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Part No. 43063

Genie Z-30/20

5 - 11

Service Manual - Third pEdition

Section 5 - Troubleshooting Flow Charts

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Содержание Z-30/20

Страница 1: ...Service Manual Technical Publications Third Edition First Printing Part No 43063 ...

Страница 2: ...equire specialized skills tools lifting equipment and a suitable workshop In these instances we strongly recommend that maintenance and repair be performed at an authorized Genie dealer service center Genie Industries has endeavored to deliver the highest degree of accuracy possible However continuous improvement of our products is a Genie policy Therefore product specifications are subject to cha...

Страница 3: ...ied 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 l...

Страница 4: ...ot reused These components may fail if they are used a second time Be sure to properly dispose of old oil or other fluids Use an approved container Please be environmentally safe Personal Safety Any person working on or around a machine must be aware of all known safety hazards Personal safety and the continued safe operation of the machine should be your top priority Read each procedure thoroughl...

Страница 5: ...ions Introduction 3 1 Table A 3 2 Table B 3 2 Table C 3 4 Table D 3 4 Maintenance Inspection Report 3 5 Section Four Scheduled Maintenance Procedures Introduction 4 1 A 1 Inspect the Operator s and Safety Manuals 4 2 A 2 Inspect the Decals and Placards 4 2 A 3 Inspect for Damage Loose or Missing Parts 4 3 A 4 Check the Hydraulic Oil Level 4 3 A 5 Check for Hydraulic Leaks 4 3 A 6 Test the Platform...

Страница 6: ...ride 4 11 B 9 Test the Platform Self leveling 4 11 B 10 Test the Service Horn 4 11 B 11 Test the Foot Switch 4 12 B 12 Test the Drive Brakes 4 12 B 13 Test the Drive Speed Stowed Position 4 12 B 14 Test the Alarm Package Optional Equipment 4 13 B 15 Perform Hydraulic Oil Analysis 4 14 B 16 Test the Turntable Rotation Stop 4 14 B 17 Check the Electrical Contactors 4 14 C 1 Check the Primary Boom We...

Страница 7: ...1 10 Secondary Boom Down Function Inoperative 5 23 11 Primary Boom Extend Function Inoperative 5 25 12 Primary Boom Retract Function Inoperative 5 28 13 Turntable Rotate Left Function Inoperative 5 31 14 Turntable Rotate Right Function Inoperative 5 33 15 All Platform Level Functions Inoperative 5 35 16 Platform Level Up Function Inoperative 5 36 17 Platform Level Down Function Inoperative 5 39 18...

Страница 8: ...TABLE OF CONTENTS viii Section Six Schematics Introduction 6 1 Electrical Symbols Legend 6 2 Electrical Schematic 6 3 Ground Control Panel Legend 6 4 Power Panel Legend 6 5 Platform Control Panel Legend 6 6 Hydraulic Symbols Legend 6 7 Hydraulic Schematic 6 8 ...

Страница 9: ...Leveling Slave Cylinder 7 7 2 3 Platform Rotator 7 9 Primary Boom Components 3 1 Plastic Cable Track 7 11 3 2 Primary Boom 7 11 3 3 Primary Boom Lift Cylinder 7 14 3 4 Extension Cylinder 7 15 3 5 Platform Leveling Master Cylinder 7 16 Secondary Boom Components 4 1 Secondary Boom 7 17 4 2 Secondary Boom Lift Cylinder 7 20 Ground Controls 5 1 Toggle Switches See 1 3 Toggle Switches 7 6 5 2 Control R...

Страница 10: ...justments Function Manifold 7 26 7 3 Brake Manifold Components 7 28 7 4 Proportional Manifold Components 7 30 Turntable Rotation Components 8 1 Rotation Hydraulic Motor 7 32 8 2 Rotation Bearing and Worm Drive 7 32 Steering Axle Components 9 1 Yoke and Hub 7 37 9 2 Steering Cylinder 7 38 9 3 Tie Rod 7 38 Non steering Axle Components 10 1 Drive Motor 7 39 10 2 Torque Hub 7 39 x ...

Страница 11: ...3 ft 9 in 4 2 m outside Minimum turning circle 6 ft 4 in 1 9 m inside Turntable rotation 359 Platform rotation 130 Tires and wheels Tire size 9 14 5 LT Load range F Tire contact area 43 5 sq in 280 sq cm Overall tire diameter 28 in 71 cm Wheel diameter 14 5 in 36 8 cm Wheel width 7 in 17 8 cm Wheel lugs Front 8 5 8 18 Rear 9 5 8 18 Lug nut torque 125 ft lbs 169 5 Nm Platform dimensions Length 48 i...

Страница 12: ...21 seconds Primary boom extend 19 to 21 seconds Primary boom retract 12 to 14 seconds Secondary boom up 23 to 25 seconds Secondary boom down 25 to 27 seconds Turntable rotate 180 10 to 12 seconds Platform level up 5 to 7 seconds Platform level down 8 to 10 seconds SPECIFICATIONS Hydraulic Specifications Hydraulic fluid Dexron equivalent Lift pump Type gear Displacement 137 cu in per revolution 2 3...

Страница 13: ... 583 637 868 949 60 68 144 168 25 25 45 50 70 80 110 120 150 170 220 240 380 420 600 660 900 1000 7 8 16 19 34 34 61 68 95 109 149 163 204 231 298 326 515 570 814 895 1221 1356 Size Threads SAE Grade 5 Bolts SAE Grade 8 Bolts per inch Bolt Torque Specifications 13 20 12 18 11 18 10 16 9 14 8 12 No 10 1 4 inch 5 16 inch 3 8 inch 7 16 inch 1 2 inch 9 16 inch 5 8 inch 3 4 inch 7 8 inch 1 inch Torque ...

Страница 14: ...2 4 Genie Z 30 20 Part No 43063 Section 2 Specifications Service Manual Third Edition This page intentionally left blank ...

Страница 15: ...onger than 3 months must complete the quarterly inspection About This Section The Schedule There are four types of maintenance inspections that must be performed according to a schedule daily quarterly annual and two year To account for repeated procedures the Maintenance Tables and the Maintenance Inspection Report have been divided into four subsections A B C D Use the following chart to determi...

