Genie Z-30/20N Service Manual
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Genie Z-30/20N Service Manual

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See also: Service & Repair Manual , Service Manual
Part No. 106373
Service Manual
Rev A1
April 2005
Refer to inside cover for serial number information
including rotating jib models

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Summary of Contents for Genie Z-30/20N

  • Page 1 Part No. 106373 Service Manual Rev A1 April 2005 Refer to inside cover for serial number information including rotating jib models...

  • Page 2: Introduction

    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.
  • Page 3 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.
  • Page 4 Please be environmentally safe. which, if not avoided, may result in property damage. Be sure that your workshop or work area Indicates special operation or is properly ventilated and well lit. maintenance information. Genie Z-30/20N Part No. 106373...

  • Page 5: Table Of Contents

    Perform Pre-operation Inspection ..............3 - 6 Perform Function Tests ................3 - 6 Perform 30 Day Service ................3 - 7 Grease the Turntable Rotation Bearing and Worm Drive Gear ....3 - 7 Part No. 106373 Genie Z-30/20N...
  • Page 6 B-14 Check the Electrical Contactors ..............3 - 16 B-15 Perform Hydraulic Oil Analysis ..............3 - 16 Checklist C Procedures Grease the Platform Overload Mechanism (if equipped) ......3 - 17 Test the Platform Overload System (if equipped) ........3 - 17 Genie Z-30/20N Part No. 106373...
  • Page 7 Jib Boom ...................... 4 - 7 Jib Boom Bell Crank (models without rotating jib boom) ......4 - 8 Jib Boom Rotator (models with rotating jib boom) ........4 - 8 Jib Boom Lift Cylinder ................4 - 10 Part No. 106373 Genie Z-30/20N...
  • Page 8 Valve Coils ....................4 - 38 Turntable Rotate Components Turntable Rotation Hydraulic Motor ............4 - 40 Steer Axle Components Hub and Bearings ..................4 - 41 Motor Controller 10-1 Motor Controller ..................4 - 42 viii Genie Z-30/20N Part No. 106373...
  • Page 9 Platform Control Box Wiring Diagram (before serial number 6290) ..... 6 - 13 Platform Control Box Wiring Diagram (after serial number 6289) ......6 - 14 Power Panel Wiring Diagram ................6 - 15 Hydraulic Schematic .................... 6 - 16 Part No. 106373 Genie Z-30/20N...
  • Page 10 April 2005 This page intentionally left blank. Genie Z-30/20N Part No. 106373...

  • Page 11: Machine Specifications

    SAE 90 multipurpose hypoid gear oil API service classification GL5 Platform level down 13 to 18 seconds Continuous improvement of our products is a Genie policy. Product specifications are subject to change without notice. Part No. 106373 Genie Z-30/20N 2 - 1...

  • Page 12: Hydraulic Specifications

    25 psi / 1.7 bar bypass Chevron Rykon MV oil is fully compatible and Function manifold mixable with Shell Donax TG (Dexron III) oils. Genie specifications require hydraulic oils which are System relief valve pressure 2800 psi designed to give maximum protection to hydraulic...

  • Page 13: Manifold Component Specifications

    19.5 Ω Proportional solenoid valve, 24V DC (schematic item H) 23.5 Ω Solenoid valve, N.C. poppet, 20V DC (schematic item M) 23.5 Ω Solenoid valve, N.O. poppet, 20V DC (schematic item P) Part No. 106373 Genie Z-30/20N 2 - 3...

  • Page 14: Hydraulic Hose And Fitting Torque Specifications

    Your machine is equipped with Parker Seal-Lok ® The O-ring cannot be re-used if the fitting or fittings and hose ends. Genie specifications require hose end has been tightened beyond finger that fittings and hose ends be torqued to tight.

  • Page 15: Observe And Obey

    · Wheels chocked Indicates that an incorrect result has occurred after performing a series of steps. · All external AC power supply disconnected from the machine Part No. 106373 Genie Z-30/20N 3 - 1...
  • Page 16 The maintenance inspection report contains checklists for each type of scheduled inspection. Make copies of the Maintenance Inspection Report to use for each inspection. Store completed forms for three years. 3 - 2 Genie Z-30/20N Part No. 106373...

