Genie Industries Z-30/20 User manual

Service
Manual
Technical
Publications
Third Edition, First Printing
Part No. 43063
®

Genie Z-30/20 Part No. 43063
Service Manual - Third Edition
ii
Introduction
Genie North America
Telephone [phone]
Toll Free 800 536-1800 in U.S.A.
Toll Free 800 426-8089 in Canada
Fax [phone]
http://www.genielift.com
Genie Europe
Telephone [phone]
Fax [phone]
http://www.genielift.com
Important
Read, understand and obey the safety rules and
operating instructions in the appropriate
Genie Z-30/20 Operator’s Manual before
attempting any maintenance or repair procedure.
This manual provides detailed scheduled
maintenance information for the machine owner
and user. It also provides troubleshooting and
repair procedures for qualified service
professionals.
Basic mechanical, hydraulic and electrical
skills are required to perform most procedures.
However, several procedures require specialized
skills, tools, lifting equipment and a suitable
workshop. In these instances, we strongly
recommend that maintenance and repair be
performed at an authorized Genie dealer
service center.
Genie Industries has endeavored to deliver the
highest degree of accuracy possible. However,
continuous improvement of our products is a
Genie policy. Therefore product specifications
are subject to change without notice.
Readers are encouraged to notify Genie of errors
and send in suggestions for improvement. All
communications will be carefully considered for
future printings of this and other manuals. Please
write to the technical publications team in care of
Genie Industries, PO Box 97030, Redmond WA
98073-9730 USA.
If you have any questions, please call Genie
Industries.
®
Copyright©1997byGenieIndustries
FirstEdition: FirstPrintingDecember,1997
"Genie" and "Z" are a registered trademark
of Genie Industries in the U.S.A. and many other
countries
Printed on recycled paper
PrintedinU.S.A.

Part No. 43063 Genie Z-30/20
Service Manual - Third Edition
iii
Danger
Failure to obey the instructions and safety rules
in this manual and the appropriate Genie Z-30/20
Operator’s Manual will result in death or serious
injury.
Many of the hazards identified in the
operator’s manual are also safety hazards
when maintenance and repair procedures
are performed.
Do Not Perform Maintenance
Unless:
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

Genie Z-30/20 Part No. 43063
Service Manual - Third Edition
SAFETY RULES
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 that your workshop or work area
is properly ventilated and well lit.
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 .
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:
Indicates the presence of
a hazard that will cause
death or serious injury.
Indicates the presence of
a hazard that may cause
death or serious injury.
Indicates the presence of
a hazard that will or may
cause serious injury or
damage to the machine.
Indicates special
operation or maintenance
information.
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.
iv

Part No. 43063 Genie Z-30/20
Service Manual - Third Edition
Table of Contents
v
Introduction
Important Information .....................................................................................................ii
Section One Safety Rules
General Safety Rules .................................................................................................... iii
Section Two Specifications
Machine Specifications............................................................................................. 2 - 1
Performance Specifications...................................................................................... 2 - 2
Hydraulic Specifications ........................................................................................... 2 - 2
Bolt Torque Specifications........................................................................................ 2 - 3
Section Three Scheduled Maintenance Inspections
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 and Ground Controls .......................................................... 4 - 4
A-7 Test the Platform Rotation.............................................................................. 4 - 4
A-8 Test the Tilt Sensor ........................................................................................ 4 - 5
A-9 Test the Manual Controls................................................................................ 4 - 5
A-10 Test the Limit Switches................................................................................... 4 - 6