Страница 16: ...or Damage Loose or Missing Parts A 4 Check the Hydraulic Oil Level A 5 Check for Hydraulic Leaks A 6 Test the Platform and Ground Controls A 7 Test the Platform Rotation A 8 Test the Tilt Sensor A 9 Test the Manual Controls A 10 Test the Drive Limit Switches A 11 Perform 30 Day Service Table B B 1 Check the Batteries B 2 Inspect the Electrical Wiring B 3 Inspect the Tires and Wheels including lug ...

Страница 17: ...h B 7 Test the Emergency Stop Buttons B 8 Test the Ground Control Override B 9 Test the Platform Self leveling B 10 Test the Service Horn B 11 Test the Foot Switch B 12 Test the Drive Brakes B 13 Test the Drive Speed Stowed Position B 14 Test the Alarm Package Optional Equipment B 15 Perform Hydraulic Oil Analysis See D 1 Test or Replace the Hydraulic Oil B 16 Test the Turntable Rotation Stop B 17...

Страница 18: ...old engine required Dealer service suggested Table C C 1 Check the Primary Boom Wear Pads C 2 Check the Turntable Rotation Bearing Bolts C 3 Check the Free wheel Configuration C 4 Grease the Turntable Rotation Bearing and Worm Drive Gear C 5 Replace the Torque Hub Oil C 6 Replace the Hydraulic Filter Table D D 1 Test or Replace the Hydraulic Oil MAINTENANCE TABLES ...

Страница 19: ...table stop B 17 Electrical contactors Checklist C Y N R Refer to Table C C 1 Boom wear pads C 2 Turntable bearing bolts C 3Free wheelconfiguration C 4 Grease rotation bearing C 5 Torque hub oil C 6 Hydraulic filter Checklist D Y N R Refer to Table D D 1 Hydraulic oil Instructions Make copies of this page to use for eachinspection Select the appropriate checklist s for the type of inspection to be ...

Страница 20: ...t No 43063 Section 3 Scheduled Maintenance Inspections Service Manual Third Edition Tools are required New parts required Warm engine required Cold engine required Dealer service suggested This page intentionally left blank ...

Страница 21: ...intenance Procedures Observe and Obey Maintenance inspections shall be completed by a person trained and qualified on the maintenance of this machine Scheduled maintenance inspections shall be completed daily quarterly annually and every 2 years as specified on the Maintenance Inspection Report Failure to properly complete each inspection when required may cause death serious injury or substantial...

Страница 22: ...ood condition 4 Always return the manuals to the storage container after use Contact your authorized Genie distributor or Genie Industries if replacement manuals are needed A 2 Inspect the Decals and Placards Maintaining all of the safety and instructional decals and placards in good condition is mandatory for safe machine operation Decals alert operators and personnel to the many possible hazards...

Страница 23: ...sential to machine operation Improper hydraulic oil levels can damage hydraulic components Daily checks allow the inspector to identify changes in oil level that might indicate the presence of hydraulic system problems 1 Be sure that the boom is in the stowed position 2 Visually inspect the sight gauge on the hydraulic power unit reservoir Result The hydraulic oil level should be visible inside th...

Страница 24: ... sound while boom is lowering 4 Push in the Emergency Stop Switch to the OFF position Result No function should operate the machine should stop 5 Turn the key switch to platform control and lift the red Emergency Stop switch cover and move the toggle switch to the ON position Pull out the Emergency Stop Button to the ON position at the platform controls 6 Operate each machine function through a pa...

Страница 25: ...ult Boom function should operate 4 Repeat steps 2 and 3 to test each boom function Manual controls will not operate the drive function A 8 Test the Tilt Sensor The tilt sensor sounds an alarm in the platform when the incline of the drive chassis exceeds 4 5 degrees Select a level test area The tilt alarm should not be sounding prior to test 1 Turn the key switch to platform control and lift the re...

Страница 26: ...ncy Stop switch cover and move the toggle switch to the ON position TABLE A PROCEDURES a 6 Activate the function enable switch and lower the primary boom into the stowed position 7 Raise the secondary boom above the drive limit switch and turn the machine off 8 Manually activate the drive limit switch Result The drive limit switch arm should move freely and spring return to center A distinct click...

Страница 27: ...ure is a one time sequence of procedures to be performed after the first 30 days or 50 hours of usage After this interval refer to the maintenance tables for continued scheduled maintenance 1 Perform the following maintenance procedures B 3 Inspect Tires and Wheels C 2 Check the Turnable Rotation Bearing Bolts C 6 Replace the Hydraulic Filter TABLE A PROCEDURES ...

Страница 28: ... correctly B 2 Inspect the Electrical Wiring Maintaining electrical wiring in good condition is essential to safe operation and good machine performance Failure to find and replace burnt chafed corroded or pinched wires could result in unsafe operating conditions and may cause component damage Electrocution hazard Contact with hot or live circuits may result in death or serious injury Remove all r...

Страница 29: ...nce Hydraulically released spring applied individual wheel brakes can appear to operate normally when they are actually not fully operational 1 Check each torque hub disconnect cap to be sure it is in the engaged position B 5 Check the Oil Level in the Torque Hubs Failure to maintain proper torque hub oil levels may cause the machine to perform poorly and continued use may cause component damage 1...

Страница 30: ...p Function A properly functioning Emergency Stop button and Emergency Stop Switch are essential for safe machine operation An improperly operating Emergency Stop function may fail to shut off power and stop all machine functions resulting in a hazardous situation As a safety feature selecting and operating the ground controls will override the platform controls including the Emergency Stop button ...

Страница 31: ...trolled by the master cylinder located at the base of the primary boom A platform self leveling failure creates an unsafe working condition 1 Turn the key switch to ground control and lift up the Emergency Stop Switch cover at the ground controls and move the toggle switch to the ON position Pull out the Emergency Stop Button to the ON position at the platform controls 2 Activate the function enab...

Страница 32: ...eel configuration Refer to B 4 in this section Confirm the Proper Brake Configuration Select a test area that is firm level and free of obstructions 1 Mark a test line on the ground for reference 2 Turn the key switch to platform control and lift the red Emergency Stop switch cover and move the toggle switch to the ON position at the ground controls Pull out the Emergency Stop Button to the ON pos...

