Service Manual First Edition

Third Printing
Part No. 35532

including rotating jib models

Introduction First Edition • Third Printing

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 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 other manuals.

Contact us: Copyright © 1996 by Genie Industries

First Edition: Third Printing June, 2002

http://www.genieindustries.com
e-mail: techsup@genieind.com "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.

ii Genie Z-30/20N Part No. 35532

First Edition • Third Printing

Safety Rules

Danger
Failure to obey the instructions and safety rules
in this manual and the Genie Z-30/20N Operator’s
Manual will result in death or serious injury.
Many of the hazards identified in the
operator’s manual are also safety hazards
when maintenance and repair procedures
are performed.

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.

Part No. 35532 Genie Z-30/20N iii


SAFETY RULES
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.
Red—used to indicate the
presence of an imminently
hazardous situation which, if not
avoided, will result in death or
serious injury.
Orange—used to indicate the
presence of a potentially
hazardous sitiuation which, if not
avoided, could result in death or
serious injury.
Yellow with safety alert symbol—
used to indicate the presence of a
potentially hazardous situation
which, if not avoided, may cause
minor or moderate injury.
Yellow 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.
iv Genie Z-30/20N
First Edition • Third Printing
Workplace Safety
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.
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.
Part No. 35532
First Edition • Third Printing

Table of Contents

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 - 3
Hydraulic Hose and Fitting Torque Specifications ..................................................... 2 - 4

Section Three Theory of Operation

Power Source ........................................................................................................... 3 - 1
Hydraulic System ...................................................................................................... 3 - 1
Electrical System ...................................................................................................... 3 - 1
Machine Controls ...................................................................................................... 3 - 2

Section Four Scheduled Maintenance Procedures

Introduction ............................................................................................................... 4 - 1
Maintenance Inspection Report ................................................................................ 4 - 3
A-1 Inspect the Operator’s and Safety Manuals .................................................... 4 - 4
A-2 Inspect the Decals and Placards ..................................................................... 4 - 4
A-3 Inspect for Damage and Loose or Missing Parts ............................................. 4 - 5
A-4 Check the Hydraulic Oil Level ......................................................................... 4 - 5

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TABLE OF CONTENTS

Section Four Scheduled Maintenance Procedures, continued

A-5 Check for Hydraulic Leaks .............................................................................. 4 - 6
A-6 Test the Platform and Ground Controls ........................................................... 4 - 6
A-7 Test the Auxiliary Power Operation ................................................................. 4 - 8
A-8 Test the Tilt Sensor ......................................................................................... 4 - 8
A-9 Test the Limit Switches ................................................................................... 4 - 9
A-10 Perform 30 Day Service ................................................................................ 4 - 12
A-11 Grease the Turntable Rotation Bearing and Worm Drive Gear ..................... 4 - 12
B-1 Check the Batteries ....................................................................................... 4 - 13
B-2 Inspect the Electrical Wiring .......................................................................... 4 - 14
B-3 Inspect the Tires and Wheels (including lug nut torque) ................................ 4 - 14
B-4 Confirm the Proper Brake Configuration ....................................................... 4 - 15
B-5 Check the Oil Level in the Drive Hubs ........................................................... 4 - 15
B-6 Test the Key Switch ...................................................................................... 4 - 16
B-7 Test the Emergency Stop .............................................................................. 4 - 17
B-8 Test the Ground Control Override ................................................................. 4 - 17
B-9 Test the Platform Self-leveling ...................................................................... 4 - 18
B-10 Test the Horn ................................................................................................ 4 - 18
B-11 Test the Foot Switch ..................................................................................... 4 - 19
B-12 Test the Drive Enable System ....................................................................... 4 - 19
B-13 Test the Drive Brakes ................................................................................... 4 - 20
B-14 Test the Drive Speed - Stowed Position ........................................................ 4 - 21
B-15 Test the Drive Speed - Raised or Extended Position .................................... 4 - 22
B-16 Test the Alarm Package (if equipped) ........................................................... 4 - 22
B-17 Test the Turntable Rotation Stop .................................................................. 4 - 23

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TABLE OF CONTENTS

Section Four Scheduled Maintenance Procedures, continued

B-18 Check the Electrical Contactors .................................................................... 4 - 24
B-19 Check the Turntable Rotation Bearing Bolts ................................................. 4 - 24
B-20 Replace the Hydraulic Tank Return Filter Element ........................................ 4 - 26
B-21 Perform Hydraulic Oil Analysis ...................................................................... 4 - 27
C-1 Check the Primary Boom Wear Pads ............................................................ 4 - 28
C-2 Check the Free-wheel Configuration ............................................................. 4 - 28
C-3 Replace the Drive Hub Oil ............................................................................. 4 - 29
C-4 Bleed the Platform Rotator ............................................................................ 4 - 30
D-1 Test or Replace the Hydraulic Oil .................................................................. 4 - 31
D-2 Grease the Steer Axle Wheel Bearings ......................................................... 4 - 33

