7B 3 BATGND BRN g Y py 1 CI3DELBURD C13DEL BL RD C84 wHs 8 Bans 2 4 PUE 8 4 12
112. The primary ACAUTION boom lift cylinder may fall when the barrel end pivot pin is removed if not properly supported 16 Attach an overhead crane or similar lifting device to the lug on the rod end of the primary boom lift cylinder Carefully loosen the straps and allow the primary boom lift cylinder to slowly swing down 17 Carefully remove the cylinder from the machine AWARNING C Ushing hazard The primary boom lift cylinder will fall if not properly supported when it is removed from the machine Part No 106373 A TEREX CON Z 30 20N Z 30 20N RJ PRIMARY BOOM COMPONENTS 4 4 Extension Cylinder The extension cylinder extends and retracts the primary boom extension tube The extension cylinder is equipped with counterbalance valves to prevent movement in the event of a hydraulic line failure How to Remove the Extension Cylinder AWARNING injury hazard This procedure requires specific repair skills lifting equipment and a suitable workshop Attempting this procedure without these skills and tools could result in death or serious injury and significant component damage Dealer service is strongly recommended Note When removing a hose assembly or fitting the O ring on the fitting and or hose end must be replaced and then torqued to specification during installation Refer to Section 2 Hydraulic Hose and Fitting Torque Specifications 1 Raise the primary boom to the horizontal position Ex
113. USA PN 77055 e TEREX COMPANY Part No 106373 Z 30 20N Z 30 20N RJ lii June 2008 F eH This page intentionally left blank A TEREX COMPANY iv Z 30 20N Z 30 20N RJ Part No 106373 June 2008 Section 1 Safety Rules Part No 106373 TEREX COMPANY Z 30 20N Z 30 20N RJ Safety Rules Danger Failure to obey the instructions and safety rules in this manual and the Genie Z 30 20N Operator s Manual will result in death or serious injury Many of the hazards identified in the operator s manual are also safety hazards when maintenance and repair procedures are performed Do Not Perform Maintenance Unless You are trained and qualified to perform maintenance on this machine You read understand and obey manufacturer s instructions and safety rules employer s safety rules and worksite regulations applicable governmental regulations You have the appropriate tools lifting equipment and a suitable workshop Section 1 Safety Rules June 2008 SAFETY RULES Personal Safety Any person working on or around a machine must be aware of all known safety hazards Perso
114. ailable and ready for use Read each procedure completely and adhere to the instructions Attempting shortcuts may produce hazardous conditions Unless otherwise specified perform each repair procedure with the machine in the following configuration Machine parked on a firm level surface Boom in stowed position Turntable rotated with the boom between the non steer wheels Key switch in the off position with the key removed Wheels chocked All external AC power supply disconnected from the machine Part No 106373 A TEREX Z 30 20N Z 30 20N RJ 4 1 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 order Symbols Legend Safety alert symbol used to alert personnel to potential personal injury hazards Obey all safety messages that follow this symbol to avoid possible injury or death Indicates an imminently hazardous situation which if not avoided will result in death or serious injury A DANGER Indicates a potentially hazardous AWARNING situation which if not avoided could result in death or serious injury Indicates a potentially hazardous
115. astle nut 7 Tighten the castle nut to 158 ft lbs 214 Nm to seat the bearings Note Rotate the hub by hand while torquing the castle nut to make sure the bearings seat properly 8 Loosen the castle nut one full turn and then torque to 35 ft lbs 47 Nm 9 Check for wheel bearing wear by attempting to move the wheel hub side to side then up and down Result If there is no side to side or up and down movement continue with step 10 to grease the wheel bearings W Result If there is side to side or up and down movement continue to step 10 and replace the wheel bearings with new ones Note When replacing a wheel bearing both the inner and outer bearings including the pressed in races must be replaced 10 Remove the castle nut 11 Pull the hub off of the spindle The washer and outer bearing should fall loose from the hub 12 Place the hub on a flat surface and gently pry the bearing seal out of the hub Remove the rear bearing 13 Pack both bearings with clean fresh grease Grease Specification Chevron Ultra duty grease EP NLGI 2 lithium based or equivalent Section 3 Scheduled Maintenance Procedures June 2008 CHECKLIST E PROCEDURES REV D 14 Place the large inner bearing into the rear of the hub 15 Install a new bearing grease seal into the hub by pressing it evenly into the hub until it is flush Note Always replace the bearing grease sea
116. at the beginning of a maintenance procedure it conveys the meaning below Indicates that tools will be required to perform this procedure Indicates that new parts will be required to perform this procedure Indicates that a cold motor or pump will be required to perform this procedure Indicates that dealer service will be required to perform this procedure A TEREX CON 3 2 Z 30 20N Z 30 20N RJ MPANY Maintenance Schedule There are five types of maintenance inspections that must be performed according to a schedule daily quarterly six months annual and two year The Scheduled Maintenance Procedures Section and the Maintenance Inspection Report have been divided into five subsections A B C D and E Use the following chart to determine which group s of procedures are required to perform a scheduled inspection Inspection Checklist Daily or every 8 hours A Quarterly or every 250 hours A B Six months or every 500 hours A B C Annual or every 1000 hours A B C D Two year or every 2000 hours A B C D E 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 Maintain completed forms for a minimum of 4 years or in compliance with employer jobsite and govermental regulations and requirements Part No 106373 Pre Delivery Preparation
117. at the jib boom rotate manifold Cap the fittings on the manifold AWARNING Bodily injury hazard Spraying hydraulic oil can penetrate and burn skin Loosen hydraulic connections very slowly to allow the oil pressure to dissipate gradually Do not allow oil to squirt or spray Section 4 Repair Procedures June 2008 SECONDARY BOOM COMPONENTS 13 Remove the hose clamp from the side of the primary boom at the pivot end 14 Remove the primary boom extend drive speed limit switch LS1 mounted on the side of the primary boom at the pivot end Do not disconnect the wiring 15 Attach a lifting strap from an overhead crane to the pivot end of the primary boom 16 Carefully lift the secondary and primary boom assembly with the overhead crane until the master cylinder and primary boom lift cylinder hydraulic hoses are accessible 17 Remove the cable covers from the top of the upper secondary boom 18 Tag disconnect and plug the primary boom lift cylinder and master cylinder hydraulic hoses Cap the fittings on the cylinders AWARNING Bodily injury hazard Spraying hydraulic oil can penetrate and burn skin Loosen hydraulic connections very slowly to allow the oil pressure to dissipate gradually Do not allow oil to squirt or spray 19 Lower the secondary boom to the fully stowed position 20 Pull all the cables and hoses through the upper pivot Component damage hazard Cables and hoses can be damaged if they are
118. ate gradually Do not allow oil to squirt or spray Bodily injury hazard Beware of ACAUTION hot oil Contact with hot oil may cause severe burns 33 Remove the hydraulic tank mounting fasteners Remove the hydraulic tank from the machine 34 Open the ground controls side turntable cover 35 Remove the terminal strip cover retaining fasteners Remove the cover 36 Remove the terminal strip retaining fasteners Do not disconnect the wiring 37 Remove the plastic plug in the bulkhead to access the secondary boom lift cylinder rod end pivot pin 38 Remove the pin retaining fastener from the rod end of the secondary boom lift cylinder Use a soft metal drift to remove the pin through the access holes in the bulkheads Secure the cylinder from moving 39 Remove the pin retaining fastener from the lower pivot pin on the compression link Use a soft metal drift to remove the pin Section 4 Repair Procedures June 2008 SECONDARY BOOM COMPONENTS 40 Attach a lifting strap from an overhead crane to the upper secondary boom 41 Remove the pin retaining fastener from the mid pivot to upper secondary boom pivot pin Use a soft metal drift to remove the pin 42 Remove the upper secondary boom with compression link from the machine AWARNING Crushing hazard The upper secondary boom with compression link could become unbalanced and fall when removed from the machine if not properly supported by the overhead crane
119. aulic oil can penetrate and burn skin Loosen hydraulic connections very slowly to allow the oil pressure to dissipate gradually Do not allow oil to squirt or spray 51 Use a slide hammer to remove the barrel end pivot pins access the pins from the access holes in the bulkheads one on each side Remove the secondary boom lift cylinder from the machine AWARNING Crushing hazard The secondary boom lift cylinder could become unbalanced and fall when removed from the machine if not properly supported by the overhead crane Part No 106373 June 2008 Section 4 Repair Procedures REV 52 Attach a lifting strap from an overhead crane to the mid pivot for support 53 Remove the pin retaining fasteners from the mid pivot to the lower secondary compression arm pivot pins Use a slide hammer and remove the pins Lower the compression arms down 54 Remove the pin retaining fasteners from the mid pivot to the lower secondary boom pivot pin Use a soft metal drift to remove the pins 55 Remove the mid pivot from the machine AWARNING Crushing hazard The mid pivot could become unbalanced and fall when removed from the machine if not properly supported by the overhead crane 56 Remove the secondary boom drive speed limit switch LS4 mounted to the turntable riser on the ground controls side Do not disconnect the wiring 57 Attach a lifting strap from an overhead crane to the ground control side lower secondary
120. boom tube Place the extension tube on blocks for support Part No 106373 A TEREX CON Z 30 20N Z 30 20N RJ PRIMARY BOOM COMPONENTS Note During removal the overhead crane strap will need to be carefully adjusted for proper balancing 7 Remove the external snap rings from the slave cylinder barrel end pivot pin 8 Use soft metal drift and drive the slave cylinder barrel end pivot pin out 9 Remove the slave cylinder from the primary extension boom tube 10 Remove the external snap rings from the extension cylinder rod end pivot pins at the platform end of the extension tube Use a soft metal drift to remove the pins 11 Support and slide the extension cylinder out of the pivot end of the boom extension tube Place the extension cylinder on blocks for support Note During removal the overhead crane strap will need to be carefully adjusted for proper balancing Section 4 Repair Procedures June 2008 PRIMARY BOOM COMPONENTS 4 3 Primary Boom Lift Cylinder The primary boom lift cylinder raises and lowers the primary boom The primary boom lift cylinder is equipped with counterbalance valves to prevent movement in the event of a hydraulic line failure How to Remove the Primary Boom Lift Cylinder AWARNING injury hazard This procedure requires specific repair skills lifting equipment and a suitable workshop Attempting this procedure without these skills and tools could result
121. cedures June 2008 Manifolds 7 1 Function Manifold Components The function manifold is locate behind the ground controls turntable cover Index Schematic No Description Item Function 1 Solenoid valve 3 position 4 way Platform level up down 2 Counterbalance valve Bons Platform level down 3 Counterbalance valve Platform level up 4 Relief valve 1100 psi 75 8 bar Turntable rotate left right 5 Relief valve 1600 psi 110 stints Secondary boom down 6 Relief valve 1600 psi 110 Primary boom down 7 Proportional solenoid valve El eet System flow regulating circuit 8 Check valve Ice Brake circuit 9 Solenoid valve 3 position 4 way J eese Steer left right 10 Solenoid valve 3 position 4 way Primary boom extend retract 11 Pressure switch M Brake circuit 12 Solenoid valve N C poppet Brake circuit 13 Orifice 0 045 inch 1 14 mm Brake circuit This list continues Please turn the page REV D Torque 20 25 ft lbs 27 34 Nm 20 25 ft lbs 27 34 Nm 20 25 ft lbs 27 34 Nm 30 35 ft lbs
