Genie Z-30/20N User manual

includingrotatingjibmodels
PartNo.106373
April2005
RevA1
ServiceManual
Refertoinsidecoverforserialnumberinformation

Genie Z-30/20N Part No. 106373
April 2004
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: [email protected]
Copyright © 1996 by Genie Industries
106373 Rev A April 2004
"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

Part No. 106373 Genie Z-30/20N
April 2004
iii
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

Genie Z-30/20N Part No. 106373
April 2004
SAFETY RULES
iv
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.
Used to indicate the presence of
an imminently hazardous situation
which, if not avoided, will result in
death or serious injury.
Used to indicate the presence of a
potentially hazardous sitiuation
which, if not avoided, could result
in death or serious injury.
With safety alert symbol—used to
indicate the presence of a
potentially hazardous situation
which, if not avoided, may cause
minor or moderate injury.
Without safety alert symbol—used
to indicate the presense of a
potentially hazardous situation
which, if not avoided, may result in
property damage.
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.
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

Part No. 106373 Genie Z-30/20N
April 2005
Table of Contents
v
Introduction
Important Information .................................................................................................. ii
Section 1 Safety Rules
General Safety Rules ................................................................................................. iii
Section 2 Rev Specifications
B Machine Specifications .......................................................................................... 2 - 1
B Performance Specifications ................................................................................... 2 - 1
B Hydraulic Specifications ........................................................................................ 2 - 2
B Manifold Component Specifications ...................................................................... 2 - 3
B Machine Torque Specifications.............................................................................. 2 - 3
A Hydraulic Hose and Fitting Torque Specifications ................................................. 2 - 4
Section 3 Rev Scheduled Maintenance Procedures
Introduction ........................................................................................................... 3 - 1
Pre-Delivery Preparation ....................................................................................... 3 - 3
Maintenance Inspection Report ............................................................................. 3 - 5
BChecklist A Procedures
A-1 Perform Pre-operation Inspection ................................................................ 3 - 6
A-2 Perform Function Tests ............................................................................... 3 - 6
A-3 Perform 30 Day Service ............................................................................... 3 - 7
A-4 Grease the Turntable Rotation Bearing and Worm Drive Gear .................... 3 - 7
Section 1 • Safety Rules

Genie Z-30/20N Part No. 106373
April 2005
TABLE OF CONTENTS
vi
Section 3 Rev Scheduled Maintenance Procedures, continued
BChecklist B Procedures
B-1 Check the Batteries ..................................................................................... 3 - 8
B-2 Inspect the Electrical Wiring ......................................................................... 3 - 9
B-3 Test the Key Switch ................................................................................... 3 - 10
B-4 Check the Lug Nut Torque (including the tires and wheels) ....................... 3 - 10
B-5 Confirm the Proper Brake Configuration .................................................... 3 - 11
B-6 Check the Oil Level in the Drive Hubs ....................................................... 3 - 11
B-7 Test the Ground Control Override .............................................................. 3 - 12
B-8 Test the Platform Self-leveling ................................................................... 3 - 12
B-9 Test the Drive Brakes ................................................................................ 3 - 13
B-10 Test the Drive Speed - Stowed Position .................................................... 3 - 13
B-11 Test the Drive Speed - Raised or Extended Position ................................. 3 - 14
B-12 Test the Alarm Package (if equipped) ........................................................ 3 - 14
B-13 Test the Turntable Rotation Stop ............................................................... 3 - 15
B-14 Check the Electrical Contactors ................................................................. 3 - 16
B-15 Perform Hydraulic Oil Analysis .................................................................. 3 - 16
BChecklist C Procedures
C-1 Grease the Platform Overload Mechanism (if equipped) ........................... 3 - 17
C-2 Test the Platform Overload System (if equipped) ...................................... 3 - 17