  • Page 17: Pre-Delivery Preparation

    The Maltings, Wharf Road PO Box 97030 Grantham, Lincolnshire Redmond, WA 98073-9730 NG31- 6BH England (425) 881-1800 (44) 1476-584333 Part No. 106373 Genie Z-30/20N 3 - 3 Copyright © 2002 by Genie Industries. Genie® is a registered trademark of Genie Industries. Rev A...
  • Page 18 Section 3 • Scheduled Maintenance Procedures April 2005 This page intentionally left blank. 3 - 4 Genie Z-30/20N Part No. 106373...

  • Page 19: Maintenance Inspection Report

    After repair, place a check in the “R” box. Legend Y = yes, acceptable N = no, remove from service R = repaired Comments Part No. 106373 Genie Z-30/20N 3 - 5...

  • Page 20: Checklist A Procedures

    Genie Z-30/20N Operator's Manual. Refer to the Operator's Manual on your Complete information to perform this procedure is available in the Genie Z-30/20N Operator's Manual machine. on your machine. 3 - 6 Genie Z-30/20N...

  • Page 21: Perform 30 Day Service

    Bearing and Worm Drive Gear The 30 day maintenance procedure is a one-time sequence of procedures to be performed after the Genie specifications require that first 30 days or 50 hours of usage. After this this procedure be performed every interval, refer to the maintenance checklists for 100 hours.

  • Page 22: Checklist B Procedures

    3 Open the latch on the battery packs. Swing open the battery packs. 11 Install the battery box cover and tighten the retaining fasteners. 12 Close and latch the battery packs. 13 Connect the battery packs to the machine. 3 - 8 Genie Z-30/20N Part No. 106373...

  • Page 23: Inspect The Electrical Wiring

    Emergency Stop button to the on position at both the ground and platform controls. 4 Raise the secondary boom until the lower mid-pivot is 10 feet / 3 m off the ground. Part No. 106373 Genie Z-30/20N 3 - 9...

  • Page 24: Test The Key Switch

    Refer to Section 2, Specifications. 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. 3 - 10 Genie Z-30/20N Part No. 106373...

  • Page 25: Confirm The Proper Brake Configuration

    Refer to Section 2, Specifications . 4 Install the plugs into the drive hub. 5 Repeat this procedure for each drive hub. Part No. 106373 Genie Z-30/20N 3 - 11...

  • Page 26: Test The Ground Control Override

    3 Adjust the platform to a level position using the platform leveling toggle switch. 4 Raise and lower the primary boom through a full cycle. Result: The platform should remain level at all times to within ±5 degrees. 3 - 12 Genie Z-30/20N Part No. 106373...

  • Page 27: Test The Drive Brakes

    Refer to Section 2, Specifications. your machine reference point. Refer to Section 2, Specifications. The brakes must be able to hold the machine on any slope it is able to climb. Part No. 106373 Genie Z-30/20N 3 - 13...

  • Page 28: Test The Drive Speed - Raised Or Extended Position

    6 Continue at full speed and note the time when your machine reference point passes over the Result: The descent alarm should sound when finish line. Refer to Section 2, Specifications. each control toggle switch is held down. 3 - 14 Genie Z-30/20N Part No. 106373...

  • Page 29: Test The Turntable Rotation Stop

    Result: The travel alarm should sound when the Result: Movement should stop when the drive joystick is moved off center in either primary boom reaches mid-point between the direction. steer tires. Part No. 106373 Genie Z-30/20N 3 - 15...

  • Page 30: Check The Electrical Contactors

    · Excessive pitting Electrocution hazard. Contact with hot or live circuits could result in death or serious injury. Remove all rings, watches and other jewelry. Replace the contactors if any damage is found. 3 - 16 Genie Z-30/20N Part No. 106373...