122. damage 26 Remove the pin retaining fastener from the primary boom pivot pin 27 Remove the primary boom pivot pin with a soft metal drift Carefully remove the primary boom assembly from the machine AWARNING C shing hazard The primary boom assembly could become unbalanced and fall when removed from the machine if not properly supported by the overhead crane Part No 106373 June 2008 Section 4 Repair Procedures REV How to Disassemble the Primary Boom Note Complete disassembly of the boom is only necessary if the outer or inner boom tubes must be replaced The extension cylinder can be removed without completely disassembling the boom See 4 4 How to Remove the Extension Cylinder 1 Remove the primary boom 4 2 How to Remove the Primary Boom 2 Place blocks under the extension cylinder for support 3 Remove the retaining fasteners from the extension cylinder barrel end pivot pin Use a soft metal drift to remove the pin 4 Remove and label the location of the wear pads from the top side of the boom tube at the platform end of the boom Note Pay careful attention to the location and amount of shims used with each wear pad 5 Support the extension tube with an overhead crane at the platform end of the boom AWARNING Crushing hazard The boom extension tube could fall when removed from the boom if not properly supported 6 Support and slide the extension tube out of the primary
123. e cotter pin to lock it in place Note Always use a new cotter pin when installing a castle nut 11 Install the dust cap then the tire and wheel assembly 12 Lower the machine and remove the blocks 13 Torque the wheel lug nuts to specification Refer to Section 2 Specifications Section 4 Repair Procedures June 2008 Motor Controller 10 1 Motor Controller The drive motor controller is located under the non steer end drive chassis cover The drive motor controller can recognize machine drive malfunctions and display controller fault codes by flashing a LED at the ground controls and on the motor controller See the Fault Code section of this manual for a list of fault codes and additional information There are no adjustments needed on the drive joystick controller For further information or assistance consult the Genie Industries Service Department REV B 5 Connect the leads from an ohmmeter to test each motor controller terminal combination listed below and check the forward reverse bias diode test Result All desired results must be within the specified range If any test has a result not within the specified range replace the motor controller Forward Bias Test Desired result Positive Lead Negative Lead M 0 4 to 0 45 How to Test the Motor Controller B M 04 to 0 45 Note Use the following procedure to test the motor F1 0
124. e machine if not properly supported by the overhead crane Section 4 Repair Procedures June 2008 Hydraulic Pumps REVA 6 1 Auxiliary and Function Pump How to Remove the Auxiliary Pump or Function Pump Note When removing a hose assembly or fitting the O ring on the fitting and or hose end must be replaced and then torqued to specification during installation Refer to Section 2 Hydraulic Hose and Fitting Torque Specifications 1 Close the hydraulic shutoff valve located at the hydraulic tank Component damage hazard The machine must not be operated with the hydraulic tank shutoff valve in the closed position or component damage will occur If the tank valve is closed remove the key from the key switch and tag the machine to inform personnel of the condition 2 Tag disconnect and plug the hydraulic hoses from the pump Cap the fittings on the pump AWARNING Bodily injury hazard Spraying hydraulic oil can penetrate and burn skin Loosen hydraulic connections very slowly to allow the oil pressure to dissipate gradually Do not allow oil to squirt or spray 3 Remove the pump mounting bolts from the pump Carefully remove the pump from the electric motor TEREX COMPANY 4 30 Z 30 20N Z 30 20N RJ Part No 106373 June 2008 Section 4 Repair Procedures Ea This page intentionally left blank A TEREX COMPANY Part No 106373 Z 30 20N Z 30 20N RJ 4 31 Section 4 Repair Pro
125. e not discovered and repaired in a timely fashion 1 Check the tire surface and sidewalls for cuts cracks and unusual wear 2 Check each wheel for damage bends and cracks 3 Check each lug nut for proper torque Refer to Section 2 Specifications PartNo 106373 Z 30 20N Z 30 20N RJ Confirm the Proper Brake Configuration Note Genie specifications require that this procedure be performed every 250 hours or quarterly whichever comes first Proper brake configuration is essential to safe operation and good machine performance Hydraulically released spring applied individual wheel brakes can appear to operate normally when they are actually not fully operational 1 Check each drive hub disconnect cap to be sure it is in the engaged position hh o disengaged position engaged position Section 3 Scheduled Maintenance Procedures June 2008 CHECKLIST B PROCEDURES REVE B 6 B 7 Check the Oil Level in the Drive Test the Ground Control Hubs and Mounting Bolt Torque Override Note Genie specifications require that this procedure be performed every 250 hours or quarterly whichever comes first Failure to maintain proper drive hub oil levels including proper drive hub fastener torque may cause the machine to perform poorly and continued use may cause component damage 1 Drive the machine to rotate the hub until one of the plugs is located on top and the other is at 90 degrees a drive hub plugs
126. e right Continue holding the toggle switch until air stops coming out of the bleed valve Close the bleed valve b b AWARNING Crushing hazard Keep clear of c the platform during rotation 7 Remove the hose from the bleed valve and clean up any hydraulic oil that may have spilled 8 Rotate the platform fully in both directions and inspect the bleed valves for leaks clear hose top bleed valve bottom bleed valve container 4 Move the function enable toggle switch to either side and hold the platform rotate toggle switch to the left position until the platform is fully rotated to the left Continue holding the toggle switch until air stops coming out of the bleed valve Close the bleed valve AWARNING Crushing hazard Keep clear of the platform during rotation A TEREX COMPANY 4 6 2 30 20 Z 30 20N RJ Part No 106373 June 2008 Section 4 Repair Procedures REVC 2 3 Platform Overload System How to Calibrate the Platform Overload System Calibration of the platform overload system is essential to safe machine operation Continued use of an improperly calibrated platform overload system could result in the system failing to sense an overloaded platform The stability of the machine is compromised and it could tip over Note Perform this procedure with the machine on a firm level surface 1 Turn the key switch to platform control 2 Determine the maxi
127. e sure that the battery cable connections are free of corrosion Note Adding terminal protectors and a corrosion preventative sealant will help eliminate corrosion on the battery terminals and cables A TEREX CON Z 30 20N Z 30 20N RJ MEANY REV E 5 sure thatthe battery retainers and cable connections are tight 6 Fully charge the batteries Allow the batteries to rest 24 hours before continuing this procedure to allow the battery cells to equalize 7 Puton protective clothing and eye wear 8 Remove the battery vent caps and check the specific gravity of each battery cell with a hydrometer Note the results 9 Check the ambient air temperature and adjust the specific gravity reading for each cell as follows Add 0 004 to the reading of each cell for every 10 5 5 C above 80 F 26 7 C Subtract 0 004 from the reading of each cell for every 10 5 5 below 80 26 7 Result All battery cells display an adjusted specific gravity of 1 277 or higher The battery is fully charged Proceed to step 13 Result One or more battery cells display specific gravity of 1 217 or below Proceed to step 10 10 Perform an equalizing charge OR fully charge the batteries and allow the batteries to rest at least 6 hours 11 Remove the battery vent caps and check the specific gravity of each battery cell with a hydrometer Note the results Part No 106373 2008
128. e the pin from the cylinder Do not remove the pin from the upper pivot Push the pin to one side only far enough to remove the cylinder The pin should remain in one side of the upper secondary boom and upper pivot AWARNING Crushing hazard The upper secondary boom and the upper pivot could fall if the pivot pin is completely removed 10 Use the strap around the rod end lug to lower the cylinder out of the machine A TEREX COMPANY Part No 106373 Z 30 20N Z 30 20N RJ 4 21 Section 4 Repair Procedures June 2008 Secondary Boom Components Secondary Boom a upper pivot upper compression arm mid pivot compression link lower secondary boom lower compression arm turntable pivot counterweight upper secondary boom TEREX COMPANY 4 22 2 30 20 Z 30 20N RJ 106373 June 2008 EE REV B 5 1 Secondary Boom How to Disassemble the Secondary Boom AWARNING injury hazard The procedures in this section require specific repair skills lifting equipment and a suitable workshop Attempting this procedure without these skills and tools could result in death or serious injury and significant component damage Dealer service is required Note When removing a hose assembly or fitting the O ring on the fitting and or hose end must be replaced and then torqued to specification d
129. ection 2 Hydraulic Hose and Fitting Torque Specifications 1 Remove the platform 2 Remove the platform mounting weldment and the platform rotator See 2 2 How to Remove the Platform Rotator 3 Tag disconnect and plug the jib boom lift cylinder hydraulic hoses Cap the fittings on the jib boom lift cylinder AWARNING Bodily injury hazard Spraying hydraulic oil can penetrate and burn skin Loosen hydraulic connections very slowly to allow the oil pressure to dissipate gradually Do not allow oil to squirt or spray 4 Remove the cable cover from the side of the jib boom 5 Remove the mounting fasteners from the jib boom platform rotate manifold and lay the manifold to the side Do not remove the hoses or disconnect the wiring Component damage hazard Hoses and cables can be damaged if they are kinked or pinched TEREX COMPANY Jib Boom Components 6 Models with rotating jib boom Tag disconnect and plug the hydraulic hoses from the jib boom rotator Cap the fittings on the rotator manifold AWARNING Bodily injury hazard Spraying hydraulic oil can penetrate and burn skin Loosen hydraulic connections very slowly to allow the oil pressure to dissipate gradually Do not allow oil to squirt or spray 7 Attach a lifting strap from an overhead crane to the jib boom Models without rotating jib boom Remove the pin retaining fastener from the jib boom pivot pin at the jib boom bellcrank Use a soft
130. ed loop See 2 2 How to Bleed the Slave Cylinder 1 Remove the counterweight cover 2 Raise the secondary boom until the master cylinder barrel end pivot pin is above the turntable counterweights 3 Raise the primary boom until the master cylinder rod end pivot pin is accessible Part No 106373 June 2008 Section 4 Repair Procedures aaa REV B PRIMARY BOOM COMPONENTS 4 Attach an overhead crane to the pivot end of the primary boom for support Do not lift it 5 Secure the upper secondary boom to the pivot end of the primary boom with a strap this will prevent the upper secondary boom from falling when the master cylinder barrel end pivot pin is removed from the cylinder 6 Tag disconnect and plug the master cylinder hydraulic hoses Cap the fittings on the cylinder AWARNING injury hazard Spraying ydraulic oil can penetrate and burn skin Loosen hydraulic connections very slowly to allow the oil pressure to dissipate gradually Do not allow oil to squirt or spray 7 Attach a lifting strap from an overhead crane to the lug on the rod end of the master cylinder then secure the strap to the primary boom use this strap to lower the master cylinder out of the upper pivot 8 Remove the pin retaining fastener from the master cylinder rod end pivot pin Use a soft metal drift to remove the pin 9 Remove the pin retaining fastener from the master cylinder barrel end pivot pin Use a soft metal drift to remov
131. ee of debris that could get into machine components and cause damage Be sure that all tools and working areas other lifting or supporting device is fully capable of supporting and stabilizing the weight to be lifted Use only chains or straps that are in good condition and of ample capacity i Be sure any forklift overhead crane or Be sure jos fasteners intended for one time use i e cotter pins and self locking nuts are not reused These components may fail if they are used a second time oy Be sure to properly dispose of old oil or other fluids U d contai 3 other fluids Use an approved container Please be environmentally safe Be sure that your workshop or work area is properly ventilated and well lit Part No 106373 Introduction Section 1 Section 2 Section Rev E Rev Section 1 Safety Rules Table of Contents Important Information 0 Serial li Serial nennen nnn nennen enne nnn iii Safety Rules General Safety Rules a i Specifications Machine Specifications 00220 11010 aiaa nennen 2 1 Performance Specifications 2 1 Hydraulic Specifications nen