Genie Z-30/20 Part No. 43063
Service Manual - Third Edition
TABLE OF CONTENTS
vi
Section Four Scheduled Maintenance Procedures, continued
A-11 Perform 30 Day Service.................................................................................. 4 - 7
B-1 Check the Batteries ........................................................................................ 4 - 8
B-2 Inspect the Electrical Wiring ........................................................................... 4 - 8
B-3 Inspect the Tires and Wheels (including lug nut torque) ................................. 4 - 9
B-4 Confirm the Proper Brake Configuration......................................................... 4 - 9
B-5 Check the Oil Level in the Torque Hubs ......................................................... 4 - 9
B-6 Test the Key Switch...................................................................................... 4 - 10
B-7 Test the Emergency Stop Buttons................................................................ 4 - 10
B-8 Test the Ground Control Override ................................................................ 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 Wear Pads ........................................................... 4 - 15
C-2 Check the Turntable Rotation Bearing Bolts................................................. 4 - 15
C-3 Check the Free-wheel Configuration ............................................................ 4 - 16
C-4 Grease the Turntable Rotation Bearing and Worm Drive Gear .................... 4 - 17
C-5 Replace the Torque Hub Oil ......................................................................... 4 - 17
C-6 Replace the Hydraulic Filter.......................................................................... 4 - 18
D-1 Test or Replace the Hydraulic Oil ................................................................. 4 - 19

Part No. 43063 Genie Z-30/20
Service Manual - Third Edition
TABLE OF CONTENTS
vii
Section Five Troubleshooting Flow Charts
Introduction............................................................................................................... 5 - 1
1 All Functions Will Not Operate........................................................................ 5 - 3
2 Lift Pump Motor Will Not Operate ................................................................... 5 - 6
3 All Functions Inoperative, Power Unit Starts and Runs .................................. 5 - 8
4 All Lift and Steer Functions Inoperative, Drive Function Operational.............. 5 - 9
5 Ground Controls Inoperative, Platform Controls Operate Normally .............. 5 - 12
6 Platform Controls Inoperative, Ground Controls Operate Normally .............. 5 - 14
7 Primary Boom Up Function Inoperative ........................................................ 5 - 17
8 Primary Boom Down Function Inoperative ................................................... 5 - 19
9 Secondary Boom Up Function Inoperative ................................................... 5 - 21
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 Steer Left Function Inoperative..................................................................... 5 - 42
19 Steer Right Function Inoperative .................................................................. 5 - 44
20 All Drive Functions Inoperative, All Other Functions Operate Normally........ 5 - 46
20A Brake Function Inoperative........................................................................... 5 - 51
21 Drive Forward Function Inoperative.............................................................. 5 - 55
22 Drive Reverse Function Inoperative.............................................................. 5 - 56
23 Machine Will Not Drive At Full Speed ........................................................... 5 - 57
24 Machine Drives At Full Speed With Platform Raised.................................... 5 - 58
25 Remote Brake Release Inoperative .............................................................. 5 - 59

Genie Z-30/20 Part No. 43063
Service Manual - Third Edition
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

Part No. 43063 Genie Z-30/20
Service Manual - Third Edition
TABLE OF CONTENTS
Section Seven Repair Procedures
Introduction............................................................................................................... 7 - 1
Platform Controls
1-1 Controllers ...................................................................................................... 7 - 2
1-2 Foot Switch..................................................................................................... 7 - 5
1-3 Toggle Switches ............................................................................................. 7 - 6
Platform Components
2-1 Platform .......................................................................................................... 7 - 7
2-2 Platform 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 Relays .............................................................................................. 7 - 21
Hydraulic Pumps
6-1 Main Function Pump..................................................................................... 7 - 22
ix

Genie Z-30/20 Part No. 43063
Service Manual - Third Edition
TABLE OF CONTENTS
Section Seven Repair Procedures, continued
Manifolds
7-1 Function Manifold Components .................................................................... 7 - 24
7-2 Valve Adjustments - 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

Part No. 43063 Genie Z-30/20 2 - 1
Section 2 - SpecificationsService Manual - Third Edition
Specifications
MachineSpecifications
Stowed dimensions
Length 15 ft 9 in 4.8 m
Width 5 ft 10 in 1.8 m
Height 6 ft 7 in 2 m
Machine Weight 8700 lbs 3946.3 kg
Ground clearance 7.38 in 18.7 cm
Operational dimensions
Maximum platform height 31 ft 9.4 m
Maximum platform working height 38 ft 11.6 m
Maximum horizontal reach 20 ft 6.1 m
Maximum turntable tailswing 14 in 35.6 cm
Wheelbase 6 ft 1.8 m
Minimum turning radius, 13 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 in 121.9 cm
Width 30 in 76.2 cm
Maximum capacity 500 lbs 227 kg
Fluid Capacities
Hydraulic tank capacity 2.5 gallons 9.5 liters
Hydraulic system capacity 4 gallons 15.1 liters
(including tank)
Continuous improvement of our products is a
Genie policy. Product specifications are subject to
change without notice.