Part No. 106373 Genie Z-30/20N
April 2005
Section 3 Rev Scheduled Maintenance Procedures, continued
BChecklist D Procedures
D-1 Check the Primary Boom Wear Pads ........................................................ 3 - 20
D-2 Check the Free-wheel Configuration .......................................................... 3 - 21
D-3 Check the Turntable Rotation Bearing Bolts .............................................. 3 - 22
D-4 Replace the Drive Hub Oil ......................................................................... 3 - 23
D-5 Replace the Hydraulic Tank Return Filter Element .................................... 3 - 23
D-6 Calibrate the Platform Overload System (if equipped) ............................... 3 - 24
BChecklist E Procedures
E-1 Test or Replace the Hydraulic Oil .............................................................. 3 - 26
E-2 Grease the Steer Axle Wheel Bearings ..................................................... 3 - 28
Section 4 Rev Repair Procedures
Introduction ........................................................................................................... 4 - 1
BPlatform Controls
1-1 Controllers ................................................................................................... 4 - 2
BPlatform Components
2-1 Platform Leveling Slave Cylinder ................................................................. 4 - 4
2-2 Platform Rotator........................................................................................... 4 - 5
BJib Boom Components
3-1 Jib Boom ...................................................................................................... 4 - 7
3-2 Jib Boom Bell Crank (models without rotating jib boom) .............................. 4 - 8
3-3 Jib Boom Rotator (models with rotating jib boom) ........................................ 4 - 8
3-4 Jib Boom Lift Cylinder ................................................................................ 4 - 10
TABLE OF CONTENTS
vii

Genie Z-30/20N Part No. 106373
April 2005
viii
Section 4 Rev Repair Procedures, continued
BPrimary Boom Components
4-1 Cable Track ............................................................................................... 4 - 11
4-2 Primary Boom ............................................................................................ 4 - 11
4-3 Primary Boom Lift Cylinder ........................................................................ 4 - 15
4-4 Extension Cylinder ..................................................................................... 4 - 17
4-5 Platform Leveling Master Cylinder ............................................................. 4 - 18
BSecondary Boom Components
5-1 Secondary Boom ....................................................................................... 4 - 21
5-2 Secondary Boom Lift Cylinder ................................................................... 4 - 26
AHydraulic Pumps
6-1 Auxiliary and Function Pump ..................................................................... 4 - 28
BManifolds
7-1 Function Manifold Components ................................................................. 4 - 30
7-2 Valve Adjustments - Function Manifold ...................................................... 4 - 34
7-3 Jib Boom and Platform / Jib Boom Rotate Manifold Components .............. 4 - 37
7-4 Valve Coils ................................................................................................. 4 - 38
BTurntable Rotate Components
8-1 Turntable Rotation Hydraulic Motor ........................................................... 4 - 40
ASteer Axle Components
9-1 Hub and Bearings ...................................................................................... 4 - 41
AMotor Controller
10-1 Motor Controller ......................................................................................... 4 - 42
TABLE OF CONTENTS

Part No. 106373 Genie Z-30/20N
April 2005
TABLE OF CONTENTS
Section 5 Rev Fault Codes
Introduction ........................................................................................................... 5 - 1
A Fault Code Chart ................................................................................................... 5 - 3
Section 6 Rev Schematics
Introduction ........................................................................................................... 6 - 1
A Load Sensor Option Diagram (before serial number 6290) ................................... 6 - 2
A Electrical Symbols Legend .................................................................................... 6 - 3
A Hydraulic Symbols Legend .................................................................................... 6 - 4
A Power Cable Diagram (before serial number 6290) ............................................... 6 - 5
A Power Cable Diagram (after serial number 6289).................................................. 6 - 6
B Electrical Schematic (before serial number 6290) ................................................. 6 - 7
B Electrical Schematic (after serial number 6289) .................................................... 6 - 9
A Ground Control Panel Wiring Diagram (before serial number 6290) .................... 6 - 11
A Ground Control Panel Wiring Diagram (after serial number 6289)....................... 6 - 12
A Platform Control Box Wiring Diagram (before serial number 6290) ..................... 6 - 13
A Platform Control Box Wiring Diagram (after serial number 6289) ........................ 6 - 14
A Power Panel Wiring Diagram .............................................................................. 6 - 15
A Hydraulic Schematic ............................................................................................ 6 - 16
ix

Genie Z-30/20N Part No. 106373
April 2005
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x