132. en the valve on the hydraulic tank and drain the oil into a container of suitable capacity Refer to Section 2 Specifications Bodily injury hazard Beware of ACAUTION hot oil Contact with hot oil may cause severe burns 9 Tag disconnect and plug the hydraulic hose from the hydraulic tank return filter housing Cap the fitting on the filter housing AWARNING Bodily injury hazard Spraying hydraulic oil can penetrate and burn skin Loosen hydraulic connections very slowly to allow the oil pressure to dissipate gradually Do not allow oil to squirt or spray Bodily injury hazard Beware of ACAUTION hot oil Contact with hot oil may cause severe burns Part No 106373 June 2008 Section 4 Repair Procedures REV 10 Remove the hydraulic tank mounting fasteners Remove the hydraulic tank from the machine 11 Open the ground controls side turntable cover 12 Remove the terminal strip cover retaining fasteners Remove the cover 13 Remove the terminal strip retaining fasteners Do not disconnect the wiring 14 Remove the plastic plug in the bulkhead to access the secondary boom lift cylinder rod end pivot pin 15 Remove the mounting fasteners from the function manifold and slide the manifold to the side This will allow access to the hydraulic tank side barrel end pivot pin 16 Attach a lifting strap from an overhead crane to the lug on the rod end of the secondary boom lift cylinder 17 From the bott
133. epair skills lifting equipment and a suitable workshop Attempting this procedure without these skills and tools could result in death or serious injury and significant component damage Dealer service is strongly recommended Note When removing a hose assembly or fitting the O ring on the fitting and or hose end must be replaced and then torqued to specification during installation Refer to Section 2 Hydraulic Hose and Fitting Torque Specifications 1 Rotate the turntable to either side until the boom is centered between the steer and non steer tires 2 Raise the primary boom to full height Do not extend it 3 Swing out the battery pack that is directly below the secondary boom lift cylinder 4 Disconnect the battery packs from the machine TEREX CON Z 30 20N Z 30 20N RJ MEANY REV B 5 Open the hydraulic tank side turntable cover 6 Tagand disconnect the power cables on the auxiliary power unit AWARNING Electrocution burn hazard Contact with electrically charged circuits could result in death or serious injury Remove all rings watches andother jewelry 7 Close the hydraulic tank shutoff valve Tag and disconnect and plug the hydraulic hose from the hydraulic tank shutoff valve AWARNING injury hazard Spraying ydraulic oil can penetrate and burn skin Loosen hydraulic connections very slowly to allow the oil pressure to dissipate gradually Do not allow oil to squirt or spray 8 Op
134. erating conditions 1 Measure each wear pad Replace the wear pad once it reaches the minimum allowable thickness If the wear pad is still within specifications shim as necessary to obtain minimum clearance with zero binding 2 Extend and retract the primary boom through the entire range of motion to check for tight spots that could cause binding or scraping Note Always maintain squareness between the primary boom outer and inner tubes Part No 106373 Z 30 20N Z 30 20N RJ Models without rotating jib boom Primary boom wear pad specifications Minimum Top and side wear pads 5 8 inch extension end of boom 15 9 mm Bottom wear pads 5 inch extension end of boom 15 9 mm Bottom and side wear pads 5 8 inch pivot end of boom 15 9 mm Top wear pads 3 8 inch pivot end of boom 9 5mm Models with rotating jib boom Primary boom wear pad specifications Minimum All wear pads 3 8 inch 9 5 3 23 Section 3 Scheduled Maintenance Procedures June 2008 CHECKLIST D PROCEDURES D 2 Check the Free wheel Configuration Note Genie specifications require that this procedure be performed every 1000 hours or annually whichever comes first Proper use of the free wheel configuration is essential to safe machine operation The free wheel configuration is used primarily for towing A machine configured to free wheel without operator knowledge may cause death or serious injury and proper
135. f any inspection receives an N remove the machine from service repair and re inspect it After repair place a check in the R box Legend yes completed N no unable to complete repaired Comments Pre Delivery Preparation Y N R Pre operation inspection completed Maintenance items completed Function tests completed Model Serial number Date Machine owner Inspected by print Inspector signature Inspector title Inspector company Section 3 Scheduled Maintenance Procedures June 2008 SSS SSS Ey This page intentionally left blank TEREX COMPANY 3 4 Z 30 20N Z 30 20N RJ Part No 106373 Maintenance Inspection Report Model Serial number Date Hour meter Machine owner Inspected by print Inspector signature Inspector title Inspector company Instructions Make copies of this page to use for each inspection Select the appropriate checklist s for the type of inspection to be performed Daily or 8 hour Inspection A Quarterly or 250 hour Inspection A B Six Month or 500 hour Inspection A B C Annual or 1000 hours Inspection A B C D 2 Year or 2000 hour Inspection A B C D E Place a check in the appropriate box after each inspection procedure is completed Use the step by step procedures in this section to learn how to perform these inspections If any inspection receives an N tag and remove the machine from serv
136. f circuit connected to the B terminal on the motor controller Z 30 20N Z 30 20N RJ Part No 106373 June 2008 Section 5 Fault Codes REVA Fault Code Programmer Condition Possible Causes Diagnostic Display FAULT CODE CHART MISSING CONTACTOR Machine will not drive MAIN CONT DNC LOW BATTERY VOLTAGE OVERVOLTAGE THERMAL CUTBACK Machine will not drive Machine will not drive Machine will not drive Machine will not drive Part No 106373 Motor controller does not detect the main contactor PR1 or brake release relay CR5 Main contactor PR1 or brake release relay CR5 did not close OR open in org red wire to PR1 and or CR5 OR main contactor and or brake release relay is defective Battery supply voltage to motor controller less than 32V DC Battery supply voltage to motor controller more than 55V DC OR machine is being operated with the battery charger plugged in Machine being operated outside of temperature range of 13 F to 185 F 25 C to 85 OR machine being driven under excessive load OR motor controller is not being cooled sufficently Consult Genie Industries Service Department Consult Genie Industries Service Department Completely charge batteries OR check battery cable condition OR check for corrosion or loose connections at battery terminals and motor controller Be sure the battery charger is disconnected OR check for loose
137. form overload indicator lights are not flashing Calibrate the platform overload system Refer to Repair Proceedure 2 3 How to Calibrate the Platform Overload System if equipped Note There may be a 2 second delay before the overload indicator lights flash and the alarm sounds Section 3 Scheduled Maintenance Procedures June 2008 CHECKLIST C PROCEDURES 7 Carefully move the test weights to each remaining location on the platform Refer to Illustration 1 Result The alarm should sound The platform overload indicator lights should be flashing at both the ground and platform controls Result The alarm does not sound and the platform overload indicator lights are not flashing Calibrate the platform overload system Refer to Repair Proceedure 2 3 How to Calibrate the Platform Overload System if equipped Note There may be a 2 second delay before the overload indicator lights flash and the alarm sounds 8 Test all machine functions from the platform controls Result All platform control functions should not operate 9 Turn the key switch to ground control 10 Test all machine functions from the ground controls Result All ground control functions should not operate 11 Using auxiliary power test all machine functions from the ground controls Result All ground control functions should operate A TEREX COMI Z 30 20N Z 30 20N RJ REV D 12 Using a suitable lifting
138. he two plugs is at the lowest point 2 Remove both plugs and drain the oil into a suitable container 3 Drive the machine until one plug is at the top and the other is at 90 degrees a drive hub plugs 4 Fill the hub with oil from the top hole until the oil level is even with the bottom of the side plug hole Refer to Section 2 Specifications 5 Install the plugs into the drive hub 6 Repeatthis procedure for the other drive hub PartNo 106373 Z 30 20N Z 30 20N RJ 3 9 Section 3 Scheduled Maintenance Procedures June 2008 Checklist B Procedures B 1 Check the Batteries Note Genie specifications require that this procedure be performed every 250 hours or quarterly whichever comes first Proper battery condition is essential to good machine performance and operational safety Improper fluid levels or damaged cables and connections can result in component damage and hazardous conditions AWARNING Electrocution burn hazard Contact with hot or live circuits could result in death or serious injury Remove all rings watches and other jewelry AWARNING Bodily injury hazard Batteries contain acid Avoid spilling or contacting battery acid Neutralize battery acid spills with baking soda and water 1 Disconnect each battery pack from the machine 2 Release the battery pack latches and rotate each battery pack out and away from the chassis 3 Remove the cover from each battery box 4 B
139. hose assembly or fitting the O ring on the fitting and or hose end must be replaced and then torqued to specification during installation Refer to Section 2 Hydraulic Hose and Fitting Torque Specifications 1 Extend the boom until the slave cylinder barrel end pivot pin is accessible 2 Raise the boom slightly and place blocks under the platform for support Lower the boom until the platform is resting on the blocks A TEREX CON Z 30 20N RJ 2 30 20 MEANY REVC 3 Tag and disconnect the hydraulic hoses to the slave cylinder at the union and connect them together with a connector Cap the fittings on the cylinder hoses AWARNING Bodily injury hazard Spraying hydraulic oil can penetrate and burn skin Loosen hydraulic connections very slowly to allow the oil pressure to dissipate gradually Do not allow oil to squirt or spray 4 Remove the external snap rings from the rod end pivot pin Do not remove the pin 5 Remove the external snap rings from the barrel end pivot pin 6 Place a block of wood under the barrel of the slave cylinder for support 7 Usea soft metal drift to remove the rod end pivot pin AWARNING Crushing hazard The platform could fall if not properly supported 8 Use a soft metal drift to remove the barrel end pivot pin 9 Carefully pull the cylinder with hydraulic hoses out of the boom AWARNING Crushing hazard The slave cylinder could fall if not properly supported Ho
140. ice repair and re inspect it After repair place a check in the R box Legend Y yes acceptable no remove from service R repaired Checklist A Rev D Y NR Checklist C Rev D YNR A 1 Manuals and decals 2 Pre operation inspection A 3 Function tests Perform after 40 hours A 4 30 Day Service Perform every 100 hours A 5 Grease rotation bearing Perform after 150 hours A 6 Replace drive hub oil Checklist Rev Y NR B 1 Batteries B 2 Electrical wiring B 3 Key switch B 4 Tires and Wheels B 5 Brake configuration B 6 Drive hub oil level B 7 Ground control override B 8 Platform leveling B 9 Drive brakes B 10 Drive speed stowed B 11 Drive speed raised B 12 Alarm package if equipped B 13 Turntable rotation stop B 14 Electrical contactors B 15 Hydraulic oil analysis Comments C 1 Grease platform overload if equipped C 2 Test platform overload if equipped Checklist D Rev D Y NR D 1 Boom wear pads 0 2 Free wheel configuration D 3 Turntable bearing bolts 0 4 Drive hub oil D 5 Hydraulic return filter D 6 Turntable bearing wear Checklist E Rev D E 1 Hydraulic oil E 2 Wheel bearings Y NR Section 3 Scheduled Maintenance Procedures June 2008 Checklist A Procedures A 1 Inspect the Manuals and Decals Note Genie s
141. in death or serious injury and significant component damage Dealer service is strongly recommended Note When removing a hose assembly or fitting the O ring on the fitting and or hose end must be replaced and then torqued to specification during installation Refer to Section 2 Hydraulic Hose and Fitting Torque Specifications 1 Raise the secondary boom enough to access the primary boom lift cylinder barrel end pivot pin 2 Raise the primary boom enough to access the primary boom lift cylinder rod end pivot pin 3 Support the primary boom lift cylinder with a suitable lifting device Place a block of wood across the upper secondary boom to support the cylinder when the rod end pin is removed A TEREX CON Z 30 20N Z 30 20N RJ MPANY REV 4 Attach an overhead crane to the primary boom at the platform end for support Raise the primary boom using the overhead crane just enough to relieve the pressure on the primary boom lift cylinder rod end pivot pin 5 Remove the counterweight cover fasteners Remove the counterweight cover from the machine 6 Place a block of wood between the counterweight plate on the leveling link and the cross member of the upper secondary boom Carefully lower the secondary boom onto the block AWARNING C ushing hazard Keep hands away from the block and all moving parts when lowering the secondary boom onto the block 7 Remove the pin retaining fasteners from the primary boom