Страница 33: ...s Travel alarm Descent alarm Flashing beacon Alarms and a beacon are installed to alert operators and ground personnel of machine proximity and motion The alarm package is installed on the function manifold side turntable cover 1 Turn the key switch to ground control and lift the red Emergency Stop switch cover and move the toggle switch to the ON position at the ground controls Result The flashin...

Страница 34: ...he red Emergency Stop switch cover and move the toggle switch to the ON position at the ground controls Pull out the Emergency Stop Button to the ON position at the platform controls 2 Rotate the turntable to the left full circle as far as it will go Result Movement should stop when the primary boom reaches mid point between the steer tires 3 Rotate the turntable to the right full circle as far as...

Страница 35: ... through the entire range of motion to check for tight spots that could cause binding or scraping Always maintain squareness between the primary boom outer and inner tubes C 2 Check the Turntable Rotation Bearing Bolts Maintaining proper torque on the turntable bearing bolts is essential to safe machine operation Improper bolt torque could result in an unsafe operating condition and component dama...

Страница 36: ... and out of the non steer end of the machine Crushing hazard The counterweights may become unbalanced and fall if they are not properly supported 10 Pull the smaller counterweight towards the steer end of the machine slightly and then lower the counterweight to the ground 11 Shift the forks of the forklift to the steer end of the machine enough for the counterweight to clear the forklift pocket tu...

Страница 37: ...el should rotate with minimum effort 6 Re engage the torque hubs by turning over the hub disconnect caps Carefully remove the jack stands lower the machine and remove the jack Collision hazard Failure to re engage the torque hubs may cause death or serious injury and property damage TABLE C PROCEDURES a C 4 Grease the Turntable Rotation Bearing and Worm Drive Gear Yearly application of lubrication...

Страница 38: ... API service classification GL5 C 6 Replace the Hydraulic Filter Replacement of the hydraulic filter is essential for good machine performance and service life A dirty or clogged filter may cause the machine to perform poorly and continued use may cause component damage Extremely dirty conditions may require that the filter be replaced more often Beware of hot oil Contact with hot oil may cause se...

Страница 39: ... fails the test Perform this procedure with the boom in the stowed position 1 Place a suitable container under the hydraulic power unit reservoir 2 Remove the power unit side turntable cover 3 Remove the drain plug from the bottom of the hydraulic power unit reservoir 4 Completely drain the reservoir into a suitable container See capacity specifications listed above 5 Remove the reservoir mounting...

Страница 40: ...4 20 Genie Z 30 20 Part No 43063 Service Manual Third Edition Section 4 Scheduled Maintenance Procedures This page intentionally left blank ...

Страница 41: ... and other jewelry Bodily injury hazard Spraying hydraulic oil can penetrate and burn skin Loosen hydraulic connections very slowly to allow the oil pressure to dissipate gradually Do not allow oil to squirt or spray Perform all troubleshooting on a firm level surface Two persons will be required to safely perform some troubleshooting procedures Troubleshooting Flow Charts Observe and Obey Trouble...

Страница 42: ...ohmmeter pressure gauges The location of terminals mentioned in this section can be found on the appropriate electrical or hydraulic schematics provided in Section 6 Schematics Since various degrees of a particular function loss may occur selecting the appropriate flow chart may be troublesome When a function will not operate with the same speed or power as a machine in good working condition refe...

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Страница 45: ...e Manual Third pEdition Section 5 Troubleshooting Flow Charts CHART 1 UTZOT KJ LXUS ZNK VXK OU Y VGMK NKIQ URZGMK UT U ZV Z YOJK UL L YK 8KVRGIK L YK XU HRKYNUUZ ROLZ GTJ JXO K Y_YZKSY YKVGXGZKR_ 58 IUTY RZ KTOK TJ YZXOKY 9KX OIK KVGXZSKTZ ...

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Страница 51: ...Troubleshooting Flow Charts CHART 4 KYZ JOUJKY UT ZNK VXOTZKJ IOXI OZ HUGXJ 8KVRGIK ZNK VXOTZKJ IOXI OZ HUGXJ MUUJ XU HRKYNUUZ MXU TJ GTJ VRGZLUXS IUTZXUR L TIZOUTY YKVKXGZKR_ XKLKX ZU INGXZY GTJ 58 IUTY RZ KTOK TJ YZXOKY 9KX OIK KVGXZSKTZ HGJ UTZOT KJ LXUS ZNK VXK OU Y VGMK ...

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Страница 55: ... YUIQKZ IZO GZK LUUZY OZIN GTJ INKIQ URZGMK UT ZNK IKTZKX ZKXSOTGR UL KGIN L TIZOUT ZUMMRK Y OZIN GZ ZNK VRGZLUXS IUTZXURY 8KVGOX UVKT OT XKJ OXK ZKXSOTGR UT ZU XKJ OXK P SVKX IOXI OZ GZ KGIN L TIZOUT ZUMMRK Y OZIN NKIQ URZGMK GZ ZNK XKJ OXK UT ZNK ROLZ VXUVUXZOUTGR IUTZXURRKX 8KVGOX UVKT OT XKJ OXK LXUS ZKXSOTGR UT ZU XKJ OXK GZ ZNK ROLZ VXUVUXZOUTGR IUTZXURRKX OZN QK_ Y OZIN OT VRGZLUXS VUYOZOUT...

Страница 56: ...6 UTZOT KJ LXUS ZNK VXK OU Y VGMK 8KVGOX UVKT OT HRQ XKJ OXK OZN JOUJK LXUS ZU UTY RZ KTOK TJ YZXOKY 9KX OIK KVGXZSKTZ OZN QK_ Y OZIN OT VRGZLUXS VUYOZOUT GTJ HUZN SKXMKTI_ 9ZUV Y OZINKY V RRKJ U Z ZU ZNK UT VUYOZOUT GTJ ZNK ROLZ VXUVUXZOUTGR IUTZXURRKX Z XTKJ ZU GIZO GZK ZNK LUUZ Y OZIN GTJ INKIQ URZGMK GZ ...