  • Page 31: Checklist C Procedures

    Grease the Platform Overload Test the Platform Overload Mechanism (if equipped) System (if equipped) Genie specifications require Genie specifications require that that this procedure be performed this procedure be performed every every 500 hours or 6 months, 500 hours or six months.
  • Page 32 See D-6, Calibrate the Platform Overload System . There may be an approximate 2 second delay before the overload indicator light turns on and the alarm sounds. 3 - 18 Genie Z-30/20N Part No. 106373...
  • Page 33 14 Test all machine functions from the platform controls. Result: All platform control functions should operate. If the platform overload system is not operating properly, see D-6, Calibrate the Platform Overload System. Part No. 106373 Genie Z-30/20N 3 - 19...

  • Page 34: Checklist D Procedures

    2 Extend and retract the primary boom through 12.7 mm 9.5 mm the entire range of motion to check for tight spots that could cause binding or scraping. Always maintain squareness between the primary boom outer and inner tubes. 3 - 20 Genie Z-30/20N Part No. 106373...

  • Page 35: Check The Free-Wheel Configuration

    3 Lift the wheels off the ground and then place blocks under the drive chassis for support. 4 Disengage the drive hubs by turning over the drive hub disconnect caps on each non-steer wheel hub. disengaged position engaged position Part No. 106373 Genie Z-30/20N 3 - 21...

  • Page 36: Check The Turntable Rotation Bearing Bolts

    A lift cylinder safety chock is available through Genie Service Bolt torque sequence Parts (Genie part no. 36555). 2 Confirm that each turntable mounting bolt is torqued in sequence to specification. Refer to Section 2, Specifications. Bolt torque sequence...

  • Page 37: Replace The Drive Hub Oil

    Refer to Section 2, Specifications. 5 Install the plugs into the drive hub. 6 Repeat this procedure for the other drive hub. Part No. 106373 Genie Z-30/20N 3 - 23...

  • Page 38: Calibrate The Platform Overload System (If Equipped)

    8 Rotate the filter element clockwise to lock it in place. Genie specifications require that this procedure be performed every 9 Install the filter housing cap. 1000 hours of operation or yearly.
  • Page 39 10 Turn the key switch to ground control. 11 Test all machine functions from the ground controls. Result: All ground control functions should not operate. If the platform overload system is not operating properly, repeat steps 1 through 4. Part No. 106373 Genie Z-30/20N 3 - 25...

  • Page 40: Test Or Replace The Hydraulic Oil

    Section 3 • Scheduled Maintenance Procedures April 2005 REV B Test or Replace the Hydraulic Oil 3 - 26 Genie Z-30/20N Part No. 106373...

  • Page 41: Gradually. Do Not Allow Oil To Squirt

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

  • Page 42: Grease The Steer Axle Wheel Bearings

    14 Pack both bearings with clean, fresh grease. Skip to step 10 if there is no movement. 15 Place the large inner bearing into the rear of the hub. 3 - 28 Genie Z-30/20N Part No. 106373...
  • Page 43 23 Install the dust cap, then the tire and wheel assembly. Torque the wheel lug nuts to specification. Refer to Section 2, Specifications. 24 Raise the machine and remove the blocks. Lower the machine to the ground. Part No. 106373 Genie Z-30/20N 3 - 29...
  • Page 44 Section 3 • Scheduled Maintenance Procedures April 2005 This page intentionally left blank. 3 - 30 Genie Z-30/20N Part No. 106373...
  • Page 45 Read, understand and obey the safety rules an imminently hazardous situation and operating instructions in the which, if not avoided, will result in Genie Z-30/20N Operator’s Manual on your death or serious injury. machine. Used to indicate the presence of a...

  • Page 46: Platform Controls

    For further battery supply voltage is above information or assistance, contact the Genie 24V DC. Industries Service Department. 1 Turn the key switch to platform controls and pull...
  • Page 47 9 Start a timer and simultaneously press down the foot switch and move the primary boom toggle switch in the down direction. Note how long it takes to reach 0.65A. Part No. 106373 Genie Z-30/20N 4 - 3...