142. in death or serious injury Remove all rings watches and other jewelry 1 Remove the drive chassis cover from the non steer end of the machine 2 Inspect the following areas for burnt chafed corroded and loose wires Electrical power panel Electrical relay panel Ground control panel Function manifold wiring Section 3 Scheduled Maintenance Procedures June 2008 CHECKLIST B PROCEDURES 3 Turn the key switch to ground controls and pull out the red Emergency Stop button to the on position at both the ground and platform controls 4 Raise the secondary boom until the mid pivot is approximately 10 feet 3 m off the ground 5 Inspect the turntable center area for burnt chafed and pinched cables 6 Lower the boom to the stowed position and turn the machine off 7 Inspect the following areas for burnt chafed corroded pinched and loose wires Cable track on the primary boom Primary boom to platform cable harness Inside of the platform control box 8 Inspect for a liberal coating of dielectric grease atthe following location All wire harness connectors to the platform control box All wire harness connectors located under the ground control side turntable cover Harness connector to the drive motor controller located in the non steer end of the drive chassis A TEREX CON Z 30 20N Z 30 20N RJ REV E B 3 Test the Key Switch Note Genie specifications require that this
143. ing condition and component damage 1 Raise the secondary boom and place a safety chock on the secondary boom lift cylinder Carefully lower the secondary boom onto the lift cylinder safety chock AWARNING Crushing hazard Keep hands away from the cylinder and all moving parts when lowering the secondary boom Note A lift cylinder safety chock is available through Genie Service Parts Genie part no 36555 2 Confirm that each turntable mounting bolt is torqued in sequence to specification Refer to Section 2 Specifications a c 4 7 vo 0 i oo T 8 10 Bolt torque sequence Part No 106373 CHECKLIST D PROCEDURES Raise the secondary boom and remove the safety chock Lower the secondary boom to the stowed position Open the latch on the battery packs and swing them out to expose the turntable bearing bolt access hole Confirm that each turntable bearing mounting bolt is torqued in sequence to specification Refer to Section 2 Specifications 1 4 O 7 O N 60 3 N T dm 2 c 5 8 Bolt torque sequence Z 30 20N Z 30 20N RJ Section 3 Scheduled Maintenance Procedures June 2008 CHECKLIST D PROCEDURES D 4 Replace the Drive Hub Oil Note Genie specifications require that this procedure be performed every 1000 hours or annually whichever comes first Replacing the drive hub oil is essential for good machine perf
144. intentionally left blank June 2008 Section 2 Specifications REV Machine Specifications Tires and wheels Specifications Performance Specifications Drive speed maximum 22 x7 18 4 in 56 18 47 Tire size solid rubber Load range 7600 16 3447 kg Overall tire diameter 22 in 56 cm Wheel diameter 18 4 in 47 Wheel width 18 Wheel lugs Front 8 6 8 Rear 9 5 8 18 Lug nut torque dry 125 ft lbs 169 5 Nm Lug nut torque lubricated 94 ft lbs 127 4 Nm Fluid Capacities Hydraulic tank capacity 4 gallons 15 1 liters Hydraulic system capacity 6 gallons including tank 22 7 liters Drive hubs 61 1 23 ounces 0 68 liter 62 5 1 25 6 ounces 0 76 liter Drive hub oil type SAE 90 multipurpose hypoid gear oil API service classification GL5 Continuous improvement of our products is a Genie policy Product specifications are subject to change without notice Part No 106373 A TEREX Z 30 20N Z 30 20N RJ Stowed position 3 3 mph 5 3 km h 40 ft 8 2 sec 12 2 8 2 sec Boom raised or extended Braking distance maximum 0 6 mph 1 km h 40 ft 44 sec 12 2 m 44 sec High range on paved surface Gradeability 2 to 4 ft 0 6 to 1 2m See Operator s Manual Boom function speeds maximum from platform controls with rated load secured to platform Jib boom up
145. ivated the system halts all normal boom operation giving visual and audible warning to the operator Models equipped with the platform overload option are provided with additional machine components an adjustable spring loaded platform support subassembly a limit switch an electronic module which receives the overload signal and interrupts power and an audio visual warning indication to alert the operator of the overload MPANY Part No 106373 June 2008 Section 3 Scheduled Maintenance Procedures REV D The platform support subassembly utilizes two load support arms that are opposed in a full parallelogram link This isolates platform loads into a shear or vertical state which translates into a compressive load A spring in the parallelogram link supports this purely compressive load regardless of where the load is placed in the platform As weight is added to the platform the spring will compress until when the platform is overloaded the lower arm contacts a limit switch and thereby activating the overload signal When adjusted correctly the platform overload system will deactivate normal boom operation at platform capacity Note Perform this procedure with the machine on a firm level surface 1 Turn the key switch to platform control Start the engine and level the platform 2 Determine the maximum platform capacity Refer to the machine serial plate 3 Remove all weight tools and accessories from
146. jib boom bell crank at the extension boom Use a soft metal drift to remove the pin Use a soft metal drift to remove the slave cylinder rod end pivot pin 10 Remove the jib boom bell crank from the extension boom AWARNING Cushing hazard The jib boom bell crank could become unbalanced and fall when the pins are removed if not properly supported and secured to the lifting device Z 30 20N RJ 4 11 2 30 20 Section 4 Repair Procedures June 2008 JIB BOOM COMPONENTS How to Bleed the Jib Boom Rotator Note This procedure will require two people 1 Turn the key switch to ground controls and pull out the red Emergency Stop buttons to the on position at both the ground and platform controls 2 Connect a clear hose to the top bleed valve Place the other end of the hose in a container to collect any drainage Open the top bleed valve but do not remove it bleed valve b clear hose 0 container d bottom bleed valve 3 Move and hold the function enable toggle switch to either side and move and hold the jib boom rotate toggle switch to the right for approximately 5 seconds then release it Repeat three times AWARNING Crushing hazard Keep hands and head clear of the platform pivot weldment during rotation TEREX COMPAN REV B 4 Move and hold the function enable switch to either side and move and hold the jib boom rotate toggle switch to the left for approximate
147. l when the hub has been removed 16 Slide the hub onto the yoke spindle Component damage hazard Do not apply excessive force or damage to the lip of the seal may occur 17 Fill the hub cavity with clean fresh grease 18 Place the outer bearing into the hub 19 Install the washer and castle nut 20 Tighten the castle nut to 158 ft lbs 214 Nm to seat the bearings Note Rotate the hub by hand while torquing the castle nut to make sure the bearings seat properly 21 Loosen the castle nut one full turn and then torque to 35 ft lbs 47 Nm 22 Install a new cotter pin Bend the cotter pin to lock it in Note Always use a new cotter pin when installing a castle nut 23 Install the dust cap then the tire and wheel assembly Torque the wheel lug nuts to specification Refer to Section 2 Specifications A TEREX COMPANY 3 32 Z 30 20N Z 30 20N RJ Part No 106373 June 2008 Section 4 Repair Procedures Observe and Obey Repair procedures shall be completed by a person trained and qualified on the repair of this machine M Immediately tag and remove from service a damaged or malfunctioning machine Repair any machine damage or malfunction before operating the machine Before Repairs Start Read understand and obey the safety rules and operating instructions in the appropriate Genie Z 30 20N Operator s Manualon your machine Be sure that all necessary tools and parts are av
148. led speed range 1 Select test area that is firm level and free of obstructions 2 Create start and finish lines by marking two lines on the ground 40 feet 12 2 m apart 3 Turn the key switch to platform control and pull out the red Emergency Stop button to the on position at both the ground and platform controls 4 Choose reference point on the machine i e contact patch of a tire as a visual reference for use when crossing the start and finish lines 5 Bring the machine to maximum drive speed before reaching the start line Begin timing when your reference point on the machine crosses the start line 6 Continue at full 50660 and note the time when your machine reference point passes over the finish line Refer to Section 2 Specifications A TEREX CON Z 30 20N Z 30 20N RJ REV E B 11 Test the Drive Speed Raised or Extended Position Note Genie specifications require that this procedure be performed every 250 hours or quarterly whichever comes first Proper drive function movement is essential to safe machine operation The drive function should respond quickly and smoothly to operator control Drive performance should also be free of hesitation jerking and unusual noise over the entire proportionally controlled speed range 1 Select a test area that is firm level and free of obstructions 2 Create start and finish lines by marking two lines on the ground 40 feet 12 2 m apart 3 Turn
149. lic Motor The turntable rotation hydraulic motor is the only serviceable component of the turntable rotation assembly The worm gear must not be removed from the housing In order to remove the housing the turntable has to be removed How to Remove the Turntable Rotation Motor Note When removing a hose assembly or fitting the O ring on the fitting and or hose end must be replaced and then torqued to specification during installation Refer to Section 2 Hydraulic Hose and Fitting Torque Specifications 1 Tag disconnect and plug the hydraulic hoses from the turntable rotation motor Cap the fittings on the motor AWARNING Bodily injury hazard Spraying hydraulic oil can penetrate and burn skin Loosen hydraulic connections very slowly to allow the oil pressure to dissipate gradually Do not allow oil to squirt or spray 2 Remove the turntable rotation motor mounting bolts Remove the motor from the machine REV B TEREX COMPANY 4 42 Z 30 20N Z 30 20N RJ Part No 106373 June 2008 Section 4 Repair Procedures REV 9 1 Hub and Bearings How to Remove the Hub and Bearings 1 Loosen the wheel lug nuts Do not remove them 2 Block the non steer wheels and place a lifting jack under the steer axle 3 Raise the machine Place blocks under the drive chassis for support 4 Remove the lug nuts Remove the tire and wheel assembly 5 Remove the dust cap cotter pin and castle nut
150. lift cylinder rod end pivot pin Use a soft metal drift to remove the pin Crushing hazard The primary A CAUTION boom lift cylinder may fall if not properly supported when the rod end pivot pin is removed 8 Lower the rod end of the cylinder onto the blocks that were placed on the upper secondary boom 9 Remove the pin retaining fastener from the ground control side upper secondary leveling link pivot pin at the upper pivot same side of machine as the primary boom lift cylinder barrel end pivot pin retainer 10 Place a rod through the upper secondary leveling link pivot pin at the upper pivot and twist to remove the pin Part No 106373 June 2008 Section 4 Repair Procedures REV 11 Swing the leveling link up out of the way and secure it from moving 12 Tag disconnect and plug the primary boom lift cylinder hydraulic hoses Cap the fittings on the cylinder AWARNING Bodily injury hazard Spraying hydraulic oil can penetrate and burn skin Loosen hydraulic connections very slowly to allow the oil pressure to dissipate gradually Do not allow oil to squirt or spray 13 Support the barrel end of the primary boom lift cylinder with straps or ropes to restrict it from swinging freely 14 Remove the pin retaining fastener from the primary boom lift cylinder barrel end pivot pin Do not remove the pivot pin 15 Place a rod through the barrel end pivot pin and twist to remove the pin Crushing hazard
151. load spring adjustment nut in a counterclockwise direction in 10 increments until the overload indicator light flashes at both the platform and ground controls and the alarm sounds Proceed to step 7 W Result The overload indicator lights are flashing at the platform and ground controls and the alarm is sounding Repeat this procedure beginning with step 5 Note The platform will need to be moved up and down and allowed to settle between each adjustment Note There may be a 2 second delay before the platform overload indicator lights and alarm responds Section 4 Repair Procedures June 2008 PLATFORM COMPONENTS 7 Move the platform up and down by hand so it bounces approximately 2 5 to 5 cm 1 to 2 inches Allow the platform to settle Result The overload indicator lights are off and the alarm does not sound Proceed to step 8 Result The overload indicator lights are flashing at the platform and ground controls and the alarm is sounding Repeat this procedure beginning with step 5 Note There may be a 2 second delay before the platform overload indicator light and alarm responds 8 Addan additional 10 Ib 4 5 kg test weight to the platform O Result The overload indicator light is flashing at both the ground and platform controls and the alarm is sounding Proceed to step 9 Result The overload indicator light is off at both the ground and platform controls and the alarm does not s
