Genie Z-30/20N, Z-30/20N RJ Workshop Service Repair Manual

Service Manual Z-30/20N Z-30/20N RJ Part No. 106373 Rev C June 2008 Serial Number Range from Z30N-5934 to Z30N08-11499

Z-30/20N • Z-30/20N RJ Part No. 106373 June 2008 ii Introduction Important Read, understand and obey the safety rules and operating instructions in the Genie Z-30/20N Operator's Manual before attempting any maintenance or repair procedure. This manual provides detailed scheduled maintenance information for the machine owner and user. It also provides troubleshooting 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://www.genieindustries.com e-mail: techsup@genieind.com 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. Printed on recycled paper Printed in U.S.A. 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 Introduction

Part No. 106373 Z-30/20N • Z-30/20N RJ June 2008 Z30N 05 - 12345 Model Year of manufacture Sequence number PN - 77055 Country of manufacture: USA This machine complies with: Genie Industries 18340 NE 76th Street Redmond, WA 98052 USA Model: Z-30/20N Serial number: Z30N05-12345 Electrical schematic number: ESXXXX Machine unladen weight: Rated work load (including occupants): XXX lb / XXX kg Maximum allowable inclination of the chassis: 0 deg Gradeability: N/A Maximum allowable side force : XXX lb / XXX N Maximum number of platfrm occupants: X Model year: Manufacture date: 04/12/05 2005 Maximum wind speed : XX mph/ XX m/s Maximum platform height : XX ft / XX m Maximum platform reach : XX ft / XX m Serial number stamped on chassis Serial label (located under cover) Serial Number Legend INTRODUCTION iii

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Part No. 106373 Z-30/20N • Z-30/20N RJ June 2008 v 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. Safety Rules Section 1 • Safety Rules

Z-30/20N • Z-30/20N RJ Part No. 106373 June 2008 SAFETY RULES vi 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 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. Indicates an imminently hazardous situation which, if not avoided, will result in death or serious injury. Indicates a potentially hazardous situation which, if not avoided, could result in death or serious injury. Indicates a potentially hazardous 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 such as moving parts, free swinging or unsecured components when lifting or placing loads. Always wear approved steel-toed shoes. Workplace Safety Be sure to keep sparks, flames and lighted tobacco away from flammable and combustible materials like battery gases and engine fuels. Always have an approved fire extinguisher within easy reach. Be sure that all tools and working areas are properly maintained and ready for use. Keep work surfaces clean and free of debris that could get into machine components and cause damage. Be sure any forklift, overhead crane or 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. Be sure that 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. Be sure to properly dispose of old oil or other fluids. Use an approved container. Please be environmentally safe. Be sure that your workshop or work area is properly ventilated and well lit. Section 1 • Safety Rules

Table of Contents vii Introduction Important Information ................................................................................................... ii Serial Number Information ............................................................................................ ii Serial Number Legend ................................................................................................. iii Section 1 Safety Rules General Safety Rules .................................................................................................. v Section 2 Rev Specifications E Machine Specifications .......................................................................................... 2 - 1 Performance Specifications ................................................................................... 2 - 1 Hydraulic Oil Specifications ................................................................................... 2 - 2 Hydraulic Component Specifications ...................................................................... 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 Section 3 Rev Scheduled Maintenance Procedures Introduction ............................................................................................................ 3 - 1 Pre-Delivery Preparation ........................................................................................ 3 - 3 Maintenance Inspection Report .............................................................................. 3 - 5 D Checklist A Procedures A-1 Inspect the Manuals and Decals .................................................................. 3 - 6 A-2 Perform Pre-operation Inspection ................................................................ 3 - 7 A-3 Perform Function Tests ............................................................................... 3 - 7 A-4 Perform 30 Day Service ............................................................................... 3 - 8 A-5 Grease the Turntable Rotation Bearing and Worm Drive Gear ...................... 3 - 8 A-6 Replace the Drive Hub Oil ............................................................................ 3 - 9 Section 1 • Safety Rules