  • Page 48: Platform Components

    1 Raise the jib boom to a horizontal position. 2 Move the platform level toggle switch up and down through two platform leveling cycles to remove any air that might be in the system. 4 - 4 Genie Z-30/20N Part No. 106373...

  • Page 49: Platform Rotator

    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. Part No. 106373 Genie Z-30/20N 4 - 5...
  • Page 50 Continue holding the toggle switch until air stops coming out of the bleed valve. Close the bleed valve. Crushing hazard. Keep clear of the platform during rotation. 4 - 6 Genie Z-30/20N Part No. 106373...

  • Page 51: Jib Boom Components

    Crushing hazard. The jib boom could fall when the pin is removed if not properly supported by the overhead crane. Part No. 106373 Genie Z-30/20N 4 - 7...

  • Page 52: Jib Boom Bell Crank (Models Without Rotating Jib Boom)

    7 Remove the jib boom bell crank from the extension boom. Crushing hazard. The jib boom bell crank could become unbalanced and fall when the pins are removed if not properly supported and secured to the lifting device. 4 - 8 Genie Z-30/20N Part No. 106373...

  • Page 53: Jib Boom Rotator (Models With Rotating Jib Boom)

    When installing the jib boom rotator, be sure to torque the fasteners to specification. Refer to Section 2, Specifications. Part No. 106373 Genie Z-30/20N 4 - 9...
  • Page 54 5 seconds, then release it. Repeat three times. Crushing hazard. Keep hands and head clear of the platform pivot weldment during rotation. 4 - 10 Genie Z-30/20N Part No. 106373...

  • Page 55: Jib Boom Lift Cylinder

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

  • Page 56: Primary Boom Components

    A 7-link repair section of cable between the outer and inner boom track is available through tubes. the Genie Industries Service Parts (Genie part no. 58919). link separation point lower clip 1 Use a slotted screwdriver to pry down on the lower clip.
  • Page 57 Models with rotating jib boom: Remove the underside of the primary boom and at the pivot jib boom rotator. See 3-3, How to Remove the end of the primary boom. Jib Boom Rotator . Part No. 106373 Genie Z-30/20N 4 - 13...
  • Page 58 Pull the cylinder back and secure it from moving. Crushing hazard. The primary boom assembly could become unbalanced and fall when removed from the machine if not properly supported by the overhead crane. 4 - 14 Genie Z-30/20N Part No. 106373...
  • Page 59 5 Support the extension tube with an overhead crane at the platform end of the boom. Crushing hazard. The boom extension tube could fall when removed from the boom if not properly supported. Part No. 106373 Genie Z-30/20N 4 - 15...

  • Page 60: Primary Boom Lift Cylinder

    10 Place a rod through the upper secondary across the upper secondary boom to support leveling link pivot pin at the upper pivot and the cylinder when the rod-end pin is removed. twist to remove the pin. 4 - 16 Genie Z-30/20N Part No. 106373...

  • Page 61: Extension Cylinder

    3 Remove the counterweight cover fasteners. Remove the counterweight cover from the machine. 4 Raise the secondary boom until the master cylinder rod-end pivot pin is accessible. Part No. 106373 Genie Z-30/20N 4 - 17...

  • Page 62: Platform Leveling Master Cylinder

    During removal, the overhead crane strap will need to be 2 Raise the secondary boom until the master carefully adjusted for proper cylinder barrel-end pivot pin is above the balancing. turntable counterweights. 4 - 18 Genie Z-30/20N Part No. 106373...
  • Page 63 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. Part No. 106373 Genie Z-30/20N 4 - 19...

  • Page 64: Secondary Boom Components

    Section 4 • Repair Procedures April 2005 Secondary Boom Components REV B Secondary Boom upper pivot upper compression arm mid-pivot compression link lower secondary boom lower compression arm turntable pivot upper secondary boom 4 - 20 Genie Z-30/20N Part No. 106373...