Страница 57: ...N OT VRGZLUXS VUYOZOUT GTJ HUZN SKXMKTI_ 9ZUV Y OZINKY V RRKJ U Z ZU ZNK UT VUYOZOUT GIZO GZK LUUZY OZIN GTJ VXOSGX_ HUUS ZUMMRK Y OZIN 9 UT VRGZLUXS IUTZXUR VGTKR OT V JOXKIZOUT GTJ INKIQ URZGMK UT XKJ OXK GZ UX SUXK XU HRKYNUUZ VXOSGX_ HUUS V ZUMMRK Y OZIN 9 58 XKVGOX UVKT OT XKJ OXK LXUS 9 ZU ZU UX SUXK 8KVRGIK VXOTZKJ IOXI OZ HUGXJ IZO GZK L TIZOUT KTGHRK GTJ VXOSGX_ HUUS ZUMMRK Y OZIN 9 UT MX...

Страница 58: ...NSY ZU UNSY 8KVRGIK VXOSGX_ HUUS V JOXKIZOUTGR GR K IUOR OZKS TYZGRR G ZU 69 VXKYY XK MG MK GZ ZNK W OIQ JOYIUTTKIZ IU VROTM UT ZNK HUUS L TIZOUT SGTOLURJ GTJ GIZO GZK L TIZOUT KTGHRK GTJ ZNK VXOSGX_ HUUS V L TIZOUT 69 RKYY ZNGT 69 8KVGOX I_ROTJKX UX I_ROTJKX IU TZKXHGRGTIK GR K 58 HUUS L TIZOUT SGTOLURJ IU RJ NG K GT OTZKXTGR JKLKIZ IUTY RZ KTOK TJ YZXOKY 9KX OIK KVGXZSKTZ NKIQ LUX SKINGTOIGR XKY...

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Страница 63: ...GZLUXS VUYOZOUT GTJ HUZN SKXMKTI_ 9ZUV Y OZINKY V RRKJ U Z ZU ZNK UT VUYOZOUT GIZO GZK LUUZY OZIN GTJ YKIUTJGX_ HUUS ZUMMRK Y OZIN 9 UT VRGZLUXS IUTZXUR VGTKR OT JU T JOXKIZOUT GTJ INKIQ URZGMK UT HR HRQ OXK GZ UX SUXK XU HRKYNUUZ YKIUTJGX_ HUUS JU T ZUMMRK Y OZIN 9 58 XKVGOX UVKT OT HR HRQ OXK LXUS 9 ZU ZU 8KVRGIK VXOTZKJ IOXI OZ HUGXJ IZO GZK L TIZOUT KTGHRK GTJ YKIUTJGX_ HUUS ZUMMRK Y OZIN 9 UT...

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Страница 73: ...S VUYOZOUT GTJ HUZN SKXMKTI_ 9ZUV Y OZINKY V RRKJ U Z ZU ZNK UT VUYOZOUT GIZO GZK LUUZY OZIN GTJ Z XTZGHRK XUZGZK ZUMMRK Y OZIN 9 UT VRGZLUXS IUTZXUR VGTKR OT ZNK XOMNZ JOXKIZOUT GTJ INKIQ URZGMK UT NZ HRQ OXK GZ UX SUXK XU HRKYNUUZ Z XTZGHRK XUZGZK ZUMMRK Y OZIN 9 58 XKVGOX UVKT OT NZ HRQ OXK LXUS 9 ZU ZU UX SUXK 8KVRGIK VXOTZKJ IOXI OZ HUGXJ IZO GZK L TIZOUT KTGHRK GTJ Z XTZGHRK XUZGZK ZUMMRK Y ...

Страница 74: ...XKIZOUTGR GR K IUOR OZKS TYZGRR G ZU 69 VXKYY XK MG MK GZ ZNK W OIQ JOYIUTTKIZ IU VROTM UT ZNK HUUS L TIZOUT SGTOLURJ GTJ GIZO GZK L TIZOUT KTGHRK GTJ ZNK Z XTZGHRK XUZGZK OT ZNK XOMNZ JOXKIZOUT 69 RKYY ZNGT 69 8KYKYZ Z XTZGHRK XUZGZK XOMNZ XKROKL GR K VXKYY XK 58 XKVGOX Z XTZGHRK XUZGZK SUZUX UX Z XTZGHRK XUZGZK XOMNZ XKROKL GR K 58 HUUS L TIZOUT SGTOLURJ IU RJ NG K GT OTZKXTGR JKLKIZ 58 IUTY RZ ...

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Страница 78: ...KTGHRK GTJ ZNK VRGZLUXS RK KR V L TIZOUT 69 RKYY ZNGT 69 8KVGOX I_ROTJKX UX I_ROTJKX IU TZKXHGRGTIK GR K 58 HUUS L TIZOUT SGTOLURJ IU RJ NG K GT OTZKXTGR JKLKIZ IUTY RZ KTOK TJ YZXOKY 9KX OIK KVGXZSKTZ NKIQ LUX SKINGTOIGR XKYZXOIZOUTY QKKVOTM VRGZLUXS RK KR V L TIZOUT LXUS SU OTM 58 XKVGOX I_ROTJKX UX I_ROTJKX IU TZKXHGRGTIK GR K 58 IUTY RZ KTOK TJ YZXOKY 9KX OIK KVGXZSKTZ UTZOT KJ LXUS ZNK VXK OU...

Страница 79: ...ZN SKXMKTI_ 9ZUV Y OZINKY V RRKJ U Z ZU ZNK UT VUYOZOUT GIZO GZK LUUZY OZIN GTJ VRGZLUXS RK KR ZUMMRK Y OZIN 9 UT VRGZLUXS IUTZXUR VGTKR OT JU T JOXKIZOUT GTJ INKIQ URZGMK UT UXM OXK GZ XU HRKYNUUZ VRGZLUXS RK KR ZUMMRK Y OZIN 9 58 XKVGOX UVKT OT UXM HRQ OXK LXUS 9 ZU ZU UX SUXK 8KVGOX UVKT LXUS ZU ZU IZO GZK L TIZOUT KTGHRK GTJ VRGZLUXS RK KR ZUMMRK Y OZIN 9 UT MXU TJ IUTZXUR VGTKR OT JU T JOXKIZ...