Section Five Repair Procedures

Introduction ............................................................................................................... 5 - 1
Platform Controls
1-1 Controllers ...................................................................................................... 5 - 2
1-2 Diodes ........................................................................................................... 5 - 10
1-3 Foot Switch ................................................................................................... 5 - 11
1-4 Toggle Switches ............................................................................................ 5 - 12
Platform Components
2-1 Platform ........................................................................................................ 5 - 13
2-2 Platform Leveling Slave Cylinder .................................................................. 5 - 14
2-3 Platform Rotator ............................................................................................ 5 - 15

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TABLE OF CONTENTS

Section Five Repair Procedures, continued

Jib Boom Components
3-1 Jib Boom ....................................................................................................... 5 - 17
3-2 Jib Boom Bell Crank (models without rotating jib boom) ............................... 5 - 18
3-3 Jib Boom Rotator (models with rotating jib boom) ......................................... 5 - 19
3-4 Jib Boom Lift Cylinder ................................................................................... 5 - 20
Primary Boom Components
4-1 Plastic Cable Track ....................................................................................... 5 - 22
4-2 Primary Boom ............................................................................................... 5 - 22
4-3 Primary Boom Lift Cylinder ........................................................................... 5 - 26
4-4 Extension Cylinder ........................................................................................ 5 - 28
4-5 Platform Leveling Master Cylinder ................................................................ 5 - 30
Secondary Boom Components
5-1 Secondary Boom .......................................................................................... 5 - 33
5-2 Secondary Boom Lift Cylinder ....................................................................... 5 - 37
Ground Controls
6-1 Control Relays .............................................................................................. 5 - 40
6-2 Toggle Switches, See 1-4, Toggle Switches ................................................. 5 - 12
6-3 Wago® Components ...................................................................................... 5 - 42
Hydraulic Pumps
7-1 Auxiliary Pump .............................................................................................. 5 - 43
7-2 Function Pump .............................................................................................. 5 - 44

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TABLE OF CONTENTS

Section Five Repair Procedures, continued

Manifolds
8-1 Function Manifold Components (before serial number 3447) ........................ 5 - 46
8-2 Function Manifold Components (after serial number 3446) ........................... 5 - 48
8-3 Valve Adjustments - Function Manifold ......................................................... 5 - 52
8-4 Valve Coils .................................................................................................... 5 - 56
8-5 Jib Boom / Platform Rotate Manifold Components
(before serial number 4083) .......................................................................... 5 - 58
8-6 Jib Boom and Platform / Jib Boom Rotate Manifold Components
(after serial number 4082) ............................................................................. 5 - 59
8-7 Steer / Brake Manifold Components (before serial number 3447) ................. 5 - 60
Turntable Rotate Components
9-1 Turntable Rotation Hydraulic Motor ............................................................... 5 - 61
Steering Axle Components
10-1 Yoke and Hub ............................................................................................... 5 - 62
10-2 Steer Cylinder ............................................................................................... 5 - 64
10-3 Tie Rod ......................................................................................................... 5 - 64
Non-steering Axle Components
11-1 Drive Motor ................................................................................................... 5 - 65
11-2 Drive Hub ...................................................................................................... 5 - 65
Motor Controller
12-1 Motor Controller (after serial number 3446) .................................................. 5 - 67

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TABLE OF CONTENTS

Section Six Troubleshooting Flow Charts

Introduction ............................................................................................................... 6 - 1
Fault Code Chart (after serial number 3446) ............................................................ 6 - 3
Chart
Number Chart Title Page
1 All Functions Will Not Operate .................................................................................. 6 - 7
2 Lift Pump Motor Will Not Operate ........................................................................... 6 - 10
3 Auxiliary Pump Motor Will Not Operate ................................................................... 6 - 16
4 All Functions Inoperative, Power Unit Starts and Runs ........................................... 6 - 19
5 All Lift and Steer Functions Inoperative, Drive Function Operational ...................... 6 - 20
6 Ground Controls Inoperative, Platform Controls Operate Normally ......................... 6 - 23
7 Platform Controls Inoperative, Ground Controls Operate Normally
(before serial number 3447) ................................................................................... 6 - 24
8 Platform Controls Inoperative, Ground Controls Operate Normally
(after serial number 3446) ...................................................................................... 6 - 28
9 Primary Boom Up Function Inoperative .................................................................. 6 - 31
10 Primary Boom Down Function Inoperative .............................................................. 6 - 34
11 Secondary Boom Up Function Inoperative ............................................................. 6 - 37
12 Secondary Boom Down Function Inoperative ......................................................... 6 - 40
13 Primary Boom Extend Function Inoperative (before serial number 5398) ............... 6 - 43
14 Primary Boom Extend Function Inoperative (after serial number 5397) .................. 6 - 47
15 Primary Boom Retract Function Inoperative ........................................................... 6 - 50
16 Turntable Rotate Left Function Inoperative (before serial number 3447) ................ 6 - 54
17 Turntable Rotate Left Function Inoperative (after serial number 3446) ................... 6 - 58
18 Turntable Rotate Right Function Inoperative (before serial number 3447) .............. 6 - 61
19 Turntable Rotate Right Function Inoperative (after serial number 3446) ................. 6 - 65
20 All Platform Level Functions Inoperative ................................................................. 6 - 68