152. lt Code Programmer Condition Possible Causes Diagnostic Display Push in the ground control red Emergency The key switch or Stop button to the off Emergency Stop position and wait for 5 Fault code LED COMMUNICATION button s was cycled on seconds Pull out the is off or is on ERROR Machine will not drive and off faster than 5 ground control red but not blinking seconds OR controller Emergency Stop button sensed an internal error to the on position If during start up problem persists replace the motor controller oee Replace th 12 HW FAILSAFE 1 2 3 Machine will not drive 712 motor controller Cp ace memoron failed self test controller The motor controller M SHORTED Machine will not drive nese omar short controller See Repair Test the motor between M and B Section terminals Check for loose or open connections at the drive Motor wiring is loose motors and motor OR motor is defective controller OR replace OR motor controller has the defective drive an internal short motor OR test the motor controller See Repair Section i Replace th ARM SENSOR Machine will not drive Defective motor eplace the motor controller controller i Replace th FLD SENSOR Machine will not drive Defective motor eplace the motor controller controller FIELD OPEN Machine will not drive TEREX COMPANY Part No 106373 Z 30 20N Z 30 20N RJ 5 3 Section 5 Fault Codes June 20
153. lug the hydraulic hoses from the jib boom platform rotate manifold 19 Pull all the electrical cables and hydraulic hoses out of the plastic cable track Then pull all the electrical cables and hydraulic hoses out through the boom rest pad Component damage hazard Cables and hoses can be damaged if they are kinked or pinched 20 Remove the pin retaining fastener from the master cylinder rod end pivot pin Use a soft metal drift to remove the pivot pin Pull the cylinder back and secure it from moving A TEREX CON Z 30 20N Z 30 20N RJ MANY REV B 21 Tag disconnect and plug the extension cylinder hydraulic hoses Cap the fittings on the cylinder AWARNING Bodily injury hazard Spraying hydraulic oil can penetrate and burn skin Loosen hydraulic connections very slowly to allow the oil pressure to dissipate gradually Do not allow oil to squirt or spray 22 Attach a lifting strap from an overhead crane to the primary boom lift cylinder 23 Place 2 x 4x 18 inch 5 x 10 x 46 cm support blocks under the cylinder across the secondary boom 24 Remove the pin retaining fastener from the primary boom lift cylinder rod end pivot pin Use a soft metal drift to remove the pin Crushing hazard The primary AWARNING boom lift cylinder could fall when it is removed from the machine if not properly supported 25 Lower the rod end of the primary boom lift cylinder onto support blocks Protect the cylinder rod from
154. ly 5 seconds then release it Repeat three times 5 Fully rotate the jib boom to the left and continue holding the jib boom rotate toggle switch until air stops coming out of the bleed valve Immediately release the platform rotate toggle switch and close the bleed valve AWARNING Crushing hazard Keep hands and head clear of the platform pivot weldment during rotation Rotate the jib boom to the right until the jib boom is centered Connect the clear hose to the bottom bleed valve and open the valve Rotate the jib boom to the right and continue holding the platform rotate toggle switch until air stops coming out of the bleed valve AWARNING Crushing hazard Keep hands and head clear of the jib boom during rotation 9 Close the bleed valve and remove the hose 10 Rotate the jib boom full left and right and inspect the bleed valves for leaks AWARNING Crushing hazard Keep hands and head clear of the platform pivot weldment during rotation 11 Turn the key switch to the off position and clean up any hydraulic oil that may have spilled 4 12 Z 30 20N Z 30 20N RJ Part No 106373 June 2008 Section 4 Repair Procedures REV 3 4 4 Jib Boom Lift Cylinder How to Remove the Jib Boom Lift Cylinder 5 Note When removing a hose assembly or fitting the O ring on the fitting and or hose end 6 must be replaced and then torqued to specification during installation Refer to Section 2 Hydraulic
155. m AWARNING lift cylinder could fall when the pin is removed if not properly supported by the overhead crane A TEREX CON Z 30 20N Z 30 20N RJ MEANY REV B 3 2 Jib Boom Bell Crank models without rotating jib boom How to Remove the Jib Boom Bell Crank Note Perform this procedure with the boom in the stowed position Note When removing a hose assembly or fitting the O ring on the fitting and or hose end must be replaced and then torqued to specification during installation Refer to Section 2 Hydraulic Hose and Fitting Torque Specifications 1 Remove the Jib Boom See 3 1 How to Remove the Jib Boom 2 Support and secure the jib boom bell crank to an appropriate lifting device 3 Remove the pin retaining fasteners from the slave cylinder rod end pivot pin Do not remove the pin 4 Place a block of wood under the platform leveling slave cylinder for support Protect the cylinder rod from damage 5 Remove the pin retaining fasteners from the jib boom bell crank at the extension boom Use a soft metal drift to remove the pin 6 Use a soft metal drift to remove the slave cylinder rod end pivot pin 7 Remove the jib boom bell crank from the extension boom AWARNING Crushing hazard The jib boom bell crank could become unbalanced and fall when the pins are removed if not properly supported and secured to the lifting device Part No 106373 June 2008 Section 4 Repair Procedures R
156. mber 8354 Section 6 Schematics April 2007 Power Cable Diagram after serial number 8354 A B LEFT SIDE BATTERY PACK AP2 Genie NOTE WIRE GAUGE NOTED IN PAENTHESES AFTER WIRE COLOR PRIMARY LIFT PUMP Sj e PRIMARY LIFT PUMP CONTACTOR PR2 CURTIS SEPEX MOTOR CONTROLLER F2 1 COMPANY 6 7 2 30 20 Z 30 20N RJ Part No 106373 BK 2 RD 10 AMMETER BK 10 WH 10 2 CHARGER BK 4 8 D1 lt 24V 5 100 AUXILIARY LIFT PUMP CONTACTOR PR3 BK 2 F2 LEFT SIDE DRIVE MOTOR RIGHT SIDE DRIVE MOTOR AUXILIARY LIFT PUMP BK 2 AP1 L RIGHT SIDE BATTERY PACK RD 2 REV A April 2007 Section 6 Schematics n Power Panel Diagram
157. metal drift to remove the pin then remove the jib boom from the jib boom bellcrank AWARNING C shing hazard The jib boom could fall when the pin is removed if not properly supported by the overhead crane Models with rotating jib boom Remove the pin retaining fastener from the jib boom pivot pin at the jib boom rotator Use a soft metal drift to remove the pin then remove the jib boom from the jib boom rotator AWARNING Crushing hazard The jib boom could fall when the pin is removed if not properly supported by the overhead crane Part No 106373 2 30 20 Z 30 20N RJ 4 9 Section 4 Repair Procedures June 2008 JIB BOOM COMPONENTS 9 Remove the pin retaining fasteners from the jib boom lift cylinder rod end pivot pin Do not remove the pin 10 Models without rotating jib boom Remove both of the jib boom leveling links from the bell crank Models with rotating jib boom Remove both of the jib boom leveling links from the jib boom rotator 11 Attach a lifting strap from an overhead crane to the rod end of the jib boom lift cylinder 12 Models without rotating jib boom Use a soft metal drift to remove the jib boom lift cylinder rod end pivot pin Remove the jib boom lift cylinder from the bell crank Models with rotating jib boom Use a soft metal drift to remove the jib boom lift cylinder rod end pivot pin Remove the jib boom lift cylinder from the jib boom rotator Crushing hazard The jib boo
158. mum platform capacity Refer to the machine serial plate 3 Remove all weight tools and accessories from the platform Note Failure to remove all weight tools and accessories from the platform will result in an incorrect calibration 4 Using a suitable lifting device place a test weight equal to the maximum platform capacity at the center of the platform floor Part No 106373 A TEREX CON Z 30 20N Z 30 20N RJ 4 7 PLATFORM COMPONENTS 5 Move the platform up and down by hand so it bounces approximately 2 5 to 5 cm 1 to 2 inches Allow the platform to settle Result The overload indicator lights are off and the alarm does not sound Proceed to step 6 W Result The overload indicator lights are flashing at the platform and ground controls and the alarm is sounding Slowly tighten the load spring adjustment nut in a clockwise direction in 10 increments until the overload indicator light turns off and the alarm does not sound Proceed to step 8 Note The platform will need to be moved up and down and allowed to settle between each adjustment Note There may be a 2 second delay before the platform overload indicator light and alarm responds 6 Move the platform up and down by hand so it bounces approximately 2 5 to 5 cm 1 to 2 inches Allow the platform to settle O Result The overload indicator lights are off at the platform and ground controls and the alarm does not sound Slowly loosen the
159. nal safety and the continued safe operation of the machine should be your top priority Read each procedure thoroughly This manual and the decals on the machine use signal words to identify the following Safety alert symbol used to alert personnel to potential personal injury hazards Obey all safety messages that follow this symbol to avoid possible injury or death A Indicates an imminently hazardous situation which if not avoided will result in death or serious injury Indicates a potentially hazardous AWARNING situation which if not avoided could result in death or serious injury Indicates a potentially hazardous ACAUTION situation which if not avoided may cause minor or moderate injury Indicates a potentially hazardous situation which if not avoided may result in property damage Be sure to wear protective eye wear and other protective clothing if the situation warrants it Be aware of potential crushing hazards 3il such as moving parts free swinging or unsecured components when lifting or placing loads Always wear approved steel toed shoes TEREX vi Z 30 20N Z 30 20N RJ Workplace Safety Be sure to keep sparks flames and lighted tobacco away from flammable combustible materials like battery gases and engine fuels Always have an approved fire extinguisher within easy reach wx are properly maintained and ready for use Keep work surfaces clean and fr
160. nen 2 2 Hydraulic Component Specifications esee 2 3 Manifold Component Specifications 2 3 Machine Torque Specifications 2 4 Hydraulic Hose and Fitting Torque Specifications 2 5 SAE and Metric Fasteners Torque Charts 2 6 Scheduled Maintenance Procedures 3 1 3 3 Maintenance Inspection nnnm 3 5 Checklist A Procedures A 1 Inspectthe Manuals and Decals 48 1 3 6 2 Perform Pre operation 3 7 A 3 Perform Function 3 7 4 Perform 30 Day 3 8 5 Grease the Turntable Rotation Bearing and Worm Drive Gear 3 8 A 6 Replace the Drive Hub 3 9 vii TABLE OF CONTENTS Section3 Scheduled Maintenance Procedures continued E Checklist B Procedures B 1 Check the 1 anoi 3 10 B 2 Inspect the Electrical 3 11 B 3 Test the Key Switch 3 12 B 4 Check the Tires Wheels and Lug Nut Torque 2 3 13 8 5 Confirmthe Proper Brake
161. o 10 41 ft lbs 55 Nm return filter 25 psi 1 7 bar bypass SAE No 12 56 ft lbs 76 Nm Function manifold System relief valve pressure 2800 psi 193 bar Primary boom down relief pressure 1600 psi 110 bar Secondary boom down relief pressure 1600 psi 110 bar Primary boom extend relief pressure 1800 psi Models with rotating jib 124 bar Turntable rotate relief pressure 1100 psi 76 bar Auxiliary pump Type Fixed displacement gear pump Displacement 0 3 gpm 1 14 L min Continuous improvement of our products is a Genie policy Product specifications are subject to change without notice Part No 106373 TEREX COMPANY Z 30 20N Z 30 20N RJ Valve Coil Resistance Note The following coil resistance specifications are at an ambient temperature of 68 F 20 C As valve coil resistance is sensitive to changes in air temperature the coil resistance will typically increase or decrease by 496 for each 18 F 10 C that your air temperature increases or decreases from 68 F 20 C Valve Coil Resistance Specification Description Specification Solenoid valve 3 position 4 way 20V DC 220 schematic items A J 0 V Y AA and Proportional solenoid valve 24V DC 19 5 9 schematic item H Solenoid valve N C poppet 20V DC 23 5 0 schematic item M Solenoid valve N O poppet 20V DC 23 5 0 schematic item P 2 3 Section 2 Specifications June 2