Страница 80: ...GIK JKLKIZO K VRGZLUXS RK KR JU T JOXKIZOUTGR GR K OZKS 2 58 IUTY RZ KTOK TJ YZXOKY 9KX OIK KVGXZSKTZ INGTMK VRGZLUXS RK KR JU T GTJ V XKROKL GR KY OZKSY 3 4 GTJ GIZO GZK VRGZLUXS RK KR JU T L TIZOUT L TIZOUT JUKY TUZ UVKXGZK L TIZOUT UVKXGZKY 8KVGOX UX XKVRGIK JKLKIZO K XKROKL GR K 58 IUTY RZ KTOK TJ YZXOKY 9KX OIK KVGXZSKTZ INGTMK VRGZLUXS RK KR JU T GTJ V INKIQ GR KY OZKSY 1 GTJ GIZO GZK VRGZLU...

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Страница 93: ...IK HXGQK XKRKGYK GR K 4 IUOR OZKS ZU UNSY OZN QK_ Y OZIN OT VRGZLUXS VUYOZOUT GTJ HUZN SKXMKTI_ 9ZUV Y OZINKY V RRKJ U Z ZU ZNK UT VUYOZOUT IUTTKIZ GT GSSKZKX OT YKXOKY OZN MXT HRQ OXK GTJ HXGQK VXUVUXZOUTGR GR K IUOR OZKS UT HXGQK SGTOLURJ GTJ GIZO GZK LUUZY OZIN GTJ JXO K IUTZXURRKX OT L J JOXKIZOUT TZOR YZXUQK SOIXU Y OZIN GIZO GZKY SVKXGMK YNU RJ VXUVUXZOUTGRR_ OTIXKGYK LXUS GSVY ZU GSVY GZ YZ...

Страница 94: ... RKYY ZNGT VYO 8KVRGIK VXKYY XK Y OZIN 69 58 IUTY RZ KTOK TJ YZXOKY 9KX OIK KVGXZSKTZ 8KVRGIK HXGQK XKRKGYK GR K NGRL YZXUQK GR K OZKS 58 XKVRGIK HXGQK XKRKGYK VXUVUXZOUTGR GR K OZKS 58 IUTY RZ KTOK TJ YZXOKY 9XK OIK KVGXZSKTZ TYZGRR G VXKYY XK MG MK UT HXGQK SGTOLURJ W OIQ JOYIUTTKIZ OZN QK_ Y OZIN OT VRGZLUXS VUYOZOUT GTJ HUZN SKXMKTI_ 9ZUV Y OZINKY V RRKJ U Z ZU ZNK UT VUYOZOUT GIZO GZK LUUZY O...

Страница 95: ...NKIQ XKYOYZGTIK UL LUX GXJ IUOR 9KK 8KVGOX 9KIZOUT OTLOTOZK UNSY UNSY 8KVGOX UX XKVRGIK LUX GXJ IUTZGIZUX 8KVGOX UX XKVRGIK LUX GXJ IUTZGIZUX IUTZGIZY 58 XKVGOX UVKT OT HXU T MXU TJ OXK IOXI OZ 58 IUTY RZ KTOK TJ YZXOKY 9KX OIK KVGXZSKTZ IZO GZK JXO K IUTZXURRKX OT LUX GXJ JOXKIZOUT GTJ INKIQ URZGMK UT UX SUXK 8KVGOX UVKT OT NZ HRQ OXK IOXI OZ LXUS ZU LUX GXJ IUTZGIZUX 58 XKVRGIK VXOTZKJ IOXI OZ H...

Страница 96: ... GTJ INKIQ XKYOYZGTIK UL XK KXYK IUOR 9KK 8KVGOX 9KIZOUT OTLOTOZK UNSY UNSY 8KVGOX UX XKVRGIK L J XK IUTZGIZUX 8KVGOX UX XKVRGIK XK KXYK IUTZGIZUX IUTZGIZY 58 XKVGOX UVKT OT HXU T MXU TJ OXK IOXI OZ 58 IUTY RZ KTOK TJ YZXOKY 9KX OIK KVGXZSKTZ IZO GZK JXO K IUTZXURRKX OT XK KXYK JOXKIZOUT GTJ INKIQ URZGMK UT UX SUXK 8KVGOX UVKT OT NZ OXK IOXI OZ LXUS ZU XK KXYK IUTZGIZUX 58 XKVRGIK VXOTZKJ IOXI OZ ...

Страница 97: ...RZGMK UT UX SUXK 8KVGOX UVKT OT HR NZ OXK IOXI OZ LXUS ZU ZNKT ZU 8 ZKXSOTGR UT JXO K IUTZXURRKX OZN QK_ Y OZIN OT VRGZLUXS VUYOZOUT GTJ HUZN SKXMKTI_ 9ZUV Y OZINKY V RRKJ U Z ZU ZNK UT VUYOZOUT INKIQ URZGMK UT 8KVGOX UVKT OT OXK IOXI OZ LXUS ZNXU MN ZNK HRQ OXK ZU 29 ZNXU MN NZ OXK ZU ZNXU MN ZNK HR NZ OXK ZU 29 ZNKT ZU 58 XKVGOX UX XKVRGIK 29 UX 29 58 INKIQ LUX SKINGTOIGR XKYZXOIZOUT QKKVOTM 29 ...

Страница 98: ...GR UT JXO K IUTZXURRKX UX SUXK 8KVGOX UX XKVRGIK 29 58 INKIQ LUX SKINGTOIGR XKYZXOIZOUT QKKVOTM 29 GIZO GZKJ 58 IUTY RZ KTOK TJ YZXOKY 9KX OIK KVGXZSKTZ 8KGJP YZ JXO K IUTZXURRKX 58 XKVGOX UX XKVRGIK JXO K IUTZXURRKX 58 IUTY RZ KTOK TJ YZXOKY 9KX OIK KVGXZSKTZ 2U KX VXOSGX_ HUUS ZU YZU KJ VUYOZOUT OZN QK_ Y OZIN OT VRGZLUXS VUYOZOUT GTJ HUZN SKXMKTI_ 9ZUV Y OZINKY V RRKJ U Z ZU ZNK UT VUYOZOUT GIZ...