  • Page 65: Secondary Boom

    5 Remove the wire loom from the cables at the the oil pressure to dissipate platform control box. gradually. Do not allow oil to squirt or spray. Part No. 106373 Genie Z-30/20N 4 - 21...
  • Page 66 20 Pull all the cables and hoses through the upper balancing. pivot. 26 Place the entire assembly onto a structure Component damage hazard. capable of supporting it. Cables and hoses can be damaged if they are kinked or pinched. 4 - 22 Genie Z-30/20N Part No. 106373...
  • Page 67 39 Remove the pin retaining fastener from the Bodily injury hazard. Beware of lower pivot pin on the compression link. Use a hot oil. Contact with hot oil may soft metal drift to remove the pin. cause severe burns. Part No. 106373 Genie Z-30/20N 4 - 23...
  • Page 68 Crushing hazard. The secondary boom lift cylinder could become unbalanced and fall when removed from the machine if not properly supported by the overhead crane. 4 - 24 Genie Z-30/20N Part No. 106373...
  • Page 69 Repeat for the hydraulic tank side lower secondary boom compression arm. Crushing hazard. The lower secondary compression arm could become unbalanced and fall when removed from the machine if not properly supported by the overhead crane. Part No. 106373 Genie Z-30/20N 4 - 25...

  • Page 70: Secondary Boom Lift Cylinder

    Do not allow oil to squirt the secondary boom lift cylinder. or spray. 4 Disconnect the battery packs from the machine. Bodily injury hazard. Beware of hot oil. Contact with hot oil may cause severe burns. 4 - 26 Genie Z-30/20N Part No. 106373...
  • Page 71 20 Remove the pin retaining fastener from the unbalanced and fall when secondary boom lift cylinder rod-end pivot pin. removed from the machine if not properly supported by the overhead crane. Part No. 106373 Genie Z-30/20N 4 - 27...

  • Page 72: Hydraulic Pumps

    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. 4 - 28 Genie Z-30/20N Part No. 106373...
  • Page 73 April 2004 Section 4 • Repair Procedures This page intentionally left blank. Part No. 106373 Genie Z-30/20N 4 - 29...

  • Page 74: Manifolds

    Solenoid valve, N.C. poppet ..... M ... Brake circuit ........20-25 ft-lbs / 27-34 Nm Orifice, 0.045 inch / 1.14 mm .... N ... Brake circuit This list continues. Please turn the page. 4 - 30 Genie Z-30/20N Part No. 106373...
  • Page 75 April 2005 Section 4 • Repair Procedures REV B MANIFOLDS Part No. 106373 Genie Z-30/20N 4 - 31...
  • Page 76 0.8 gpm / 3 L/min ....... X ... Jib boom/platform rotate circuit ..20-25 ft-lbs / 27-34 Nm Solenoid valve, 3 position 4 way ..Y ... Turntable rotate left/right ....20-25 ft-lbs / 27-34 Nm 4 - 32 Genie Z-30/20N Part No. 106373...
  • Page 77 April 2005 Section 4 • Repair Procedures REV B MANIFOLDS Part No. 106373 Genie Z-30/20N 4 - 33...

  • Page 78: Valve Adjustments - Function Manifold

    6 Repeat steps 2 and 3 to confirm the relief valve cap. pressure setting. Tip-over hazard. Do not adjust the relief valve higher than specified. 6 Repeat steps 2 and 3 to confirm the relief valve pressure setting. 4 - 34 Genie Z-30/20N Part No. 106373...
  • Page 79 6 Repeat steps 2 and 3 to confirm the relief valve 6 Repeat steps 2 and 3 to confirm the relief valve pressure setting. pressure setting. Part No. 106373 Genie Z-30/20N 4 - 35...
  • Page 80 Install the relief valve cap. Tip-over hazard. Do not adjust the relief valve higher than specified. 6 Repeat steps 2 and 3 to confirm the relief valve pressure setting. 4 - 36 Genie Z-30/20N Part No. 106373...