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TABLE OF CONTENTS

Section Six Troubleshooting Flow Charts, continued

21 Platform Level Up Function Inoperative .................................................................. 6 - 70
22 Platform Level Down Function Inoperative ............................................................. 6 - 75
23 Platform Rotate Left Function Inoperative
(before serial number 4083) ................................................................................... 6 - 80
24 Platform Rotate Left Function Inoperative
(after serial number 4082) ...................................................................................... 6 - 84
25 Platform Rotate Right Function Inoperative
(before serial number 4083) ................................................................................... 6 - 87
26 Platform Rotate Right Function Inoperative
(after serial number 4082) ...................................................................................... 6 - 91
27 Jib Boom Up Function Inoperative
(before serial number 4083) ................................................................................... 6 - 94
28 Jib Boom Up Function Inoperative
(after serial number 4082) ...................................................................................... 6 - 98
29 Jib Boom Down Function Inoperative
(before serial number 4083) ................................................................................. 6 - 101
30 Jib Boom Down Function Inoperative
(after serial number 4082) .................................................................................... 6 - 105
31 Jib Boom Rotate Left Function Inoperative
(after serial number 4082) .................................................................................... 6 - 108
32 Jib Boom Rotate Right Function Inoperative
(after serial number 4082) .................................................................................... 6 - 111
33 Steer Left Function Inoperative
(before serial number 3447) ................................................................................. 6 - 114
34 Steer Left Function Inoperative
(after serial number 3446) .................................................................................... 6 - 116
35 Steer Right Function Inoperative
(before serial number 3447) ................................................................................. 6 - 118
36 Steer Right Function Inoperative
(after serial number 3446) .................................................................................... 6 - 120

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TABLE OF CONTENTS

Section Six Troubleshooting Flow Charts, continued

37 All Drive Functions Inoperative, All Other Functions Operate Normally
(before serial number 3447) ................................................................................. 6 - 122
38 Brake Function Inoperative
(before serial number 3447) ................................................................................. 6 - 128
39 All Drive Functions Inoperative, All Other Functions Operate Normally
(after serial number 3446) .................................................................................... 6 - 132
39A Motor Controller Fault Code 21: Throttle Fault (after serial number 3446) ............ 6 - 134
39B Motor Controller Fault Code 32: Main Contactor Welded
(after serial number 3446) .................................................................................... 6 - 135
39C Motor Controller Fault Code 34: Missing Main Contactor OR
Main Contactor Did Not Close (after serial number 3446) ..................................... 6 - 136
40 Brake Release Function Inoperative
(after serial number 3446) .................................................................................... 6 - 139
41 Drive Forward Function Inoperative ...................................................................... 6 - 142
42 Drive Reverse Function Inoperative ...................................................................... 6 - 143
43 Machine Will Not Drive At Full Speed
(before serial number 3447) ................................................................................. 6 - 144
44 Machine Will Not Drive At Full Speed
(after serial number 3446) .................................................................................... 6 - 145
45 Machine Drives At Full Speed With Platform Raised Or Extended
(before serial number 3447) ................................................................................. 6 - 147
46 Machine Drives At The Incorrect Speed With Platform Raised Or Extended
(after serial number 3446) .................................................................................... 6 - 148
47 Drive Enable System Is Malfunctioning
(before serial number 3447) ................................................................................. 6 - 149
48 Drive Enable System Is Malfunctioning
(after serial number 3446) .................................................................................... 6 - 150
49 Remote Brake Release Inoperative ...................................................................... 6 - 151

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TABLE OF CONTENTS

Section Seven Schematics

Introduction ............................................................................................................... 7 - 1
Electrical Components .............................................................................................. 7 - 2
Load Sensor Option Diagram (before serial number 4083) ....................................... 7 - 4
Load Sensor Option Diagram (from serial number 4083 to 4255) ............................. 7 - 5
Load Sensor Option Diagram (after serial number 4255) .......................................... 7 - 6
Power Cable Diagram (before serial number 3447) .................................................. 7 - 7
Power Cable Diagram (after serial number 3446) ..................................................... 7 - 8
Electrical Symbols Legend ..................................................................................... 7 - 10
Electrical Schematic (before serial number 747) ..................................................... 7 - 11
Electrical Schematic (from serial number 747 to 3446) ........................................... 7 - 13
Electrical Schematic (from serial number 3447 to 4082) ......................................... 7 - 15
Electrical Schematic (after serial number 4082) ...................................................... 7 - 17
Ground Control Panel Legend (before serial number 747) ..................................... 7 - 19
Ground Control Panel Legend (from serial number 747 to 3446) ............................ 7 - 20
Ground Control Panel Legend (from serial number 3447 to 4082) .......................... 7 - 21
Ground Control Panel Wiring Diagram (after serial number 4082) .......................... 7 - 22
Platform Wiring Diagram (before serial number 3447) ............................................ 7 - 23
Platform Wiring Diagram (from serial number 3447 to 4082) .................................. 7 - 24
Platform Wiring Diagram (after serial number 4082) ............................................... 7 - 25
Hydraulic Symbols Legend ..................................................................................... 7 - 27
Hydraulic Schematic (before serial number 3447) .................................................. 7 - 28
Hydraulic Schematic (from serial number 3447 to 4082) ........................................ 7 - 29
Hydraulic Schematic (from serial number 4083 to 5397) ........................................ 7 - 30
Hydraulic Schematic (after serial number 5397) ..................................................... 7 - 31