2 - 2 Genie Z-30/20 Part No. 43063
Section 2 - Specifications Service Manual - Third Edition
PerformanceSpecifications
Drive speeds, maximum
Boom stowed, 4.3 mph 6.9 km/h
35:1 torque hubs 40 ft/6.1 sec 12.2 m/6.1 sec
Boom stowed, 3.2 mph 5.1 km/h
49:1 torque hubs 40 ft/8.6 sec 12.2 m/8.6 sec
Boom raised 0.6 mph 1.0 km/h
40 ft/45.5 sec 12.2 m/45.5 sec
Gradeability (boom stowed)
35:1 torque hubs 30%
49:1 torque hubs 37%
Boom function speeds, maximum
from platform controls
Primary boom up 24 to 26 seconds
Primary boom down 19 to 21 seconds
Primary boom extend 19 to 21 seconds
Primary boom retract 12 to 14 seconds
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
HydraulicSpecifications
Hydraulic fluid Dexron equivalent
Lift pump
Type: gear
Displacement .137 cu in
per revolution 2.31 cc
Displacement 1.75 gallons per minute
(2200 psi/152 bar) 6.6 liters per minute
Function manifold
Function relief 2200 psi
valve pressure 152 bar
Primary Boom down relief 1250 psi
Function relief 86.2 bar
Secondary boom down relief 1000 psi
valve pressure 69 bar
Turntable rotate relief 850 psi
valve pressures 58.6 bar

Part No. 43063 Genie Z-30/20 2 - 3
Section 2 - SpecificationsService Manual - Third Edition
SPECIFICATIONS
24
32
20
28
18
24
16
24
14
20
Torque - Dry
inch-pounds Torque - Dry foot-pounds Torque - Dry Newton meters Torque - Dry inch-pounds Torque - Dry foot-pounds Torque - Dry Newton meters
43
49
96
120
17
19
30
35
50
55
75
90
110
120
150
170
260
300
430
470
640
700
5
6
11
14
23
28
41
48
68
75
102
122
149
163
204
231
353
407
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 specifications for lubricated bolts are 25% less than dry torque specifications for each bolt size.
These bolt torque specifications are for general use only. Specification may vary depending on application of bolt.

2 - 4 Genie Z-30/20 Part No. 43063
Section 2 - Specifications Service Manual - Third Edition
Thispageintentionallyleftblank.

Part No. 43063 Genie Z-30/20 3 - 1
Section 3 - Scheduled Maintenance InspectionsService Manual - Third Edition
Tools are
required New parts required
Warm
engine
required
Cold
engine
required
Dealer
service
suggested
Scheduled Maintenance Inspections
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 machine damage.
Immediately tag and remove from service a
damaged or malfunctioning machine.
Repair any machine damage or malfunction
before operating machine.
Keep records on all inspections for three years.
Machines that have been out of service for a
period longer than 3 months must complete the
quarterly inspection.
About This Section
The Schedule
There are four types of maintenance inspections
that must be performed according to a schedule—
daily, quarterly, annual and two year. To account
for repeated procedures, the Maintenance Tables
and the Maintenance Inspection Report have been
divided into four subsections—A, B, C, D. Use the
following chart to determine which group(s) of
procedures are required to perform a scheduled
inspection.
Inspection Table or Checklist
Daily A
Quarterly A + B
Annual A + B + C
Two year A + B + C + D
Maintenance Tables
The maintenance tables contained in this section
provide summary information on the specific
physical requirements for each inspection.
Complete step-by-step instructions for each
scheduled maintenance procedure are provided in
section 4, Scheduled Maintenance Procedures.
Maintenance Inspection Report
The maintenance inspection report contains
checklists for each type of scheduled inspection.
Make copies of the Maintenance Inspection
Report to use for each inspection. Store
completed forms for three years.