162. o changes in air temperature the coil resistance will typically increase or decrease by 496 for each 18 F 10 C that your air temperature increases or decreases from 68 F 20 Valve Coil Resistance Specification Description Specification Solenoid valve 3 position 4 way 20V DC 22 Q schematic items A J K U V Y AA BB and CC Proportional solenoid valve 24V DC 19 5 9 schematic item H Solenoid valve N C poppet 20V DC 23 5 Q schematic item M Solenoid valve N O poppet 20V DC 23 5 Q schematic item P Part No 106373 June 2008 Section 4 Repair Procedures REV D How to Test a Coil Diode Genie incorporates spike suppressing diodes in all of its valve coils Properly functioning coil diodes protect the electrical circuit by suppressing voltage spikes Voltage spikes naturally occur within a function circuit following the interruption of electrical current to a coil Faulty diodes can fail to protect the electrical system resulting in a tripped circuit breaker or component damage AWARNING Electrocution burn hazard Contact with electrically charged circuits could result in death or serious injury Remove all rings watches and other jewelry 1 Test the coil for resistance See How to Test a Coil 2 Connect 100 resistor to the negative terminal of a known good 9V DC battery Connect the other end of the resistor to a terminal on the coil Note The battery should read
163. o not allow oil to squirt or spray General Repair Process Be sure that all necessary tools and test Malfunction Identify Troubleshoot equipment are available and ready for use discovered symptoms problem still exists Retum to Perform service problem repair solved Part No 106373 Z 30 20N Z 30 20N RJ 6 1 Section 6 Schematics _ __________________ Load Sensor Option Diagram before serial number 6290 June 2008 REVA QA NANANA 1 2 3 4 LOAD SENSE OPTION n 123456789 x 8 8 0 kn CABLE CABLE CABLE 3 2 1 LOAD CELL WHT FS TS15 512 TS10 BP1 O O O BLK RED TS7 TS11 TS8 RED GRN 5 59 TS13 TS16 N D 6 0 al 6 f LABEL DESCRIPTION L1 ML OT L2 L o P2 EMERGENCY STOP BUTTON P3 HORN BUTTON DP1 CONTROLLER BP1 BOOM FUNCTION SPEED CONTROLLER TS1 AUXILIARY TOGGLE SWITCH 0 TS7_ PLATFORM ROTATE TOGGLE SWITCH TS8 JIB BOOM UP D
164. oil 16 Open the hydraulic tank shutoff valve Component damage hazard Be sure to open the hydraulic tank shutoff valve after installing the hydraulic tank Part No 106373 June 2008 Section 3 Scheduled Maintenance Procedures REV D E 2 Grease the Steer Axle Wheel Bearings Note Genie requires that this procedure be performed every 2000 hours or every two years whichever comes first Maintaining the steer axle wheel bearings is essential for safe machine operation and service life Operating the machine with loose or worn wheel bearings may cause an unsafe operating condition and continued use may result in component damage Extremely wet or dirty conditions or regular steam cleaning and pressure washing of the machine may require that this procedure be performed more often 1 Loosen the wheel lug nuts Do not remove them 2 Block the non steer wheels and center a lifting jack under the steer axle 3 Raise the machine 6 inches 15 cm and place blocks under the drive chassis for support 4 Remove the lug nuts Remove the tire and wheel assembly 5 Check for wheel bearing wear by attempting to move the wheel hub side to side then up and down Result There should be no side to side or up and down movement Skip to step 10 if there is no movement Part No 106373 Z 30 20N Z 30 20N RJ 3 31 CHECKLIST E PROCEDURES 6 Remove the dust cap from the hub Remove the cotter pin from the c
165. om side of the cylinder remove the retaining fasteners from the secondary boom lift cylinder barrel end pivot pins 18 Remove the hose clamp under the lower secondary boom 19 Use a slide hammer to remove both barrel end pivot pins access the pins from the access holes in the bulkheads one on each side 20 Remove the pin retaining fastener from the secondary boom lift cylinder rod end pivot pin Part No 106373 TEREX COMI Z 30 20N Z 30 20N RJ SECONDARY BOOM COMPONENTS 21 Use a soft metal drift to remove the secondary boom rod end pivot pin Crushing hazard The secondary ACAUTION boom lift cylinder may fall when the rod end pivot pin is removed if not properly supported by the overhead crane 22 Carefully lower the cylinder down through the secondary boom enough to access the hydraulic hoses Do not pinch the hoses Component damage hazard Hoses can be damaged if they are kinked or pinched 23 Tag disconnect and plug the hydraulic hoses from the secondary boom lift cylinder Cap the fittings on the cylinder AWARNING Bodily injury hazard Spraying hydraulic oil can penetrate and burn skin Loosen hydraulic connections very slowly to allow the oil pressure to dissipate gradually Do not allow oil to squirt or spray 24 Remove the cylinder through the top of the secondary boom AWARNING Crushing hazard The secondary boom lift cylinder could become unbalanced and fall when removed from th
166. om toggle switch to the down position hold for a moment then release it 3 Hold the function enable toggle switch to either side then move the secondary boom toggle Switch to the down position hold for a moment then release it Part No 106373 Z 30 20N Z 30 20N RJ CHECKLIST B PROCEDURES 4 Hold the function enable toggle switch to either side then move the jib boom toggle switch to the down position hold for a moment then release it Result The descent alarm should sound when each control toggle switch is held down 5 Turn the key switch to platform controls Result The flashing beacon should be on and flashing 6 Press down the foot switch 7 Move the primary boom toggle switch to the down position hold for a moment then release it 8 Move the secondary boom toggle switch to the down position hold for a moment then release it 9 Move the jib boom toggle switch to the down position hold for a moment then release it Result The descent alarm should sound when each control toggle switch is held down 10 Move the drive joystick off center hold for a moment then release it Move the drive joystick off center in the opposite direction hold for a moment then release it Result The travel alarm should sound when the drive joystick is moved off center in either direction Section 3 Scheduled Maintenance Procedures June 2008 CHECKLIST B PROCEDURES B 13 Test the Turntable
167. on suppression properties Optional fluids Biodegradable Petro Canada Environ MV46 Statoil Hydra Way Bio Pa 32 BP Biohyd SE S Fire resistant UCON Hydrolube HP 5046 Quintolubric 822 Mineral based Shell Tellus T32 Shell Tellus T46 Chevron Aviation A Continued use of Chevron Aviation A hydraulic fluid when ambient temperatures are consistently above 32 F 0 C may result in component damage Note Use Chevron Aviation A hydraulic fluid when ambient temperatures are consistently below O F 18 C Note Use Shell Tellus T46 hydraulic oil when oil temperatures consistently exceed 205 F 96 Note Genie specifications require additional equipment and special installation instructions for the approved optional fluids Consult the Genie Industries Service Department before use Continuous improvement of our products is a Genie policy Product specifications are subject to change without notice 2 2 Z 30 20N Z 30 20N RJ Part No 106373 June 2008 Section 2 Specifications REV Hydraulic Component SPECIFICATIONS Manifold Component Specifications Specifications Function pump Plug torque Type Fixed displacement gear pump SAE No 2 36 4 Nm Displacement 0 183 cu in SAE No 4 10 ft lbs 13 Nm Sem SAE No 6 14 ft Ibs 19 Nm Flow rate 2 1 gpm 2800 psi 172 bar 7 9L min SAE 8 38 ft lbs 51 Nm Hydraulic tank 10 micron with SAE N
168. or s manual to the decals inspection section Carefully and thoroughly inspect all decals on the machine for legibility and damage Result The machine is equipped with all required decals and all decals are legible and in good condition Result The machine is not equipped with all required decals or one or more decals are illegible or in poor condition Remove the machine from service until the decals are replaced 4 Always return the manuals to the storage container after use Note Contact your authorized Genie distributor or Genie Industries if replacement manuals or decals are needed Part No 106373 June 2008 Section 3 Scheduled Maintenance Procedures REV D A 2 Perform Pre operation Inspection Note Genie specifications require that this procedure be performed daily or every 8 hours whichever comes first Completing a pre operation inspection is essential to safe machine operation The pre operation inspection is a visual inspection performed by the operator prior to each work shift The inspection is designed to discover if anything is apparently wrong with a machine before the operator performs the function tests The pre operation inspection also serves to determine if routine maintenance procedures are required Complete information to perform this procedure is available in the appropriate Genie Z 30 20N Operator s Manual Refer to the Operator s Manual on your machine Part No 1063
169. ormance and service life Failure to replace the drive hub oil at yearly intervals may cause the machine to perform poorly and continued use may cause component damage 1 Select the drive hub to be serviced Drive the machine until one of the two plugs is at the lowest point 2 Remove both plugs and drain the oil into a suitable container 3 Drive the machine until one plug is at the top and the other is at 90 degrees a drive hub plugs 4 Fill the hub with oil from the top hole until the oil level is even with the bottom of the side plug hole Refer to Section 2 Specifications 5 Install the plugs into the drive hub REVD D 5 Replace the Hydraulic Tank Return Filter Element Note Genie specifications require that this procedure be performed every 1000 hours or annually whichever comes first Perform this procedure more often if dusty conditions exist Replacement of the hydraulic return filter element is essential for good machine performance and service life A dirty or clogged filter element may cause the machine to perform poorly and continued use may cause component damage Extremely dirty conditions may require that the filter element be replaced more often Bodily injury hazard Beware of A CAUTION hot oil Contact with hot oil may cause severe burns 1 Locate the hydraulic return filter housing on top of the hydraulic tank 2 Clean the area around the oil filter housing cap located on top of the re
170. ound Remove the additional 10 Ib 4 5 kg test weight Repeat this procedure beginning with step 6 Note There may be a 2 second delay before the platform overload indicator light and alarm responds 9 Testall machine functions from the platform controls O Result All platform control functions should not operate A TEREX CON Z 30 20N Z 30 20N RJ MEANY REVC 10 Turn the key switch to ground control 11 Test all machine functions from the ground controls O Result All ground control functions should not operate 12 Using a suitable lifting device lift the test weight off the platform floor O Result The platform overload indicator light should be off at both the ground and platform controls and the alarm should not sound Note There may be a 2 second delay before the overload indicator lights and alarm turn off 13 Test all machine functions from the ground controls O Result All ground control functions should operate normally 14 Turn the key switch to platform control 15 Test all machine functions from the platform controls Result All platform control functions should operate normally Part No 106373 June 2008 Section 4 Repair Procedures REV 3 1 Jib Boom How to Remove the Jib Boom Note When removing a hose assembly or fitting the O ring on the fitting and or hose end must be replaced and then torqued to specification during installation Refer to S
171. ounterclockwise to decrease the amperage 9 Start a and simultaneously press down the foot switch and move the primary boom toggle switch in the down direction Note how long it takes to reach 0 65A Part No 106373 A TEREX COMI Z 30 20N Z 30 20N RJ PLATFORM CONTROLS 10 Set the ramp rate Turn the ramp rate trimpot to obtain 2 second delay from 0 to 0 65A Turn the trimpot clockwise to increase the time or counterclockwise to decrease the time 11 Disconnect the leads from the multi meter and connect the white red wire to the diode on the black red wire Boom function speed controller specifications Threshold controller turned to CREEP 0 28A Max out 0 65A controller turned to 9 Ramp rate 2 seconds Section 4 Repair Procedures June 2008 Platform Components 2 1 Platform Leveling Slave Cylinder The slave cylinder and the rotator pivot are the two primary supports for the platform The slave cylinder keeps the platform level through the entire range of primary boom motion It operates in a closed loop hydraulic circuit with the master cylinder The slave cylinder is equipped with counterbalance valves to prevent platform movement in the event of a hydraulic line failure How to Remove the Slave Cylinder Note Before cylinder removal is considered bleed the slave cylinder to be sure there is no air in the closed loop hydraulic circuit Note When removing a