Part No. 35532 Genie Z-30/20N xiii

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xiv Genie Z-30/20N Part No. 35532

First Edition • Third Printing Section 2 • Specifications

Specifications
Machine Specifications Wheelbase 5 ft 2 in
1.57 m
Stowed dimensions
Turning radius, outside 9 ft 10 in
Length, stowed 16 ft 9 in 3m
Models without rotating jib boom 5.1 m
Turning radius, inside 5 ft 5 in
Length, stowed 17 ft 6 in 1.65 m
Models with rotating jib boom 5.3 m

Width 3 ft 11 in
1.2 m Tires and wheels

Height, stowed maximum 6 ft 7 in Tire size (solid rubber) 22 x 7 x 17.75 in

2m 56 x 18 x 45 cm

Weight See Serial Plate Load range 7600 lbs

3447 kg
Ground clearance 31/2 in
8.9 cm Tire contact area 35 sq in
226 sq cm
Operational dimensions
Overall tire diameter 22 in
Platform height, maximum 30 ft 56 cm
Models without rotating jib boom 9.1 m
Wheel diameter 17.75 in
Platform height, maximum 29 ft 2 in 45 cm
Models with rotating jib boom 8.8 m
Wheel width 7 in
Working height, maximum 36 ft 18 cm
Models without rotating jib boom 11 m
Wheel lugs
Working height, maximum 35 ft 2 in
Models with rotating jib boom 10.7 m Front 8 @ 5/8 -18
Rear 9 @ 5/8 -18
Horizontal reach, maximum 21 ft
Models without rotating jib boom 6.4 m Lug nut torque, dry 125 ft-lbs
169.5 Nm
Horizontal reach, maximum 20 ft 8 in
Models with rotating jib boom 6.3 m Lug nut torque, lubricated 94 ft-lbs
127.4 Nm
Up and over clearance 12 ft 6 in
3.8 m Platform dimensions

Turntable tailswing 0° Length 46 in

1.17 m
Turntable rotation 359°
Width 30 in
Platform rotation 180° 76 cm

Jib boom rotation (optional) 200 ° Load capacity, maximum 500 lbs
227 kg

Part No. 35532 Genie Z-30/20N 2-1

Section 2 • Specifications First Edition • Third Printing

SPECIFICATIONS

Machine Specifications, continued Performance Specifications

Fluid Capacities Drive speed, maximum
Hydraulic tank capacity 4 gallons Stowed position (before serial number 3447)
15.1 liters 35:1 drive hubs 3.1 mph
5 km/h
Hydraulic tank capacity 6 gallons 40ft / 8.8 sec
(including tank) 22.7 liters 12.2 m / 8.8 sec
Drive hubs Stowed position (before serial number 3447)
35:1 and 49:1 17 ounces 0.5 liter 49:1 drive hubs 2.8 mph
62.5:1 25.6 ounces 0.76 liter 4.5 km/h
Continuous improvement of our products is a Genie 40 ft / 9.7 sec
policy. Product specifications are subject to change 12.2 m / 9.7 sec
without notice. Stowed position (after serial number 3446)
62:1 drive hubs 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

Gradeability

35:1 drive hubs 17%

49:1 drive hubs 20%
62:1 drive hubs 35%

2-2 Genie Z-30/20N Part No. 35532

First Edition • Third Printing Section 2 • Specifications

SPECIFICATIONS

Boom function speeds, maximum from platform Hydraulic Specifications

controls (with rated load secured to platform)
(before serial number 3447) Hydraulic fluid Dexron equivalent

Jib boom up 30 to 40 seconds Function pump

Jib boom down 15 to 25 seconds Type: Fixed displacement gear pump
Primary boom up 25 to 35 seconds Displacement 0.183 cu in
3 cc
Primary boom down 15 to 25 seconds
Flow rate @ 2.1 gpm
Primary boom extend 25 to 35 seconds
2800 psi / 172 bar 7.9 L/min
Primary boom retract 15 to 25 seconds
Hydraulic tank 10 micron with
Secondary boom up 15 to 25 seconds return line filter 25 psi / 1.7 bar bypass

Secondary boom down 10 to 15 seconds Function manifold

Turntable rotate, 355° 50 to 70 seconds System relief valve pressure 2800 psi
193 bar
Platform rotate, 160° 5 to 10 seconds
Boom down relief pressure 1400 psi
Platform level up 10 to 20 seconds 97 bar
Platform level down 10 to 20 seconds Secondary boom down relief pressure 1600 psi
110 bar
Boom function speeds, maximum from platform
controls (with rated load secured to platform) Primary boom extend relief pressure 2800 psi
(after serial number 3446) Models without rotating jib 193 bar
(after serial number 5619)
Jib boom up 20 to 30 seconds
Primary boom extend relief pressure 1800 psi
Jib boom down 15 to 25 seconds
Models without rotating jib 124 bar
Jib boom rotate, 200° 12 to 18 seconds (before serial number 5620)