3 - 2 Genie Z-30/20 Part 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
Table A
A-1 Inspect the Operator's and Safety Manuals
A-2 Inspect the Decals and Placards
A-3 Inspect for Damage, Loose or Missing Parts
A-4 Check the Hydraulic Oil Level
A-5 Check for Hydraulic Leaks
A-6 Test the Platform and Ground Controls
A-7 Test the Platform Rotation
A-8 Test the Tilt Sensor
A-9 Test the Manual Controls
A-10 Test the Drive Limit Switches
A-11 Perform 30 Day Service
Table B
B-1 Check the Batteries
B-2 Inspect the Electrical Wiring
B-3 Inspect the Tires and Wheels
(including lug nut torque)
B-4 Confirm the Proper Brake Configuration
B-5 Check the Oil Level in the Torque Hubs
Maintenance Tables

Part No. 43063 Genie Z-30/20 3 - 3
Section 3 - Scheduled Maintenance InspectionsService Manual - Third Edition
Tools are
required New parts required
Warm
engine
required
Cold
engine
required
Dealer
service
suggested
Table B, continued
B-6 Test the Key Switch
B-7 Test the Emergency Stop Buttons
B-8 Test the Ground Control Override
B-9 Test the Platform Self-leveling
B-10 Test the Service Horn
B-11 Test the Foot Switch
B-12 Test the Drive Brakes
B-13 Test the Drive Speed - Stowed Position
B-14 Test the Alarm Package - Optional Equipment
B-15 Perform Hydraulic Oil Analysis
See D-1 Test or Replace the Hydraulic Oil
B-16 Test the Turntable Rotation Stop
B-17 Check the Electrical Contactors
MAINTENANCE TABLES

3 - 4 Genie Z-30/20 Part 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
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

Part No. 43063 Genie Z-30/20 3 - 5
Section 3 - Scheduled Maintenance InspectionsService Manual - Third Edition
Tools are
required New parts required
Warm
engine
required
Cold
engine
required
Dealer
service
suggested
ChecklistA Y N R
Refer to Table A
A-1Operator'sand
Safetymanuals
A-2 Decals and placards
A-3Damage,looseor
missingparts
A-4Hydraulic oil level
A-5 Hydraulic leaks
A-6Platformand
groundcontrols
A-7Platformrotation
A-8 Tilt sensor
A-9Manualcontrols
A-10Drivelimitswitches
A-11 30 Day Service
ChecklistB Y N R
Refer to Table B
B-1Batteries
B-2Electricalwiring
B-3 Tires and wheels
B-4Brakeconfiguration
B-5Torquehuboillevel
B-6 Key Switch
B-7EmergencyStop
B-8Groundcontrol override
B-9Platformleveling
B-10Servicehorn
B-11Foot switch
B-12 Drive brakes
B-13Drivespeed-stowed
B-14Alarmpackage
B-15Hydraulicoilanalysis
B-16Turntablestop
B-17Electricalcontactors
ChecklistC Y N R
Refer to Table C
C-1 Boom wear pads
C-2Turntablebearingbolts
C-3Free-wheelconfiguration
C-4Greaserotationbearing
C-5Torquehuboil
C-6Hydraulicfilter
ChecklistD Y N R
Refer to Table D
D-1Hydraulicoil
Instructions
·Make copies of this page to use for
eachinspection.
·Select the appropriate checklist(s) for
thetypeofinspectiontobeperformed.
DailyInspection: A
QuarterlyInspection: A+B
AnnualInspection:A+B+C
2YearInspection:A+B+C+D
·Place a check in the appropriate box
aftereachinspectionprocedure is
completed.
·Use the maintenance tables in this
sectionandthestep-by-step
procedures in section 4 to learn how to
performtheseinspections.
·If any inspection receives an “N”, tag
andremovethemachinefromservice,
repairandre-inspectit.Afterrepair,
place a check in the “R”box.
Legend
Y = yes, acceptable
N = no, remove from service
R=repaired
Comments
Maintenance Inspection Report
Model
Serial number
Date
Hour meter
Machine owner
Inspected by (print)
Inspector signature
Inspector title
Inspector company

3 - 6 Genie Z-30/20 Part 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
Thispageintentionallyleftblank.