172. pecifications require that this procedure be performed daily or every 8 hours whichever comes first Maintaining the operator 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 In addition maintaining all of the safety and instructional decals 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 Check to make sure that the operator s and safety manuals are present and complete in the storage container on the platform 2 Examine the pages of each manual to be sure that they are legible and in good condition Result The operator s manual is appropriate for the machine and all manuals are legible and in good condition Result The operator s manual is not appropriate for the machine or all manuals are not in good condition or are illegible Remove the machine from service until the manual is replaced A TEREX CON 3 6 Z 30 20N Z 30 20N RJ REV D 3 Open the operat
173. rease the Platform Overload Mechanism if equipped Note Genie specifications require that this procedure be performed every 500 hours or 6 months whichever comes first Perform this procedure more often if dusty conditions exist Application of lubrication to the platform overload mechanism is essential to safe machine operation Continued use of an improperly greased platform overload mechanism could result in the system not sensing an overloaded platform condition and will result in component damage 1 Locate the grease fittings on each pivot pin of the platform overload assembly 2 Thoroughly pump grease into each grease fitting using a multi purpose grease Grease Specification Chevron Ultra duty grease EP NLGI 2 lithium based or equivalent A TEREX CON Z 30 20N Z 30 20N RJ REV D C 2 Test the Platform Overload System if equipped Note Genie specifications require that this procedure be performed every 500 hours or six months whichever comes first Testing the platform overload system regularly is essential to safe machine operation Continued use of an improperly operating platform overload system could result in the system not sensing an overloaded platform condition Machine stablity could be compromised resulting in the machine tipping over The platform overload system is designed to detect an overloaded platform and prevent machine operation anytime the machine is turned on When act
174. ressure gauge Refer to Section 2 Specifications Turn the machine off Hold the turntable relief valve s with a wrench and remove the cap item D Adjust the internal hex socket Turn it clockwise to increase the pressure or counterclockwise to decrease the pressure Install the relief valve cap AWARNING hazard Do not adjust the relief valve higher than specified 6 Repeat steps 2 and 3 to confirm the relief valve pressure setting June 2008 REV D A TEREX COMPANY Z 30 20N Z 30 20N RJ Part No 106373 June 2008 Section 4 Repair Procedures REV 0 MANIFOLDS 7 3 Jib Boom and Platform Jib Boom Rotate Manifold Components The jib boom platform rotate manifold is mounted to the jib boom Index Schematic No Description Item Function Torque 1 Solenoid valve 3 position 4 way Jib boom 20 25 ft lbs 27 34 Nm 2 Solenoid valve 3 position 4 way BB Platform rotate left right 20 25 ft lbs 27 34 Nm 3 Solenoid valve 3 position 4 way CC Jib boom rotate left right 20 25 ft lbs 27 34 Nm 4 Flow regulator valve 0 3 1 14 L MIN Platform rotate circuit 20 25 ft lbs 27 34 Nm 5 Orifice plug 0 025 inch 0 64 mm DD Jib boom rotate circuit located under plug
175. rial number 6290 to 8354 M L K J H G F E D LEFT SIDE gx AMMETER RIGHT SIDE 1 BATTERY PACK BLK 10 1 Iw E WHT 10 id AC i sem CHARGER et Z 0 PRIMARY 3 A1 Di BLK 4 9 YT AUXILIARY zB i PUMP D w ETE m 4 R 2 7 7 KS AP2 AP1 RED 2 BLK 2 BLK 2 ee RED 2 5 oV DC AUXILIARY PUMP 2s M CONTACTOR PR3 PRIMARY LIFT o 100A PUMP CONTACTOR PR2 5 1 6 MOTOR CONTROLLER NOTES 9 WIRE GAUGE NOTED IN PARENTHESES AFTER 7 WIRE COLOR RED 10 10 DO NOT ROUTE POWER CABLES ACROSS FRONT OF MOTOR CONTROLLER DOING SO CAN AFFECT INTERNAL CURRENT SENSORS RIGHT SIDE CAUSING REDUCED MOTOR PERFORMANCE BLK 2 DRIVE MOTOR F2 1 0 1 8 2 1 LEFT SIDE E BLK 2 BLK 2 A DRIVE MOTOR e OF A1 A2 RED 10 Part No 106373 Z 30 20N Z 30 20N RJ 6 6 April 2007 Section 6 Schematics Power Cable Diagram from serial number 6290 to 8354 April 2007 Section 6 Schematics Power Cable Diagram after serial nu
176. ring Boss Port tube fitting installed into Aluminum Replace the O ring The O ring must be replaced anytime the seal has been broken The O ring cannot be re used if the fitting or hose end has been tightened beyond finger tight Note The O rings used in the Parker Seal Lok fittings and hose ends are custom size O rings They are not standard SAE size O rings They are available in the O ring field service kit Genie part number 49612 SAE Torque 2 Lubricate the O ring before installation 11 ftlbs 14 9Nm 5 Be sure that the face seal O ring is seated and 6 23 ft lbs 31 2 Nm retained properly 8 40 ft lbs 54 2 Nm 4 Position the tube and nut squarely on the face seal end of the fitting and tighten the nut finger 10 69 ft lbs 93 6 Nm tight 12 93 ft lbs 126 1 Nm 5 Tighten the nut or fitting to the appropriate torque per given size as shown in the table 16 139 ft Ibs 188 5 Nm 6 Operate all machine functions and inspect the 0 172 ft lbs 233 2 Nm hoses and fittings and related components to 24 208 ft lbs 282 Nm confirm that there are no leaks SAE O ring Boss Port tube fitting installed into Steel Seal Lok Fittings hose end SAE Dash size Torque SAE Dash size Torque 4 16 ft lbs 21 7 Nm 4 18 ft lbs 24 4 Nm 6 35 ft lbs 47 5 Nm 6 27 ft lbs 36 6 Nm 8 60 ft lbs 81 3 Nm 8 40 ft lbs
177. rntable bearing wear is essential to safe machine operation good machine performance and service life Continued use of a worn turntable bearing could create an unsafe operating condition resulting in death or serious injury and component damage 1 Grease the turntable bearing See 5 Grease the Turntable Bearing and Rotate Gear 2 Torque the turntable bearing bolts to specification See D 3 Check the Turntable Rotation Bearing Bolts 3 Raise the primary and secondary booms to full height using the ground controls Do not extend the primary boom Section 3 Scheduled Maintenance Procedures June 2008 CHECKLIST D PROCEDURES 4 Place dial indicator between the drive chassis and the turntable at a point that is directly under or in line with the boom and no more than 1 inch 2 5 cm from the bearing Note To obtain an accurate measurement place the dial indicator no more than 1 inch 2 5 cm from the turntable rotation bearing lt 4 turntable dial indicator drive chassis turntable rotation bearing 5 Adjust the dial indicator to 0 6 Lower the secondary boom to the stowed position and lower the primary boom to a horizontal position Fully extend the primary boom A TEREX CON Z 30 20N Z 30 20N RJ REV D 7 Note the reading on the dial indicator Result The measurement is less than 0 055 inch 1
178. rocedure be performed every 100 hours Frequent application of lubrication to the turntable bearing and worm drive gear is essential to good machine performance and service life Continued use of an insufficently greased gear will result in component damage 1 Locate the grease fitting on the tank side turntable cover bulkhead 2 Pump grease into the turntable rotation bearing Rotate the turntable in increments of 4 to 5 inches 10 to 13 cm at a time and repeat this step until the entire bearing has been greased 3 Locate the 2 grease fittings on top of the worm drive housing a grease fittings 4 Pump grease into the gear until you see it coming out of the side of the gear housing 5 Grease each tooth on the outside of the turntable rotation bearing Grease Specification Chevron Ultra duty grease EP NLGI 2 lithium based or equivalent Part No 106373 June 2008 Section 3 Scheduled Maintenance Procedures REV D CHECKLIST A PROCEDURES A 6 Replace the Drive Hub Oil Note Manufacturer drive hub specifications require that this one time procedure be performed after the first 150 hours Replacing the drive hub oil is essential for good machine performance and service life Failure to replace the drive hub oil after the first 150 hours of use may cause the machine to perform poorly and continued use may cause component damage 1 Select the drive hub to be serviced Drive the machine until one of t
179. rol and pull out the red Emergency Stop button to the on position 3 Move and hold the function enable toggle switch to either side and move and hold the primary boom extend retract toggle switch in the retract direction with the primary boom fully retracted Observe the pressure reading on the pressure gauge Refer to Section 2 Specifications 4 Turn the machine off Hold the system relief valve with a wrench and remove the cap item R 5 Adjust the internal hex socket Turn it clockwise to increase the pressure or counterclockwise to decrease the pressure Install the relief valve cap AWARNING Tip over hazard Do not adjust the relief valve higher than specified 6 Repeat steps 2 and 3 to confirm the relief valve pressure setting A TEREX CON Z 30 20N Z 30 20N RJ MEANY REVD How to Adjust the Primary Boom Down Relief Valve 1 Connect a 0 to 3000 psi 0 to 200 bar pressure gauge to the test port on the function manifold 2 Turn the key switch to ground control and pull out the red Emergency Stop button to the on position 3 Move and hold the function enable toggle switch to either side and move and hold the primary boom up down toggle switch in the down direction with the primary boom fully lowered Observe the pressure reading on the pressure gauge Refer to Section 2 Specifications 4 Turn the machine off Hold the primary down relief valve with a wrench and remove the cap item F 5 Adjust
180. servoir Remove the cap from the housing Lift the handle on the filter element and rotate the element counterclockwise to release the element from the housing 5 Remove the filter element from the filter housing 6 Repeat this procedure for the other drive hub A TEREX COMPANY 3 26 Z 30 20N Z 30 20N RJ Part No 106373 June 2008 Section 3 Scheduled Maintenance Procedures REV D 6 Install the new oil filter element into the filter housing 7 Push the filter element down to be sure the o ring on the element is fully seated into the housing 8 Rotate the filter element clockwise to lock it in place 9 Install the filter housing cap 10 Clean up any oil that may have spilled during the replacement procedure 11 Use a permanent ink marker to write the date and number of hours from the hour meter on the oil filter housing 12 Turn the key switch to ground controls and pull out the red Emergency Stop button to the on position 13 Move and hold the function enable toggle switch to either side and move and hold the primary boom toggle switch in the up direction 14 Inspect the filter housing and related components to be sure that there are no leaks PartNo 106373 Z 30 20N Z 30 20N RJ CHECKLIST D PROCEDURES D 6 Inspect for Turntable Bearing Wear Note Genie requires that this procedure be performed every 1000 hours or annually whichever comes first Periodic inspection of tu
181. tend the boom 3 to 4 feet 1 until the extension cylinder rod end pivot pins are accessible 2 Remove the external snap rings from the extension cylinder rod end pivot pins Use a soft metal drift to remove the pins 3 Remove the counterweight cover fasteners Remove the counterweight cover from the machine 4 Raise the secondary boom until the master cylinder rod end pivot pin is accessible Section 4 Repair Procedures June 2008 PRIMARY BOOM COMPONENTS 5 Remove the primary boom extend drive limit switch from the pivot end of the primary boom Do not disconnect the wiring 6 Remove the retaining fastener from the master cylinder rod end pivot pin Use a soft metal drift to remove the pin 7 Manually retract the master cylinder and push it toward the platform end of the boom to obtain enough clearance for extension cylinder removal 8 Tag disconnect and plug the extension cylinder hydraulic hoses Cap the fittings on the cylinder AWARNING Bodily injury hazard Spraying hydraulic oil can penetrate and burn skin Loosen hydraulic connections very slowly to allow the oil pressure to dissipate gradually Do not allow oil to squirt or spray 9 Remove the retaining fastener from the extension cylinder barrel end pivot pin Use a soft metal drift to remove the pin 10 Carefully pull out and properly support the extension cylinder from the primary boom with a lifting strap from an overhead crane AWARNING
182. the hydraulic oil is not replaced at the two year inspection test the oil quarterly Replace the oil when it fails the test Note When removing a hose assembly or fitting the O ring on the fitting and or hose end must be replaced and then torqued to specification during installation Refer to Section 2 Hydraulic Hose and Fitting Torque Specifications Part No 106373 Z 30 20N Z 30 20N RJ 1 Close the hydraulic shutoff valve located at the hydraulic tank Component damage hazard The machine must not be operated with the hydraulic tank shutoff valve in the closed position or component damage will occur If the tank valve is closed remove the key from the key switch and tag the machine to inform personnel of the condition 2 Place a suitable container under the hydraulic tank Refer to Section 2 Specifications 3 Tag disconnect and plug the hydraulic hose from the hydraulic tank shutoff valve AWARNING injury hazard Spraying ydraulic oil can penetrate and burn skin Loosen hydraulic connections very slowly to allow the oil pressure to dissipate gradually Do not allow oil to squirt or spray 4 Open the valve on the hydraulic tank and completely drain the oil into a suitable container Bodily injury hazard Beware of ACAUTION hot oil Contact with hot oil may cause severe burns Section 3 Scheduled Maintenance Procedures June 2008 CHECKLIST E PROCEDURES 5 Tag disconnect and plug the hydra