  • Page 81: Jib Boom And Platform / Jib Boom Rotate Manifold Components

    0.3 gpm / 1.14 L/min ......EE ..Platform rotate circuit ......20-25 ft-lbs / 27-34 Nm Orifice plug, 0.025 inch / 0.64 mm ... DD ..Jib boom rotate circuit (located under plug) Models without rotating jib boom Models with rotating jib boom Part No. 106373 Genie Z-30/20N 4 - 37...

  • Page 82: Valve Coils

    MANIFOLDS REV B How to Test a Coil Diode Valve Coils Genie incorporates spike suppressing diodes in all of its valve coils. Properly functioning coil diodes How to Test a Coil protect the electrical circuit by suppressing voltage spikes. Voltage spikes naturally occur within a...
  • Page 83 Result: If one or both of the current readings are 0 mA, or if the two current readings do not differ by a minimum of 20%, the coil and/or its internal diode are faulty and the coil should be replaced. Part No. 106373 Genie Z-30/20N 4 - 39...

  • Page 84: Turntable Rotate Components

    Do not allow oil to squirt or spray. 2 Remove the turntable rotation motor mounting bolts. Remove the motor from the machine. 4 - 40 Genie Z-30/20N Part No. 106373...

  • Page 85: Steer Axle Components

    10 Install the dust cap. 11 Install the tire and wheel assembly. 12 Lower the machine and remove the blocks. 13 Torque the wheel lug nuts to specification. Refer to Section 2, Specifications. Part No. 106373 Genie Z-30/20N 4 - 41...

  • Page 86: Motor Controller

    There are or more. If any test has a result of less than no adjustments needed on the drive joystick. For 500 kilohms, replace the motor controller. further information or assistance, consult the Genie Industries Service Department. Test Desired result...

  • Page 87: Troubleshooting And Repair Procedures Shall Be Completed By A Person Trained And Qualified On The Repair Of This Machine

    Fault Codes Before Troubleshooting: Read, understand and obey the safety rules and operating instructions printed in the Genie Z-30/20N Operator’s Manual on your machine. Be sure that all necessary tools and test equipment are available and ready for use. Observe and Obey:...
  • Page 88 1 second, and then motor controller programmer blinks 1 time. That would indicate Fault Code 41. (Genie part number 56303). When using the hand-held pendant motor controller programmer, the M1 MAX SPEED needs to be set to 33.

  • Page 89: Fault Code Chart

    OR test the motor controller. See Repair Section. Defective motor Replace the motor ARM SENSOR Machine will not drive. controller. controller. Defective motor Replace the motor FLD SENSOR Machine will not drive. controller. controller. Part No. 106373 Genie Z-30/20N 5 - 3...
  • Page 90 PRECHARGE FAULT Machine will not drive. controller and ground Note: Short can be on OR motor controller is any part of circuit defective. connected to the B+ terminal on the motor controller. 5 - 4 Genie Z-30/20N Part No. 106373...
  • Page 91 Machine will not drive. OR machine being proper cooling of the driven under excessive controller OR check for load OR motor mechanical restrictions controller is not being causing excessive load cooled sufficently. on the machine. Part No. 106373 Genie Z-30/20N 5 - 5...
  • Page 92 Section 5 • Fault Codes April 2004 This page intentionally left blank. 5 - 6 Genie Z-30/20N Part No. 106373...
  • Page 93 Do not allow oil to squirt Read, understand and obey the safety rules or spray. and operating instructions printed in the General Repair Process Genie Z-30/20N Operator's Manual on your machine. Be sure that all necessary tools and test Identify Malfunction...

  • Page 94: Load Sensor Option Diagram (Before Serial Number 6290)

    TS11 PRIMARY BOOM TOGGLE SWITCH TS12 TURNTABLE ROTATE TOGGLE SWITCH TS13 BOOM EXTEND TOGGLE SWITCH TS15 DRIVE ENABLE TOGGLE SWITCH TS16 JIB ROTATE TOGGLE SWITCH (OPTION) DRIVE ENABLE LIGHT OVERLOAD LIGHT (OPTION) 6 - 2 Genie Z-30/20N Part No. 106373...