Part No. 106373 Genie Z-30/20N 2 - 1
Section 2 • SpecificationsApril 2005
REV B Specifications
Machine Specifications
Tires and wheels
Tire size (solid rubber) 22 x 7 x 18.4 in
56 x 18 x 47 cm
Load range 7600 lbs
3447 kg
Tire contact area 35 sq in
226 sq cm
Overall tire diameter 22 in
56 cm
Wheel diameter 18.4 in
47 cm
Wheel width 7 in
18 cm
Wheel lugs
Front 8 @ 5/8 -18
Rear 9 @ 5/8 -18
Lug nut torque, dry 125 ft-lbs
169.5 Nm
Lug nut torque, lubricated 94 ft-lbs
127.4 Nm
Fluid Capacities
Hydraulic tank capacity 4 gallons
15.1 liters
Hydraulic tank capacity 6 gallons
(including tank) 22.7 liters
Drive hubs
61:1 23 ounces 0.68 liter
62.5:1 25.6 ounces 0.76 liter
Drive hub oil type:
SAE 90 multipurpose hypoid gear oil API service
classification G 5
Continuous improvement of our products is a
Genie policy. Product specifications are
subject to change without notice.
Performance Specifications
Drive speed, maximum
Stowed position 3.3 mph
5.3 km/h
40 ft / 8.3 sec
12.2 m / 8.3 sec
Boom raised or extended 0.6 mph
1 km/h
40 ft / 44 sec
12.2 m / 44 sec
Braking distance, maximum
High range on paved surface 2 to 4 ft
0.6 to 1.2m
Boom function speeds, maximum from platform
controls (with rated load secured to platform)
Jib boom up 26 to 32 seconds
Jib boom down 23 to 29 seconds
Jib boom rotate, 200° 12 to 18 seconds
Primary boom up 14 to 22 seconds
Primary boom down 12 to 20 seconds
Primary boom extend
(models with rotating jib boom) 14 to 24 seconds
(models without rotating jib boom) 9 to 15 seconds
Primary boom retract 12 to 18 seconds
Secondary boom up 11 to 18 seconds
Secondary boom down 7 to 15 seconds
Turntable rotate, 355° 50 to 65 seconds
Platform rotate, 160° 5 to 11 seconds
Platform level up 14 to 19 seconds
Platform level down 13 to 18 seconds

2 - 2 Genie Z-30/20N Part No. 106373
Section 2 • Specifications April 2005
REV BSPECIFICATIONS
Hydraulic Specifications
Hydraulic Oil Specifications
Hydraulic oil type Chevron Rykon MV equivalent
ISO viscosity grade Multi-viscosity
Viscosity index 200
Cleanliness level, minimum 15/13
Water content, maximum 200 ppm
Chevron Rykon MV oil is fully compatible and
mixable with Shell Donax TG (Dexron III) oils.
Genie specifications require hydraulic oils which are
designed to give maximum protection to hydraulic
systems, have the ability to perform over a wide
temperature range, and have a minimum viscosity index
of 150. They should provide excellent antiwear,
oxidation, corrosion inhibition, seal conditioning, and
foam and aeration suppression properties.
Optional fluids
Biodegradable Petro Canada Premium ECO 46
Statoil Hydra Way Bio Pa 32
BP Biohyd SE-S
Fire resistant UCON Hydrolube HP-5046
Quintolubric 822
Mineral based Shell Tellus T32
Shell Tellus T46
Chevron Aviation A
Use Chevron Aviation A hydraulic
oil when in ambient temperatures
consistently below 0°F / -18°C.
Use Shell Tellus T46 hydraulic oil
when oil temperatures consistently
exceed 205°F / 96°C.
Genie specifications require
additional equipment and special
installation instructions for the
approved optional fluids. Consult
the Genie Industries Service
Department before use.
Function pump
Type: Fixed displacement gear pump
Displacement 0.183 cu in
3 cc
Flow rate @ 2.1 gpm
2800 psi / 172 bar 7.9 L/min
Hydraulic tank 10 micron with
return filter 25 psi / 1.7 bar bypass
Function manifold
System relief valve pressure 2800 psi
193 bar
Primary boom down relief pressure 1600 psi
110 bar
Secondary boom down relief pressure 1600 psi
110 bar
Primary boom extend relief pressure 2800 psi
Models without rotating jib 193 bar
Primary boom extend relief pressure 1800 psi
Models with rotating jib 124 bar
Turntable rotate relief pressure 1100 psi
76 bar
Auxiliary pump
Type: Fixed displacement gear pump
Displacement 0.3 gpm
1.14 L/min