Страница 99: ... Z ZU ZNK UT VUYOZOUT GIZO GZK XKSUZK HXGQK XKRKGYK GTJ INKIQ URZGMK GZ 8KVRGIK JOUJK LXUS ZU OZN MXU TJ IUTZXUR SKXMKTI_ 9ZUV Y OZIN V RRKJ U Z ZU ZNK UT VUYOZOUT GIZO GZK XKSUZK HXGQK XKRKGYK GTJ INKIQ URZGMK GZ U ZV Z YOJK UL XKSUZK HXKGQ XKRKGYK VR M UT MXU TJ IUTZXUR VGTKR 8KVGOX UVKT OT XKJ OXK IOXI OZ LXUS U ZV Z YOJK UL XKSUZK HXGQK XKRKGYK VR M ZU OZN MXU TJ IUTZXUR SKXMKTI_ 9ZUV Y OZIN V...

Страница 100: ...Z OZN MXU TJ IUTZXUR SKXMKTI_ 9ZUV Y OZIN V RRKJ U Z ZU ZNK UT VUYOZOUT GIZO GZK XKSUZK HXGQK XKRKGYK GTJ INKIQ URZGMK GZ U ZV Z YOJK UL XKSUZK HXGQK XKRKGYK VR M UT MXU TJ IUTZXUR VGTKR 8KVGOX UVKT OT XKJ OXK IOXI OZ LXUS U ZV Z YOJK UL XKSUZK HXGQK XKRKGYK VR M ZU OZN MXU TJ IUTZXUR SKXMKTI_ 9ZUV Y OZIN V RRKJ U Z ZU ZNK UT VUYOZOUT INKIQ URZGMK GZ OTV Z YOJK UL XKSUZK HXGQK XKRKGYK VR M 8KVGOX ...

Страница 101: ...5 UTZOT KJ LXUS ZNK VXK OU Y VGMK OZN MXU TJ IUTZXUR SKXMKTI_ 9ZUV Y OZIN V RRKJ U Z ZU ZNK UT VUYOZOUT GIZO GZK XKSUZK HXGQK XKRKGYK GTJ INKIQ URZGMK GZ XKJ NZ OXK UT HXGQK XKRKGYK GR K 4 OZKS 8KVGOX UVKT OT XKJ NZ OXK IOXI OZ LXUS ZU HXGQK XKRKGYK GR K 4 OZKS UX SUXK UTY RZ KTOK TJ YZXOKY 9KX OIK KVGXZSKTZ ...

Страница 102: ...5 62 Genie Z 30 20 Part No 43063 Service Manual Third Edition Section 5 Troubleshooting Flow Charts This page intentionally left blank ...

Страница 103: ... There are two groups of schematics in this section An illustration legend precedes each group of drawings Electrical Schematics Electrocution hazard Contact with electrically charged circuits may result in death or serious injury Remove all rings watches and other jewelry Hydraulic Schematics Bodily injury hazard Spraying hydraulic oil can penetrate and burn skin Loosen hydraulic connections very...

Страница 104: ...Service Manual Third Edition Section 6 Schematics 6 2 Genie Z 30 20 Part No 43063 Electrical Symbols Legend ...

Страница 105: ...Service Manual Section 6 Schematics Part No 43063 Genie Z 30 20 6 3 Electrical Schematic 1 2 3 4 5 6 7 8 O N M L K J I H G F E D C B A RED WHT BLU BLK BLU BLK ...

Страница 106: ...Service Manual Third Edition Section 6 Schematics Ground Controls Legend Part No 43063 Genie Z 30 20 6 4 ...

Страница 107: ...Service Manual Third Edition Section 6 Schematics 6 5 Genie Z 30 20 Part No 43063 Contactor Box and Turntable PC Board Legend ...

Страница 108: ...Part No 43063 Genie Z 30 20 6 6 Section 6 Schematics Service Manual Third Edition Platform Controls Legend ...

Страница 109: ...Service Manual Third Edition Section 6 Schematics Hydraulic Symbols Legend 6 7 Genie Z 30 20 Part No 43063 ...

Страница 110: ...Part No 43063 Genie Z 30 20 6 8 Hydraulic Schematic 1 2 3 4 5 6 7 8 O N M L K J I H G F E D C B A Service Manual Section 6 Schematics ...

Страница 111: ...eral Repair Process Observe and Obey 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 Before Repairs Start Read understand and obey the safety rules and operating instructions in the Genie Z 30 20 Opera...

Страница 112: ...ve all rings watches and other jewelry 1 Block the steering wheels and then center a lifting jack under the drive chassis between the non steer tires 2 Raise the drive chassis 1 to 2 inches 2 54 to 5 0 cm off the ground and place jack stands under the chassis 3 Open the platform control box lid and locate the printed circuit board on the drive controller a terminal R activates max out range b term...

Страница 113: ...o the FORWARD position Adjust the high range trimpot on the circuit board to 5 00 to 5 20V DC Turn the high range trimpot adjustment screw clockwise to increase the voltage or counterclockwise to decrease the voltage 12 Raise the primary boom or the secondary boom approximately 5 feet 1 5 m to activate the drive limit switch 13 Set the drive lo range on the circuit board Press down the foot switch...

Страница 114: ...orque hubs Boom Function Speed Controller Adjustments Do not adjust the controllers unless the static battery supply voltage is above 24V DC Electrocution hazard Contact with electrically charged circuits may result in death or serious injury Remove all rings watches and other jewelry 1 Turn the key switch to platform control and pull the Emergency Stop switch to the ON position at the ground cont...

Страница 115: ...and check for continuity Test Desired result black to white continuity zero W 6 Turn the boom function speed controller at the platform controls to the CREEP position 7 Set the threshold Press down the foot switch then move the primary boom switch to the UP position until the amperage reading appears Adjust the amperage to 0 to 0 12 amps Turn the threshold trimpot adjustment screw clockwise to inc...