  • Page 95: Electrical Symbols Legend

    Relay contact Drive motor normally closed Circuits crossing Toggle switch SPDT no connection Relay panel contactor Fuse PLATFORM PUMP GROUND Auxiliary lift pump NOHC Key switch Diode Limit switch normally open held closed Part No. 106373 Genie Z-30/20N 6 - 3...

  • Page 96: Hydraulic Symbols Legend

    1.7 bar Pump prime mover Filter with by-pass Solenoid operated (motor) 2 position, 3 way directional valve N.O. N.C. Normally closed Solenoid operated 3 position, Pressure switch poppet valve 4 way, directional valve 6 - 4 Genie Z-30/20N Part No. 106373...

  • Page 97: Power Cable Diagram (Before Serial Number 6290)

    April 2004 Section 6 • Schematics Power Cable Diagram (before serial number 6290)
  • Page 98 500A 100A (PR3) PRIMARY 3 DIODES LIFT PUMP 48V DC CONTACTOR (PR2) MOTOR CONTROLLER RED (10 BLK (2 LEFT SIDE BLK (2 RIGHT SIDE BLK (2 DRIVE MOTOR DRIVE MOTOR RED (10 6 - 5 Genie Z-30/20N Part No. 106373...

  • Page 99: Power Cable Diagram (After Serial Number 6289)

    DO NOT ROUTE POWER CABLES ACROSS FRONT OF CURTIS CONTROLLER. DOING SO CAN AFFECT INTERNAL CURRENT SENSORS, RIGHT SIDE DRIVE MOTOR CAUSING REDUCED MOTOR PERFORMANCE. BLK (2) BLK (2) BLK (2) LEFT SIDE DRIVE MOTOR RED (10) Part No. 106373 Genie Z-30/20N 6 - 6...
  • Page 100 April 2004 Section 6 • Schematics Power Cable Diagram (after serial number 6289)

  • Page 102: Electrical Schematic (Before Serial Number 6290)

    LS1* 100A Shown SEPEX CONTROLLER with 24V DC boom +24V DC extended BOOM EXTEND/ RETRACT MOTOR PRIMARY BOOM MOTOR UP/DOWN PUMP PUMP SECONDARY BOOM UP/DOWN (GND) GROUND (GND) TB52 BLK (24V DC) 6 - 7 Genie Z-30/20N Part No. 106373...
  • Page 103 ENABLE LIMIT ORG-6 WHT/RED #6 SWITCH* Shown PLATFORM LEVEL with boom CR10 CUTOUT rotated past CE VERSION either ONLY non-steer wheel TB16 CR20 (GND) FUNCTION MANIFOLD (GND) GROUND TB52 BLK (24V DC) Part No. 106373 Genie Z-30/20N 6 - 8...
  • Page 104 April 2005 Section 6 • Schematics Electrical Schematic (before serial number 6290)

  • Page 106: Electrical Schematic (After Serial Number 6289)

    CE & PLATFORM LOAD SENSE OPTION. SWITCH SHOWN WITH BOOM EXTENDED ADD D40 ONLY IF UNIT HAS BOTH L4 & L48. REDUNDANT COIL SUPPRESION DIODE FOR PR1 IS INSIDE CONTROLLER BETWEEN J1-9 AND J1-17. ANSI/CSA ONLY 6 - 9 Genie Z-30/20N Part No. 106373...
  • Page 107 ORG-6 WHT/RED #6 LIMIT SWITCH PLATFORM LEVEL CR10 CUTOUT CE VERSION ONLY TB16 CR20 (GND) FUNCTION MANIFOLD GROUND (GND) TB52 BLK (24V) NOTES: SWITCH SHOWN WITH BOOM ROTATED PAST EITHER NON-STEER WHEEL Part No. 106373 Genie Z-30/20N 6 - 10...
  • Page 108 April 2005 Section 6 • Schematics Electrical Schematic (after serial number 6289)

  • Page 109: Ground Control Panel Wiring Diagram (Before Serial Number 6290)

    Section 6 • Schematics April 2004 Ground Control Panel Wiring Diagram (before serial number 6290)
  • Page 110 BLU/WHT-1 CONTROL RELAY CR5 - BRAKE RELEASE BLU/RED-1 BRAKE RELEASE/TRAVEL ALARM CR10A - PLATFORM LEVEL CUTOUT (CE ONLY) GRN/WHT-1 DESCENT ALARM (OPTION) CR10B - PLATFORM LEVEL CUTOUT (CE ONLY) CONTROLLER STATUS LED 6 - 11 Genie Z-30/20N Part No. 106373...