Part No. 106373 Genie Z-30/20N 2 - 3
Section 2 • SpecificationsApril 2005
REV B
Manifold Component
Specifications
Plug torque
SAE No. 2 36 in-lbs / 4 Nm
SAE No. 4 10 ft-lbs / 13 Nm
SAE No. 6 14 ft-lbs / 19 Nm
SAE No. 8 38 ft-lbs / 51 Nm
SAE No. 10 41 ft-lbs / 55 Nm
SAE No. 12 56 ft-lbs / 76 Nm
Valve Coil Resistance Specification
Description Specification
Solenoid valve, 3 position 4 way, 20V DC 22 Ω
(schematic items A, J, K, U, V, Y, AA, BB and CC)
Proportional solenoid valve, 24V DC 19.5 Ω
(schematic item H)
Solenoid valve, N.C. poppet, 20V DC 23.5 Ω
(schematic item M)
Solenoid valve, N.O. poppet, 20V DC 23.5 Ω
(schematic item P)
Machine Torque Specifications
Platform rotator and jib boom rotator (Z-30/20NRJ)
1-8 center bolt 480 ft-lbs
651 Nm
3/8-16 bolts 44 ft-lbs
60 Nm
Turntable rotate bearing
Rotate bearing mounting bolts, lubricated 180 ft-lbs
244 Nm
Drive hubs, brakes and motors
Drive hub mounting bolts, lubricated 180 ft-lbs
244 Nm
Brake mounting bolts, lubricated 93 ft-lbs
126 Nm
Drive motor mounting bolts 31 ft-lbs
42 Nm
SPECIFICATIONS

2 - 4 Genie Z-30/20N Part No. 106373
Section 2 • Specifications April 2004
REV ASPECIFICATIONS
Hydraulic Hose and Fitting
Torque Specifications
Your machine is equipped with Parker Seal-Lok®
fittings and hose ends. Genie specifications require
that fittings and hose ends be torqued to
specification when they are removed and installed
or when new hoses or fittings are installed.
Seal-Lok® fittings
1 Replace the O-ring. The O-ring must be
replaced anytime the seal has been broken.
The O-ring cannot be re-used if the fitting or
hose end has been tightened beyond finger
tight.
The O-rings used in the Parker
Seal Lok® fittings and hose ends
are custom-size O-rings. They are
not standard SAE size O-rings.
They are available in the O-ring
field service kit (Genie part
number 49612).
2 Lubricate the O-ring before installation.
3 Be sure that the face seal O-ring is seated and
retained properly.
4 Position the tube and nut squarely on the face
seal end of the fitting and tighten the nut finger
tight.
5 Tighten the nut or fitting to the appropriate
torque per given size as shown in the table.
6 Operate all machine functions and inspect the
hoses and fittings and related components to
confirm that there are no leaks.
SAE O-ring Boss Port
(tube fitting - installed into Aluminum)
SAE Dash size Torque
-4 11 ft-lbs / 14.9 Nm
-6 23 ft-lbs / 31.2 Nm
-8 40 ft-lbs / 54.2 Nm
-10 69 ft-lbs / 93.6 Nm
-12 93 ft-lbs / 126.1 Nm
-16 139 ft-lbs / 188.5 Nm
-20 172 ft-lbs / 233.2 Nm
-24 208 ft-lbs / 282 Nm
SAE O-ring Boss Port
(tube fitting - installed into Steel)
SAE Dash size Torque
-4 16 ft-lbs / 21.7 Nm
-6 35 ft-lbs / 47.5 Nm
-8 60 ft-lbs / 81.3 Nm
-10 105 ft-lbs / 142.4 Nm
-12 140 ft-lbs / 190 Nm
-16 210 ft-lbs / 284.7 Nm
-20 260 ft-lbs / 352.5 Nm
-24 315 ft-lbs / 427.1 Nm
Seal-Lok®Fittings
(hose end)
SAE Dash size Torque
-4 18 ft-lbs / 24.4 Nm
-6 27 ft-lbs / 36.6 Nm
-8 40 ft-lbs / 54.2 Nm
-10 63 ft-lbs / 85.4 Nm
-12 90 ft-lbs / 122 Nm
-16 120 ft-lbs / 162.7 Nm
-20 140 ft-lbs / 190 Nm
-24 165 ft-lbs / 223.7 Nm