Primary boom up 14 to 20 seconds Primary boom extend relief pressure 1800 psi
Models with rotating jib 124 bar
Primary boom down 13 to 19 seconds
Turntable rotate relief pressures
Primary boom extend (after serial number 3446) 1100 psi
(models with rotating jib boom) 14 to 24 seconds 76 bar
(models without rotating jib boom) 9 to 15 seconds
(before serial number 3447) 1750 psi
Primary boom retract 11 to 17 seconds
121 bar
Secondary boom up 11 to 17 seconds
Auxiliary pump
Secondary boom down 8 to 14 seconds
Type: Fixed displacement gear pump
Turntable rotate, 355° 52 to 68 seconds
Displacement 0.5 gpm
Platform rotate, 160° 5 to 11 seconds 1.9 L/min

Platform level up 14 to 19 seconds

Platform level down 13 to 18 seconds

Part No. 35532 Genie Z-30/20N 2-3

Section 2 • Specifications First Edition • Third Printing

SPECIFICATIONS

Hydraulic Hose and Fitting Seal-Lok® fittings

Torque Specifications 1 Replace the O-ring. The O-ring must be
replaced anytime the seal has been broken.
Your machine is equipped with Parker Seal-Lok® The O-ring cannot be re-used if the fitting or
fittings and hose ends. Genie specifications require hose end has been tightened beyond finger
that fittings and hose ends be torqued to tight.
specification when they are removed and installed
or when new hoses or fittings are installed. The O-rings used in the Parker
Seal Lok® fittings and hose ends
are custom-size O-rings. They are
SAE O-ring Boss Port not standard SAE size O-rings.
(tube fitting - installed into Aluminum) They are available in the O-ring
SAE Dash size Torque field service kit (Genie part
number 49612).
-4 11 ft-lbs / 14.9 Nm
2 Lubricate the O-ring before installation.
-6 23 ft-lbs / 31.2 Nm
3 Be sure that the face seal O-ring is seated and
-8 40 ft-lbs / 54.2 Nm retained properly.
-10 69 ft-lbs / 93.6 Nm 4 Position the tube and nut squarely on the face
seal end of the fitting and tighten the nut finger
-12 93 ft-lbs / 126.1 Nm tight.
-16 139 ft-lbs / 188.5 Nm 5 Tighten the nut or fitting to the appropriate
-20 172 ft-lbs / 233.2 Nm torque per given size as shown in the table.

-24 208 ft-lbs / 282 Nm 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 Seal-Lok Fittings

®

(tube fitting - installed into Steel) (hose end)