183. the internal hex socket Turn it clockwise to increase the pressure or counterclockwise to decrease the pressure Then install the relief valve cap AWARNING Tip over hazard Do not adjust the relief valve higher than specified 6 Repeat steps 2 and to confirm the relief valve pressure setting Part No 106373 June 2008 Section 4 Repair Procedures REV D How to Adjust the Secondary Boom Down Relief Valve 1 Connect a 0 to 3000 psi 0 to 200 bar pressure gauge to the test port on the function manifold 2 Turn the key switch to ground control and pull out the red Emergency Stop button to the on position 3 Move and hold the function enable toggle switch to either side and move and hold the secondary boom up down toggle switch in the down direction with the secondary boom fully lowered Observe the pressure reading on the pressure gauge Refer to Section 2 Specifications 4 Turn the machine off Hold the secondary boom down relief valve with a wrench and remove the cap item E 5 Adjust the internal hex socket Turn it clockwise to increase the pressure or counterclockwise to decrease the pressure Install the relief valve cap AWARNING Tip over hazard Do not adjust the relief valve higher than specified 6 Repeat steps 2 and to confirm the relief valve pressure setting A TEREX COMPANY MANIFOLDS How to Adjust the Primary Boom Extend Relief Valve 1 Connect a 0 to 3000 psi 0 to 20
184. the maximum raised drive speed must not exceed 0 6 mph 1Km h or 40 feet 45 seconds 12 2 meters 45 seconds If the machine is allowed to drive faster than specification the machine could become unstable and will tip over Note Additional troubleshooting of the fault codes may by accomplished by using the hand held pendant motor controller programmer Genie part number 56303 Note When using the hand held pendant motor controller programmer the M1 MAX SPEED needs to be set to 33 If needed adjust the M1 MAX SPEED higher or lower to achieve the maximum raised drive speed of 0 6 mph 1Km h or 40 feet 45 seconds 12 2 meters 45 seconds A TEREX COME Z 30 20N Z 30 20N RJ REVA The controller status indicator light will flash a fault code to aid in troubleshooting This indicator light is mounted on the tilt level sensor mounting bracket located behind the cover on the ground controls side Fault codes are two digits The controller status indicator light will blink the first digit of a two digit code pause for 1 second and then blink the second digit There will be a 2 second pause between codes For example the indicator light blinks 4 consecutive times pauses for 1 second and then blinks 1 time That would indicate Fault Code 41 Motor c Circuit Contr Oller Status 10 AMP Indicator Light Part No 106373 June 2008 Section 5 Fault Codes Fault Code Chart REVA Fau
185. the pin retaining fasteners from the jib boom and leveling links to platform rotator pivot pins Do not remove the pins 7 Support the jib boom jib boom cylinder and leveling links with an overhead crane 8 Use a soft metal drift to drive both pins out then remove the platform rotator from the machine Crushing hazard The platform ACAUTION rotator may fall when the pins are removed if not properly supported Note When installing the platform rotator be sure to torque the fasteners to specification Refer to Section 2 Specifications How to Bleed the Platform Rotator Note This procedure will require two people 1 Move the function enable toggle switch to either side and activate the platform rotate toggle switch to the right and then to the left through two platform rotation cycles Then hold the switch to the right position until the platform is fully rotated to the right Section 4 Repair Procedures June 2008 E PLATFORM COMPONENTS REV 2 Connecta clear hose to the top bleed valve 5 Connect the clear hose to the bottom bleed Place the other end of the hose in a container valve and open the valve Do not remove the to collect any drainage Secure the container to bleed valve 6 Move the function enable toggle switch to either 3 Open the top bleed valve on the rotator but do side and hold the platform rotate toggle switch not remove it to the right position until the platform is fully rotated to th
186. trap from an overhead crane at the center of the control box side upper secondary compression arm 29 Use a soft metal drift to remove the upper secondary boom compression arm pivot pins and remove the compression arm from the machine Repeat this step for the hydraulic tank side upper secondary compression arm AWARNING Crushing hazard The upper secondary compression arm could become unbalanced and fall when removed from the machine if not properly supported by the overhead crane 30 Close the hydraulic tank shutoff valve Tag disconnect and plug the hydraulic hose from the hydraulic tank shutoff valve AWARNING injury hazard Spraying ydraulic oil can penetrate and burn skin Loosen hydraulic connections very slowly to allow the oil pressure to dissipate gradually Do not allow oil to squirt or spray 31 Open the valve on the hydraulic tank and drain the oil into a container of suitable capacity Refer to Section 2 Specifications Bodily injury hazard Beware of ACAUTION hot oil Contact with hot oil may cause severe burns Part No 106373 A TEREX CON Z 30 20N Z 30 20N RJ SECONDARY BOOM COMPONENTS 32 Tag disconnect and plug the hydraulic hose from the hydraulic tank return filter housing Cap the fitting on the filter housing AWARNING Bodily injury hazard Spraying hydraulic oil can penetrate and burn skin Loosen hydraulic connections very slowly to allow the oil pressure to dissip
187. ty damage AWARNING Collision hazard Select a work site that is firm and level Component damage hazard If the machine must be towed do not exceed 2 mph 3 2 km h 1 Chock the steer wheels to prevent the machine from rolling 2 Center a lifting jack of ample capacity 15 000 Ibs 7000 kg under the drive chassis between the non steer wheels 3 Liftthe wheels off the ground and then place blocks under the drive chassis for support A TEREX CON Z 30 20N Z 30 20N RJ REV D 4 Disengage the drive hubs by turning over the drive hub disconnect caps on each non steer wheel hub disengaged position engaged position 5 Manually rotate each non steer wheel Result Each non steer wheel should rotate with minimum effort 6 Engage the drive hubs by turning over the drive hub disconnect caps 7 Carefully remove the blocks lower the machine and remove the jack AWARNING Collision hazard Failure to engage the drive hubs could result in death or serious injury and property damage MPANY Part No 106373 June 2008 Section 3 Scheduled Maintenance Procedures REV D D 3 Check the Turntable Rotation Bearing Bolts Note Genie specifications require that this procedure be performed every 1000 hours or annually whichever comes first Maintaining proper torque on the turntable bearing bolts is essential to safe machine operation Improper bolt torque could result in an unsafe operat
188. ulic hoses from the hydraulic tank return filter housing Cap the fittings on the filter housing AWARNING sud injury hazard Spraying ydraulic oil can penetrate and burn skin Loosen hydraulic connections very slowly to allow the oil pressure to dissipate gradually Do not allow oil to squirt or spray Bodily injury hazard Beware of ACAUTION hot oil Contact with hot oil may cause severe burns 6 Remove the hydraulic tank mounting fasteners Remove the hydraulic tank from the machine 7 Remove the tank lid retaining fasteners and remove the lid and return filter assembly from the tank 8 Remove the suction strainer from the hydraulic tank and clean it using a mild solvent 9 Rinse out the inside of the tank with a mild solvent 10 Install the suction strainer into the tank 11 Install the lid and return filer assembly onto the hydraulic tank 12 Install the hydraulic tank on the machine Install the hydraulic tank mounting fasteners and torque them to 8 ft lbs 10 8 Nm Component damage hazard The hydraulic tank is plastic and may become damaged if the tank mounting fasteners are over tightened A TEREX CON Z 30 20N Z 30 20N RJ REV D 13 Install the hydraulic hoses 14 Fill the tank with hydraulic oil until the fluid is within the FULL and App marks on the hydraulic tank Do not overfill Refer to Section 2 Specifications 15 Clean up any oil that may have spilled Properly discard of used
189. uring installation Refer to Section 2 Hydraulic Hose and Fitting Torque Specifications 1 2 Remove the counterweight cover Place a suitable lifting device under the platform for support 3 Disconnect the battery packs from the machine Remove the cable cover from the side of the jib boom Remove the wire loom from the cables at the platform control box Part No 106373 A TEREX Z 30 20N Z 30 20N RJ 4 23 MEANY Section 4 Repair Procedures SECONDARY BOOM COMPONENTS 6 Locate the cables from the primary boom cable track to the platform control box Number each cable and its entry location at the platform control box 7 Openthe platform control box 8 Tag and disconnect each wire from the cables in the platform control box AWARNING Electrocution burn hazard Contact with electrically charged circuits could result in death or serious injury Remove all rings watches andother jewelry 9 Pullthe cables out of the platform control box 10 Pull all of the electrical cables out of the plastic cable track Do not pull out the hydraulic hoses 11 Remove the hose clamps from the bottom side of the primary boom 12 Before serial number 5945 Tag disconnect and plug the platform rotator hydraulic hoses at the union located on the bottom side of the primary boom Cap the fittings on the union After serial number 5944 Tag disconnect and plug the hydraulic hoses from the P and ports
190. vel surface Boom in stowed position Turntable rotated with the boom between the non steer wheels Key switch in the off position with the key removed Wheels chocked All external AC power supply disconnected from the machine Part No 106373 A TEREX Z 30 20N Z 30 20N RJ 5 1 Fault Codes Before Troubleshooting Read understand and obey the safety rules and operating instructions printed in the Genie Z 30 20N Operator s Manualon your machine Be sure that all necessary tools and test equipment are available and ready for use Be aware of the following hazards and follow generally accepted safe workshop practices Crushing hazard When testing or replacing any hydraulic component always support the structure and secure it from movement AWARNING Electrocution burn hazard Contact with electrically charged circuits could result in death or serious injury Remove all rings watches and other jewelry AWARNING injury hazard Spraying ydraulic oil can penetrate and burn skin Loosen hydraulic connections very slowly to allow the oil pressure to dissipate gradually Do not allow oil to squirt or spray Note Perform all troubleshooting on a firm level surface Note Two persons will be required to safely perform some troubleshooting procedures Section 5 Fault Codes June 2008 FAULT CODES Tip over hazard When adjusting the raised drive speed settings
191. w to Bleed the Slave Cylinder 1 Raise the jib boom to a horizontal position 2 Move the platform level toggle switch up and down through two platform leveling cycles to remove any air that might be in the system Part No 106373 June 2008 Section 4 Repair Procedures REV 2 2 Platform Rotator The platform rotator is a hydraulically activated helical gear assembly used to rotate the platform 180 degrees How to Remove the Platform Rotator Note When removing a hose assembly or fitting the O ring on the fitting and or hose end must be replaced and then torqued to specification during installation Refer to Section 2 Hydraulic Hose and Fitting Torque Specifications 1 Remove the platform 2 Tag disconnect and plug the hydraulic hoses from the platform rotate manifold AWARNING Bodily injury hazard Spraying hydraulic oil can penetrate and burn skin Loosen hydraulic connections very slowly to allow the oil pressure to dissipate gradually Do not allow oil to squirt or spray 3 Supportthe platform mounting weldment Do not apply any lifting pressure 4 Remove the six mounting bolts from the platform mounting weldment Remove the center bolt and slide the platform mounting weldment off of the platform rotator 5 Support the platform rotator with a suitable lifting device Do not apply any lifting pressure Part No 106373 TEREX COMI Z 30 20N Z 30 20N RJ PLATFORM COMPONENTS 6 Remove

Service Manual - Genie Industries

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