Part No. 106373 Genie Z-30/20N 3 - 1
Section 3 • Scheduled Maintenance ProceduresApril 2005
Scheduled Maintenance Procedures
About This Section
This section contains detailed procedures for each
scheduled maintenance inspection.
Each procedure includes a description, safety
warnings and step-by-step instructions.
Symbols Legend
Safety alert symbol—used to alert
personnel to potential personal
injury hazards. Obey all safety
messages that follow this symbol
to avoid possible injury or death.
Used to indicate the presence of
an imminently hazardous situation
which, if not avoided, will result in
death or serious injury.
Used to indicate the presence of a
potentially hazardous situation
which, if not avoided, could result
in death or serious injury.
With safety alert symbol—used to
indicate the presence of a
potentially hazardous situation
which, if not avoided, may cause
minor or moderate injury.
CAUTION
Without safety alert symbol—used
to indicate the presence of a
potentially hazardous situation
which, if not avoided, may result in
property damage.
Used to indicate operation or
maintenance information.
Indicates that a specific result is expected after
performing a series of steps.
Indicates that an incorrect result has occurred
after performing a series of steps.
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, six months, annually
and every 2 years as specified on the
Maintenance Inspection Report.
Failure to properly complete each
inspection when required could
result in 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.
Unless otherwise specified, perform each
procedure with the machine in the following
configuration:
· Machine parked on a firm, level surface
· Boom in the stowed position
· Turntable rotated with the boom between the
non-steer wheels
· Key switch in the off position with the
key removed
· Wheels chocked
· All external AC power supply disconnected
from the machine

3 - 2 Genie Z-30/20N Part No. 106373
Section 3 • Scheduled Maintenance Procedures April 2005
Maintenance Symbols Legend
The following symbols have been
used in this manual to help
communicate the intent of the
instructions. When one or more of
the symbols appear at the
beginning of a maintenance
procedure, it conveys the meaning
below.
Indicates that tools will be required to
perform this procedure.
Indicates that new parts will be required
to perform this procedure.
Indicates that a cold motor or pump will
be required to perform this procedure.
Indicates that dealer service will be
required to perform this procedure.
Maintenance Schedule
There are five types of maintenance inspections
that must be performed according to a schedule—
daily, quarterly, six months, annual, and two year.
The Scheduled Maintenance Procedures Section
and the Maintenance Inspection Report have been
divided into five subsections—A, B, C, D and E.
Use the following chart to determine which
group(s) of procedures are required to perform a
scheduled inspection.
Inspection Checklist
Daily or every 8 hours A
Quarterly or every 250 hours A + B
Six months or every 500 hours A + B + C
Annual or every 1000 hours A + B + C + D
Two year or every 2000 hours A + B + C + D + E
Maintenance Inspection Report
The maintenance inspection report contains
checklists for each type of scheduled inspection.
Make copies of the Maintenance Inspection Report
to use for each inspection. Store completed forms
for three years.
SCHEDULED MAINTENANCE PROCEDURES