SAE Dash size Torque SAE Dash size Torque

-4 16 ft-lbs / 21.7 Nm -4 18 ft-lbs / 24.4 Nm

-6 35 ft-lbs / 47.5 Nm -6 27 ft-lbs / 36.6 Nm

-8 60 ft-lbs / 81.3 Nm -8 40 ft-lbs / 54.2 Nm

-10 105 ft-lbs / 142.4 Nm -10 63 ft-lbs / 85.4 Nm

-12 140 ft-lbs / 190 Nm -12 90 ft-lbs / 122 Nm

-16 210 ft-lbs / 284.7 Nm -16 120 ft-lbs / 162.7 Nm

-20 260 ft-lbs / 352.5 Nm -20 140 ft-lbs / 190 Nm

-24 315 ft-lbs / 427.1 Nm -24 165 ft-lbs / 223.7 Nm

2-4 Genie Z-30/20N Part No. 35532

First Edition • Third Printing
Power Source
The Genie Z-30/20N is powered by eight six-volt
(350 AH) batteries, separated into two groups of
four. Each group of four batteries is wired in series
to produce 24V DC. The two battery groups are
then joined to produce 48V DC. The drive system
uses 48V DC and the control system uses 24V
DC.
Hydraulic System
All machine functions are performed by the
hydraulic system. The hydraulic system is powered
by a single-section gear pump, rated at 2.1 gpm @
2800 psi / 7.9L/min @ 172 bar.
When the pump is activated, it supplies hydraulic
fluid under pressure to the function manifold,
where the directional flow control valves are
located. To protect from over-pressurization of the
hydraulic system, the pump is protected by a
pressure relief valve, set at 2800 psi / 193 bar.
Activating a machine function is accomplished by
actuating or moving a toggle switch and/or control
handle, which sends voltage to the appropriate
directional control valves. The directional valves
determines which direction the hydraulic fluid will
travel. When operating the machine from the
platform controls, the amount of hydraulic fluid
volume is determined by the proportional valve
input voltage from the boom function speed
controller at the platform controls. Each boom lift
cylinder incorporates a counterbalance valve to
prevent movement in the event of a hydraulic line
failure.
Part No. 35532 Genie Z-30/20N
Section 3 • Theory of Operation
Theory of Operation
Electrical System
Drive system
On machines before serial number 3447, the drive
function is managed by a 48V DC motor controller.
The motor controller, located under the non-steer
end drive chassis cover, is activated when it
receives electrical current from the platform
controller (joystick) when it is moved in either
direction.
On machines after serial number 3446, the drive
function is managed by a Sepex motor controller.
The motor controller, located under the non-steer
end drive chassis cover, uses resistance input
from the potentiometer to control the amount of
electrical current supplied to the drive motors.
Moving the joystick in either direction varies the
resistance from the potentiometer. There are no
adjustments needed on the joystick.
The Sepex system also incorporates regenerative
braking. Regenerative braking occurs when the
drive joystick is returned to the center position
while driving and the electrical current produced by
the drive motors is directed back into the batteries.
This allows longer machine run time and higher
performance.
The Sepex motor controller also incorporates self
diagnostics. An LED on the motor controller will
flash a fault code when a fault is present to aid in
troubleshooting. Refer to the fault code chart in
Section Six.
A remote motor controller status
LED is located under the level
sensor behind the ground controls
turntable cover.
3-1
Section 3 • Theory of Operation
THEORY OF OPERATION
Limit switches
There are two types of limit switches, which are
found in various locations on the machine: drive
speed limit switches and a drive enable limit
switch. The function of a drive speed limit switch is
to limit the raised machine drive speed to 0.6 miles
per hour / 1 km/h when either the primary or
secondary boom is raised more than 2 feet / 0.6 m
OR when the primary boom is extended more than
12 inches / 30 cm. The function of the drive enable
limit switch is to limit the ability of the machine to
drive when the boom is rotated outside the area
between the non-steer wheels.
3-2 Genie Z-30/20N
First Edition • Third Printing
Machine Controls
The Z-30/20N machine is equipped with
operational controls which are found in two
locations: the ground controls, located opposite the
hydraulic tank side of the machine, and the
platform controls, located in the platform. All boom
and drive functions are available at the platform
controls. Only boom functions are available at the
ground controls. Moving a boom function toggle
switch in the direction indicated on the control
panel decal will determine which boom function will
operate and its direction of travel.
The platform controls incorporate a rotary boom
function speed controller which, by varying the
position of the controller, controls the amount of
voltage to the proportional valve. This determines
the speed at which the function will operate.
The drive joystick is fitted with a potentiometer that
communicates the joystick position with the motor
controller. A thumb rocker switch on the top of the
joystick is used for steering.
Component damage hazard.
Avoid shock or impact to the
motor controller. Internal damage
may not be visible from the
outside.
Washing electronic components is
not suggested. Instead, use
compressed air to remove debris
from these components.
Part No. 35532
First Edition • Third Printing
Scheduled Maintenance 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 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
Part No. 35532 Genie Z-30/20N
Section 4 • 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.
Red—used to indicate the
presence of an imminently
hazardous situation which, if not
avoided, will result in death or
serious injury.
Orange—used to indicate the
presence of a potentially
hazardous situation which, if not
avoided, could result in death or
serious injury.
Yellow with safety alert symbol—
used to indicate the presence of a
potentially hazardous situation
which, if not avoided, may cause
minor or moderate injury.
Yellow without safety alert
CAUTION symbol—used to indicate the
presence of a potentially
hazardous situation which, if not
avoided, may result in property
damage.
Green—used to indicate operation
or maintenance information.
Indicates that a specific result is expected after
performing a series of steps.
4-1
Section 4 • Scheduled Maintenance Procedures
SCHEDULED MAINTENANCE PROCEDURES
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.
4-2 Genie Z-30/20N
First Edition • Third Printing
Maintenance Schedule
There are four types of maintenance inspections
that must be performed according to a schedule—
daily, quarterly, annual, and two year. The
Scheduled Maintenance Procedures Section and
the Maintenance Inspection Report have been
divided into four subsections—A, B, C and D. 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
Annual or every 1000 hours A+B+C
Two year or every 2000 hours A+B+C+D
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.
Part No. 35532
First Edition • Third Printing Section 4 • Scheduled Maintenance Procedures

Maintenance Inspection Report

Model Checklist A Y N R Checklist B, continued Y N R
A-1 Manuals B-10 Horn
Serial number
A-2 Decals and placards B-11 Foot switch
Date A-3 Damage and loose or B-12 Drive enable system
missing parts B-13 Drive brakes
Hour meter A-4 Hydraulic oil level B-14 Drive speed-stowed
A-5 Hydraulic leaks B-15 Drive speed-raised
Machine owner
A-6 Platform and B-16 Alarm package
Inspected by (print) ground controls (if equipped)
A-7 Auxiliary power B-17 Turntable rotation stop
Inspector signature A-8 Tilt sensor B-18 Electrical contactors
A-9 Limit switches B-19 Turntable bearing bolts
Inspector title
A-10 30 Day Service B-20 Hydraulic return filter
Inspector company Perform every 100 hours: B-21 Hydraulic oil analysis
A-11 Grease rotation
Instructions bearing
· Make copies of this page to use for Checklist C Y N R
each inspection. C-1 Boom wear pads
Checklist B Y N R
· Select the appropriate checklist(s) for C-2 Free-wheel
the type of inspection to be B-1 Batteries configuration
performed. B-2 Electrical wiring C-3 Drive hub oil
B-3 Tires and wheels C-4 Platform rotator
Daily or 8 hour
Inspection: A B-4 Brake configuration
B-5 Drive hub oil level Checklist D Y N R
Quarterly or 250 hour
Inspection: A+B B-6 Key switch D-1 Hydraulic oil
Annual or 1000 hour B-7 Emergency stop D-2 Wheel bearings
Inspection: A+B+C B-8 Ground control
2 Year or 2000 hour override
Inspection: A+B+C+D B-9 Platform leveling

· Place a check in the appropriate box

after each inspection procedure is
completed.
· Use the step-by-step procedures in
this section to learn how to perform
these inspections.
· 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