Страница 116: ...5 6 no continuity infinite W terminal 2 to 3 4 5 6 no continuity terminal 3 to 4 5 6 no continuity terminal 4 to 5 continuity terminal 4 to 6 no continuity terminal 5 to 6 no continuity 1 3 Toggle Switches Toggle switches used for single function switching are single pole double throw SPDT switches Dual function switching requires a double pole double throw DPDT switch How to Test a Toggle Switch ...

Страница 117: ...supports for the platform The slave cylinder keeps the platform level through the entire range of primary boom motion It operates in a closed circuit hydraulic loop with the master cylinder The slave cylinder is equipped with a counterbalance valve to prevent movement in the event of a hydraulic line failure How to Remove the Slave Cylinder Before cylinder removal is considered bleed the slave cyl...

Страница 118: ...n the lock nut on the needle valve Do not remove the valve a locknut b primary extension boom c needlevalve d platform pivot mount 4 Open the needle valve by turning the needle valve counterclockwise until it stops PLATFORM COMPONENTS 5 Hold the platform leveling switch in the down position for one minute Close the needle valve by turning the needle valve clockwise until it stops 6 Move the platfo...

Страница 119: ...he platform rotator is too loose the platform may rotate side to side unexpectedly resulting in a unsafe operating condition 1 Raise the primary boom approximately 3 feet 0 9 m 2 Activate the function enable switch and the platform level toggle switch in the down direction until the platform is horizontal Do not allow the platform to contact the ground 3 Open the platform control box lid and remov...

Страница 120: ...tly rusted or corroded remove them and clean rust or corrosion off with a wire brush If parts are heavily rusted or corroded replace them 4 Loosen the locknut in the counterclockwise direction just enough to allow the handle to rotate 5 Thoroughly grease the entire mechanical platform rotator assembly 6 Tighten the locknut and check for platform tighteness by grabbing the rails of the platform and...

Страница 121: ...lace the wear pad if it is less than 0 41 inches 1 cm thick If the wear pad is more than 0 41 inches 1 cm thick perform the following procedure 1 Extend the boom until the wear pads are accessible 2 Loosen the wear pad mounting fasteners 3 Install the new shims under the wear pad to obtain zero clearance and zero drag 4 Tighten the mounting fasteners 5 Extend and retract the boom through an entire...

Страница 122: ... if they are kinked or pinched 10 Support the platform pivot weldment and platform rotator with a lifting strap from an overhead crane 11 Remove the retaining fasteners from the rod end pivot pin of the platform level cylinder Use a soft metal drift to remove the pin 12 Remove the retaining fasteners from the pivot pin of the platform pivot weldment Use a soft metal drift to remove the pin Crushin...

Страница 123: ...the Primary Boom Complete disassembly of the boom is only necessary if the outer or inner boom tubes must be replaced The extension cylinder can be removed without completely disassembling the boom See 3 4 How to Remove the Extension Cylinder 1 Remove the boom See 3 2 How to Remove the Primary Boom 2 Place blocks under the extension cylinder for support 3 Remove the cotter pin from the extension c...

Страница 124: ... and burn skin Loosen hydraulic connections very slowly to allow the oil pressure to dissipate gradually Do not allow oil to squirt or spray 3 Support the rod end of the cylinder with a lifting strap from an overhead crane 4 Remove the pin retainer from the primary boom lift cylinder rod end pin Then use a soft metal drift to remove the pin 5 Lower the rod end of the cylinder onto the turntable co...

Страница 125: ...te the inspection cover at the platform end of the extension tube 4 Remove the inspection cover fasteners then remove the inspection cover 5 Remove the cylinder rod end retaining bracket fasteners 6 Tag disconnect and plug the extension cylinder hydraulic hoses Cap the fittings on the cylinder Bodily injury hazard Spraying hydraulic oil can penetrate and burn skin Loosen hydraulic connections very...

Страница 126: ...that there is no air in the closed loop See 2 2 How to Bleed the Slave Cylinder 1 Tag disconnect and plug the master cylinder hydraulic hoses Cap the fittings on the cylinder Bodily injury hazard 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 pin retainer f...

Страница 127: ...fting equipment and a suitable workshop Attempting this procedure without these skills and tools may result in death or serious injury and significant component damage Dealer service is required Follow the disassembly steps to the point required to complete the repair Then re assemble the secondary boom by following the disassembly steps in reverse order SecondaryBoom a secondaryboom b mid pivot c...

Страница 128: ...d The tension link will fall when the tension link pivot pin is removed from the mid pivot if it is not properly supported 19 Lower the tension link and rest it on the chassis 20 Use a soft metal drift to remove the secondary boom pivot pin at the mid pivot SECONDARY BOOM COMPONENTS 1 Lower the boom to the stowed position 2 Remove the platform See 2 1 How to Remove the Platform 3 Remove the primar...

Страница 129: ...inder will fall unless it is properly supported 27 Lower the rod end of the secondary boom lift cylinder onto the wood block 28 Remove the pin retaining fasteners from the secondary boom pivot pin at the turntable pivot Use a soft metal drift to remove the pin If the overhead crane is not properly attached the secondary boom may become unbalanced and fall when it is removed from the machine 29 Rem...

Страница 130: ...oom lift cylinder Cap the cylinder fittings 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 Secure the barrel end of the cylinder to the secondary boom using a strap to prevent the cylinder from falling when the pivot pin is removed 5 Attach a stra...

Страница 131: ...onnect all the wiring from the relay to be tested 3 Connect the leads from an ohmmeter to each terminal combination and check for continuity Terminals 7 and 8 represent the coil and should not be tested in any other combination Bubble number represents the terminal number Test Desired result terminal 7 to 8 640 to 650W terminal 1 to 2 3 4 6 no continuity infinite W terminal 2 to 3 4 5 no continuit...

Страница 132: ...ey switch to ground control and lift up the Emergency Stop Switch cover at the ground controls and move the switch to the ON position 4 Activate the function enable switch any lift function from the ground controls Result If the pressure gauge reads 2000 psi 137 9 bar immediately stop The pump is good Result If pressure fails to reach 2000 psi 137 9 bar the internal relief valve setting is incorre...