Part No. 106373 Genie Z-30/20N 3 - 3
Section 3 • Scheduled Maintenance ProceduresApril 2004
Genie Industries USA
18340 NE 76th Street
PO Box 97030
Redmond, WA 98073-9730
[phone]
Copyright © 2002 by Genie Industries. Genie® is a registered trademark of Genie Industries.
Rev A
Genie UK
The Maltings, Wharf Road
Grantham, Lincolnshire
NG31- 6BH England
(44) 1476-584333
Pre-Delivery Preparation
Pre-Delivery Preparation Y N R
Pre-operation inspection completed
Maintenance items completed
Function tests completed
Model
Serial number
Date
Machine owner
Inspected by (print)
Inspector signature
Inspector title
Inspector company
Instructions
Use the operator’s manual on your machine.
The Pre-delivery Preparation consists of completing the
Pre-operation Inspection, the Maintenance items and the
Function Tests.
Use this form to record the results. Place a check in the
appropriate box after each part is completed. Follow the
instructions in the operator’s manual.
If any inspection receives an N, remove the machine from
service, repair and re-inspect it. After repair, place a check
in the R box.
Legend
Y = yes, completed
N = no, unable to complete
R = repaired
Comments
Fundamentals
It is the responsibility of the dealer to perform the
Pre-delivery Preparation.
The Pre-delivery Preparation is performed prior to each
delivery. The inspection is designed to discover if anything
is apparently wrong with a machine before it is put into
service.
A damaged or modified machine must never be used. If
damage or any variation from factory delivered condition is
discovered, the machine must be tagged and removed
from service.
Repairs to the machine may only be made by a qualified
service technician, according to the manufacturer's
specifications.
Scheduled maintenance inspections shall be performed by
qualified service technicians, according to the
manufacturer's specifications and the requirements listed
in the responsibilities manual.

3 - 4 Genie Z-30/20N Part No. 106373
Section 3 • Scheduled Maintenance Procedures April 2005
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Part No. 106373 Genie Z-30/20N 3 - 5
Section 3 • Scheduled Maintenance ProceduresApril 2005
Checklist A - Rev B YNR
A-1 Pre-operation
inspection
A-2 Function tests
Perform after 40 hours:
A-3 30 Day Service
Perform every 100 hours:
A-4 Grease rotation
bearing
Checklist B - Rev B YNR
B-1 Batteries
B-2 Electrical wiring
B-3 Key switch
B-4 Lug nut torque
B-5 Brake configuration
B-6 Drive hub oil level
B-7 Ground control
override
B-8 Platform leveling
B-9 Drive brakes
B-10 Drive speed-stowed
B-11 Drive speed-raised
B-12 Alarm package
(if equipped)
B-13 Turntable rotation stop
B-14 Electrical contactors
B-15 Hydraulic oil analysis
Checklist C - Rev B YNR
C-1 Grease platform
overload (if equipped)
C-2 Test platform
overload (if equipped)
Checklist D - Rev B YNR
D-1 Boom wear pads
D-2 Free-wheel
configuration
D-3 Turntable bearing bolts
D-4 Drive hub oil
D-5 Hydraulic return filter
D-6 Calibrate platform
overload system
(if equipped)
Checklist E - Rev B YNR
E-1 Hydraulic oil
E-2 Wheel bearings
Instructions
· Make copies of this page to use for
each inspection.
· Select the appropriate checklist(s) for
the type of inspection to be
performed.
Daily or 8 hour
Inspection: A
Quarterly or 250 hour
Inspection: A+B
Six Month or 500 hour
Inspection: A+B+C
Annual or 1000 hours
Inspection: A+B+C+D
2 Year or 2000 hour
Inspection: A+B+C+D+E
· Place a check in the appropriate box
after each inspection procedure is
completed.
· If any inspection receives an “N”, tag
and remove the machine from service,
repair and re-inspect it. After repair,
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-30/20N Part No. 106373
Section 3 • Scheduled Maintenance Procedures April 2005
REV B
Checklist A Procedures
A-1
Perform Pre-operation Inspection
Completing a pre-operation inspection is essential
to safe machine operation. The pre-operation
inspection is a visual inspection performed by the
operator prior to each work shift. The inspection is
designed to discover if anything is apparently
wrong with a machine before the operator performs
the function tests. The pre-operation inspection
also serves to determine if routine maintenance
procedures are required.
Complete information to perform this procedure is
available in the Genie Z-30/20N Operator's Manual
on your machine.
A-2
Perform Function Tests
Completing the function tests is essential to safe
machine operation. Function tests are designed to
discover any malfunctions before the machine is
put into service. A malfunctioning machine must
never be used. If malfunctions are discovered, the
machine must be tagged and removed from
service.
Complete information to perform this procedure is
available in the Genie Z-30/20N Operator's
Manual. Refer to the Operator's Manual on your
machine.