Part No. 35532 Genie Z-30/20N 4-3

Section 4 • Scheduled Maintenance Procedures
Checklist A Procedures
A-1
Inspect the Operator’s and
Safety Manuals
Maintaining the operator’s and safety manuals in
good condition is essential to safe machine
operation. Manuals are included with each machine
and should be stored in the container provided in
the platform. An illegible or missing manual will not
provide safety and operational information
necessary for a safe operating condition.
1 Confirm that the storage container is present
and in good condition.
2 Confirm that the operator's, responsibilities and
safety manuals are present and complete in the
storage container in the platform.
3 Examine the pages of each manual to be sure
that they are legible and in good 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.
4-4 Genie Z-30/20N
First Edition • Third Printing
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
associated with using this machine. They also
provide users with operation and maintenance
information. An illegible decal will fail to alert
personnel of a procedure or hazard and could result
in unsafe operating conditions.
1 Refer to the Decals section in the Genie
Z-30/20N Operator’s Manual and use the decal
list and illustrations to determine that all decals
and placards are in place.
2 Inspect all decals for legibility and damage.
Replace any damaged or illegible decal
immediately.
Contact your authorized Genie
distributor or Genie Industries if
replacement decals are needed.
Part No. 35532
First Edition • Third Printing Section 4 • Scheduled Maintenance Procedures

CHECKLIST A PROCEDURES

A-3 A-4
Inspect for Damage and Loose Check the Hydraulic Oil Level
or Missing Parts

Maintaining the hydraulic oil at the proper level is

Daily machine condition inspections are essential
to safe machine operation and good machine
performance. Failure to locate and repair damage,
and discover loose or missing parts may result in
an unsafe operating condition.
essential 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 Inspect the entire machine for damage and 1 Be sure that the boom is in the stowed position,
improperly installed or missing parts including: then visually inspect the hydraulic tank.

· Electrical components, wiring and electrical Result: The hydraulic oil level should be within
cables Before serial number 2008: the top 2 inches /
5 cm of the hydraulic oil decal.
· Hydraulic power unit, tank, hoses, fittings, After serial number 2007: the FULL and ADD
cylinders and manifolds marks on the hydraulic tank.
· Drive and turntable motors and drive hubs.
· Boom wear pads Hydraulic oil type Dexron equivalent
· Tires and wheels Hydraulic oil capacity
· Limit switches, alarms and horn
Hydraulic tank 4 gallons
· Nuts, bolts and other fasteners
15.1 liters
· Platform entry mid-rail/gate
· Beacon and alarms (if equipped) Hydraulic system 6 gallons
(including tank) 22.7 liters
· Battery packs and connections
· Compartment covers and latches
Check entire machine for:
· Cracks in welds or structural components
· Dents or damage to machine

Part No. 35532 Genie Z-30/20N 4-5

Section 4 • Scheduled Maintenance Procedures
CHECKLIST A PROCEDURES
A-5
Check for Hydraulic Leaks
Detecting hydraulic fluid leaks is essential to
operational safety and good machine performance.
Undiscovered leaks can develop into hazardous
situations, impair machine functions and damage
machine components.
1 Inspect for hydraulic oil puddles, dripping or
residue on or around the following areas:
· Hydraulic tank—filter, fittings, hoses and
turntable surface
· Compartments—hydraulic power unit,
auxiliary power unit, pumps, suction filter,
fittings, hoses, and turntable surface
· All hydraulic cylinders
· All hydraulic manifolds
· Primary, secondary and jib booms
· The underside of the turntable
· The underside of the drive chassis
· Ground area under the machine
4-6
First Edition • Third Printing
A-6
Test the Platform and
Ground Controls
Testing the machine functions and the Emergency
Stop buttons for malfunctions is essential for safe
machine operation. An unsafe working condition
exists if any function fails to operate properly or
either red Emergency Stop button fails to stop all
the machine functions. Each function should
operate smoothly and be free of hesitation, jerking
and unusual noise.
Before serial number 747:
1 Turn the key switch to ground controls and pull
out the red Emergency Stop button to the ON
position at both the ground and platform
controls.
2 Attempt to activate each boom and platform
function toggle switch.
Result: All machine functions should operate
through a full cycle. The descent alarm (if
equipped) should sound while the boom is
lowering.
3 Push in the red Emergency Stop button to the
OFF position.
Result: No function should operate. The
machine should stop.
4 Turn the key switch to platform controls and pull
out the red Emergency Stop button to the ON
position at both the ground and the platform
controls.
Genie Z-30/20N Part No. 35532
First Edition • Third Printing Section 4 • Scheduled Maintenance Procedures

CHECKLIST A PROCEDURES

5 Press down the foot switch and operate each 4 Push in the red Emergency Stop button to the
machine function through a full cycle. OFF position.