  • Page 111: Ground Control Panel Wiring Diagram (After Serial Number 6289)

    BLK-CH ORG-3 ORG-CR10A ORG-SP PLAT. LEVEL UP TS63 BOOM EXTEND/RETRACT TOGGLE SWITCH TS66 JIB BOOM ROTATE TOGGLE SWITCH (OPTION) ORG/RED-42A PLATFORM LEVEL CUTOUT (CE MODELS ONLY) BRN-CH PLATFORM OVERLOAD MODULE (CE MODELS) Part No. 106373 Genie Z-30/20N 6 - 12...
  • Page 112 April 2004 Section 6 • Schematics Ground Control Panel Wiring Diagram (after serial number 6289)

  • Page 113: Platform Control Box Wiring Diagram (Before Serial Number 6290)

    Section 6 • Schematics April 2004 Platform Control Box Wiring Diagram (before serial number 6290)
  • Page 114 TILT ALARM DRIVE ENABLE LIGHT BATTERY CHARGE INDICATOR (OPTION) 6 7 8 9 10 REMOVE THIS WIRE WHEN LOAD REMOVE JUMPER JIB BOOM ROTATE SENSE OPTION IS REQUIRED. FOR CE MODELS OPTION 6 - 13 Genie Z-30/20N Part No. 106373...

  • Page 115: Platform Control Box Wiring Diagram (After Serial Number 6289)

    PRIMARY BOOM UP/DOWN TOGGLE SWITCH TS11 TS12 TURNTABLE ROTATE TOGGLE SWITCH TS13 EXTEND/RETRACT TOGGLE SWITCH TS15 DRIVE ENABLE TOGGLE SWITCH TS16 JIB ROTATE TOGGLE SWITCH (OPTION) NOTE: JIB ROTATE REMOVE JUMPER JP1 FOR CE VERSION. OPTION Part No. 106373 Genie Z-30/20N 6 - 14...
  • Page 116 April 2004 Section 6 • Schematics Platform Control Box Wiring Diagram (after serial number 6289)

  • Page 117: Power Panel Wiring Diagram

    CR20 LIFT PUMP CONTACTOR RELAY GRN/WHT #PR2 CR20 LIFT PUMP CONTACTOR RELAY SOCKET WIRING (WIRE INSERTION SIDE SHOWN) BRN #CB2 WHT/BLK #31 WHT #30 BLK #L3 ORG #40 BLU/WHT #12 ORG/RED #CR2 Part No. 106373 Genie Z-30/20N 6 - 15...
  • Page 118 April 2004 Section 6 • Schematics Power Panel Wiring Diagram...

  • Page 119: Hydraulic Schematic

    75.8 bar 0.045 inch 1.14 mm 10 MICRON 100 MESH 0.8 gpm 1.5 gpm 3 L/min 5.7 L/min HYDRAULIC RESERVOIR FUNCTION MANIFOLD Note: 0.035 inch Orifice added after serial number 5396 0.89 mm Part No. 106373 Genie Z-30/20N 6 - 16...
  • Page 120 April 2004 Section 6 • Schematics Hydraulic Schematic...
  • Page 121 Genie North America Phone 425.881.1800 Toll Free USA and Canada 800.536.1800 425.883.3475 Genie Holland Genie Australia Pty Ltd. Phone + Phone + 31 70 51 78836 61 7 3375 1660 Fax + Fax + 31 70 51 13993 61 7 3375 1002...

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