Страница 133: ...Part No 43063 Genie Z 30 20 7 23 Service Manual Third Edition Section 7 Repair Procedures This page intentionally left blank ...

Страница 134: ...s 11 13 ft lbs 15 18 Nm 9 3 position 4 way D03 valve G Boom extend retract 30 35 in lbs 3 4 Nm 10 3 position 4 way D03valve H Primary boom up down 30 35 in lbs 3 4 Nm 11 3 position 4 way D03 valve J Secondary boom up down 30 35 in lbs 3 4 Nm 12 Orifice 0 060 inch 1 52 mm BB Primary boom up down 13 Relief valve 1600 psi 110 3 bar D Secondary boom down 25 30 ft lbs 34 41 Nm 14 Relief valve 1400 psi ...

Страница 135: ...Part No 43063 Genie Z 30 20 7 25 Service Manual Third Edition Section 7 Repair Procedures MANIFOLDS ...

Страница 136: ...epeat steps 2 through 3 and recheck the valve pressure Primary boom down relief valve specifications Pressure 1400 psi 97 bar MANIFOLDS How to Adjust the Secondary Boom Down Relief Valve Perform this procedure with the boom in the stowed position 1 Connect a 0 to 3000 psi 0 to 206 bar pressure gauge to the test port on the function manifold 2 Turn the key switch to ground control and lift up the E...

Страница 137: ...e off Hold the relief valve and remove the cap item 15 function manifold If adjusting the turntable rotate left hold switch to the left and adjust the left relief valve item 16 function manifold 5 Adjust the internal hex socket Turn it clockwise to increase the pressure or counterclockwise to decrease the pressure Then install the relief valve cap Tip over hazard Do not adjust the relief valves hi...

Страница 138: ...lve Q Brake release circuit 25 30 ft lbs 34 41 Nm 6 Pressure switch S Brake release circuit 7 Orifice Plug 0 040 in 1 27 mm W Brake release circuit MANIFOLDS PlugTorqueSpecifications Description Hex Size Torque SAE No 2 1 8 50 in lbs 6 Nm SAE No 4 3 16 13 ft lbs 18 Nm SAE No 6 1 4 18 ft lbs 24 Nm SAE No 8 5 16 50 ft lbs 68 Nm SAE No 10 9 16 55 ft lbs 75 Nm SAE No 12 5 8 75 ft lbs 102 Nm How to Che...

Страница 139: ...Part No 43063 Genie Z 30 20 7 29 Service Manual Third Edition Section 7 Repair Procedures MANIFOLDS ...

Страница 140: ...rential sensing circuit 10 12 ft lbs 14 16 Nm PlugTorqueSpecifications Description Hex Size Torque SAE No 2 1 8 50 in lbs 6 Nm SAE No 4 3 16 13 ft lbs 18 Nm SAE No 6 1 4 18 ft lbs 24 Nm SAE No 8 5 16 50 ft lbs 68 Nm SAE No 10 9 16 55 ft lbs 75 Nm SAE No 12 5 8 75 ft lbs 102 Nm How to Check the Resistance of a Valve Coil 1 Turn the key switch to the OFF position and disconnect the wires from the va...

Страница 141: ...Part No 43063 Genie Z 30 20 7 31 Service Manual Third Edition Section 7 Repair Procedures MANIFOLDS ...

Страница 142: ...hen remove the motor Turntable Rotation Components 8 2 Rotation Bearing and Worm Drive How to Remove the Rotation Bearing or Worm Drive The turntable and all components above it must be removed prior to removing the rotation bearing or worm drive This procedure requires specific repair skills lifting equipment and a suitable workshop Attempting this procedure without these skills and tools may res...

Страница 143: ...fittings on the brakes 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 10 Label and then disconnect all the wiring from the contactor panel to the ground controls Pull the wiring up through the turntable Electrocution hazard Contact with electrically...

Страница 144: ...the threaded rod Support the smaller counterweight with a floor jack from the steer end of the machine and lift it slightly to take the weight off of the threaded rod 22 Remove the fasteners from the cover at the non steer end of the drive chassis Remove the cover from the machine 23 Remove the nut from the threaded rod that runs through the center of the counterweights at the steer end of the mac...

Страница 145: ...jury and significant component damage Dealer service is required If a repair requires that the turntable be removed from the drive chassis installing a new rotation bearing is recommended Consider the service life of the rotation bearing before installing a used bearing 1 Position the rotation bearing on the drive chassis Use appropriate lifting techniques 2 Locate the G mark stamped on the outsid...

Страница 146: ... the worm drive in relation to the ring gear Pull the worm drive away from the rotate bearing 0 035 inches 0 889 mm 0 020 inches 0 508 mm 11 Tighten the two 5 16 fasteners Observe the dial indicator to be sure that the worm drive does not move while tightening the fasteners 12 Locate the 1 inch hex head on the end of the worm gear housing Turn the hex head to rotate the worm drive until it is posi...

Страница 147: ...mbly for support 9 Use a soft metal drift to remove the pin Crushing hazard The yoke hub assembly will fall when the king pin is removed if it is not properly supported Torque specifications Lug nuts 125 foot pounds 169 5 Newton meters How to Remove the Hub and Bearings 1 Loosen the wheel lug nuts Do not remove them 2 Block the non steering wheels and place a lifting jack under the steering axle 3...

Страница 148: ... nuts to 125 foot pounds 169 5 Nm STEERING AXLE COMPONENTS 9 2 Steering Cylinder How to Remove a Steering Cylinder 1 Tag disconnect and plug the hydraulic hoses from the steering cylinder Cap the fittings on the cylinder Bodily injury hazard Spraying hydraulic oil can penetrate and burn skin Loosen hydraulic connections very slowly to allow the oil pressure to dissipate gradually Do not allow oil ...

Страница 149: ...How to Remove a Drive Motor 3 Disconnect the hydraulic hose from the brake and plug it Cap the fitting on the brake 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 brake mounting fasteners Then slide the brake out of the torque hub 5 Loo...

Страница 150: ...Genie North America 18340 NE 76th Street P O Box 97030 Redmond Washington 98073 9730 Genie Europe Brunel Drive Newark Nottinghamshire NG24 2EG England Distributed By ...

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