TABLE OF CONTENTS viii Section 3 Rev Scheduled Maintenance Procedures, continued E Checklist B Procedures B-1 Check the Batteries .................................................................................... 3 - 10 B-2 Inspect the Electrical Wiring ....................................................................... 3 - 11 B-3 Test the Key Switch ................................................................................... 3 - 12 B-4 Check the Tires, Wheels and Lug Nut Torque ............................................ 3 - 13 B-5 Confirm the Proper Brake Configuration ...................................................... 3 - 13 B-6 Check the Oil Level in the Drive Hubs and Mounting Bolt Torque ............... 3 - 14 B-7 Test the Ground Control Override ............................................................... 3 - 14 B-8 Test the Platform Self-leveling ................................................................... 3 - 15 B-9 Test the Drive Brakes ................................................................................ 3 - 15 B-10 Test the Drive Speed - Stowed Position ..................................................... 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 Test the Turntable Rotation Stop ................................................................ 3 - 18 B-14 Check the Electrical Contactors ................................................................. 3 - 18 B-15 Perform Hydraulic Oil Analysis ................................................................... 3 - 19 D 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 Rev Scheduled Maintenance Procedures, continued D Checklist D Procedures D-1 Check the Primary Boom Wear Pads ......................................................... 3 - 23 D-2 Check the Free-wheel Configuration ........................................................... 3 - 24 D-3 Check the Turntable Rotation Bearing Bolts ............................................... 3 - 25 D-4 Replace the Drive Hub Oil .......................................................................... 3 - 26 D-5 Replace the Hydraulic Tank Return Filter Element ..................................... 3 - 26 D-6 Inspect for Turntable Bearing Wear ............................................................ 3 - 27 C Checklist E Procedures E-1 Test or Replace the Hydraulic Oil ............................................................... 3 - 29 E-2 Grease the Steer Axle Wheel Bearings ...................................................... 3 - 31 Section 4 Rev Repair Procedures Introduction ............................................................................................................ 4 - 1 B Platform Controls 1-1 Controllers .................................................................................................... 4 - 2 C Platform Components 2-1 Platform Leveling Slave Cylinder .................................................................. 4 - 4 2-2 Platform Rotator ........................................................................................... 4 - 5 2-3 Platform Overload System ........................................................................... 4 - 7 B Jib Boom Components 3-1 Jib Boom ...................................................................................................... 4 - 9 3-2 Jib Boom Bell Crank (models without rotating jib boom) ............................. 4 - 10 3-3 Jib Boom Rotator (models with rotating jib boom) ....................................... 4 - 11 3-4 Jib Boom Lift Cylinder ................................................................................ 4 - 13 TABLE OF CONTENTS ix

x Section 4 Rev Repair Procedures, continued B Primary Boom Components 4-1 Cable Track ................................................................................................ 4 - 14 4-2 Primary Boom ............................................................................................ 4 - 14 4-3 Primary Boom Lift Cylinder ......................................................................... 4 - 18 4-4 Extension Cylinder ..................................................................................... 4 - 19 4-5 Platform Leveling Master Cylinder .............................................................. 4 - 20 B Secondary Boom Components 5-1 Secondary Boom ........................................................................................ 4 - 23 5-2 Secondary Boom Lift Cylinder .................................................................... 4 - 28 A Hydraulic Pump 6-1 Auxiliary and Function Pump ...................................................................... 4 - 30 D Manifolds 7-1 Function Manifold Components .................................................................. 4 - 32 7-2 Valve Adjustments - Function Manifold ...................................................... 4 - 36 7-3 Jib Boom and Platform / Jib Boom Rotate Manifold Components ............... 4 - 39 7-4 Valve Coils ................................................................................................. 4 - 40 B Turntable Rotation Components 8-1 Turntable Rotation Hydraulic Motor ............................................................. 4 - 42 C Steer Axle Components 9-1 Hub and Bearings ....................................................................................... 4 - 43 B Motor Controller 10-1 Motor Controller .......................................................................................... 4 - 44 Section 5 Rev Fault Codes Introduction ............................................................................................................ 5 - 1 A Fault Code Chart .................................................................................................... 5 - 3 TABLE OF CONTENTS

Genie Z-30/20N, Z-30/20N RJ Workshop Service Repair Manual

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