Result: All machine functions should operate Result: No function should operate. The
smoothly. machine should stop.
6 Push in the red Emergency Stop button to the 5 Turn the key switch to platform controls and pull
OFF position. out the red Emergency Stop button to the ON
position at both the ground and the platform
Result: No function should operate. The controls.
machine should stop.
6 Do not press down the foot switch. Activate
As a safety feature, selecting each machine funtion.
and operating the ground
controls will override the Result: The machine functions should not
platform controls, including operate.
the red Emergency Stop button.
7 Press down the foot switch.
After serial number 746:
8 Activate each machine function toggle switch.
1 Turn the key switch to ground controls and pull
Result: All boom/platform functions should
out the red Emergency Stop button to the ON
operate through a full cycle.
position at both the ground and platform
controls. 9 Push in the red Emergency Stop button to the
OFF position.
2 Do not hold the function enable toggle switch to
either side. Attempt to activate each boom and Result: No function should operate. The
platform function toggle switch. machine should stop.
Result: All boom and platform functions should As a safety feature, selecting
not operate. and operating the ground
controls will override the
3 Hold the function enable toggle switch to either
platform controls, including
side and activate each boom and platform
the red Emergency Stop button.
function toggle switch.
Control the speed of the boom
Result: All machine functions should operate
functions by adjusting the boom
through a full cycle. The descent alarm (if
function speed controller. Drive
equipped) should sound while the boom is
and steer functions are not
lowering.
affected by the boom function
Machines equipped with Platform speed controller.
Level Control Disable Function:
The platform level toggle switch
will not operate when the primary
boom is raised past the drive
speed limit switch.

Part No. 35532 Genie Z-30/20N 4-7

Section 4 • Scheduled Maintenance Procedures First Edition • Third Printing

CHECKLIST A PROCEDURES

A-7
Test the Auxiliary Power
Operation
Detection of auxiliary power system malfunctions is
essential for safe machine operation. An unsafe
working condition exists if the auxiliary powered
functions do not operate in the event of a main
power loss. Auxiliary power is designed for short
term emergency use only. Excessive use will result
in battery drain and component damage.
1 Turn the key switch to ground controls and pull
out the red Emergency Stop button to the ON
position.
2 Lift the red auxiliary power switch cover (if
equipped).
3 Simultaneously hold the auxiliary power toggle
switch in the ON direction while activating each
function through a partial cycle.
Result: Each function should operate smoothly.
To conserve battery power, test
each function through a partial
cycle.
4 Turn the key switch to platform controls.
A-8
Test the Tilt Sensor
The tilt sensor sounds an alarm in the platform
when the incline of the drive chassis exceeds
the rating on the serial plate.
Select a level test area. The tilt
alarm should not be sounding prior
to test.
1 Turn the key switch to platform controls and pull
out the red Emergency Stop button to the ON
position at both the ground and platform
controls.
2 Open the ground control side turntable cover and
locate the tilt sensor next to the function
manifold.
3 Press down on one side of the tilt sensor.
Result: The alarm located in the platform should
sound.
Tip-over hazard. The alarm should
be heard at the ground controls. If
you can't hear the alarm at the
ground controls, replace the alarm
in the platform.

5 At the platform controls, pull out the red

Emergency Stop button to the ON position, then
press down the foot switch.
6 Lift the red auxiliary power switch cover (if
equipped).
7 Simultaneously hold the auxiliary power toggle
switch on while activating each function through
a partial cycle.
Result: Each function should operate smoothly.
To conserve battery power, test
each function through a partial
cycle.

4-8 Genie Z-30/20N Part No. 35532

First Edition • Third Printing Section 4 • Scheduled Maintenance Procedures

CHECKLIST A PROCEDURES

A-9 Drive Limit Switches

Test the Limit Switches 1 With the boom in the stowed position, visually
inspect the drive limit switches for the following:
· Broken or missing rollers or arms
· Missing fasteners
Detecting limit switch malfunctions is essential to
safe machine operation. The drive limit switches · Loose wiring
are used to restrict drive speed when the boom is
raised or extended. The drive enable limit switch a
activates a signal light to inform the operator that
the platform is over the steering wheels, and stops b
drive movement unless the drive enable override
d
switch is used. Improperly functioning limit c
switches will allow the boom to raise and/or drive
into an unsafe position.

Machines equipped with Platform

a primary boom drive limit switch (LS2)
Level Control Disable Function:
(after serial number 746)
The platform level toggle switch
b boom extend drive limit switch (LS1)
will not operate when the primary c secondary boom drive
boom is raised past the drive limit switch (LS4)
speed limit switch. (after serial number 746)
d primary/secondary boom drive limit
switch (LS2)
(before serial number 747)

2 Extend the primary boom approximately

12 inches / 30 cm.
3 Manually activate the boom extend drive limit
switch (LS1).
Result: The boom extend drive limit switch arm
should move freely and spring return to center.
A distinct click should be felt and heard.
4 Fully retract the primary boom.

Part No. 35532 Genie Z-30/20N 4-9

Section 4 • Scheduled Maintenance Procedures
CHECKLIST A PROCEDURES
Before serial number 747:
5 Turn the key switch to ground controls and pull
out the red Emergency Stop buttons to the ON
position at both the ground and platform
controls.
6 Raise the primary boom approximately
12 inches / 30 cm.
7 Manually activate the primary and secondary
boom drive limit switch (LS2).
Result: The primary and secondary boom drive
limit switch arm should move freely and spring
return to center. A distinct click should be felt
and heard.
8 Lower the primary boom to the stowed position.
After serial number 746:
5 Remove the rear counterweight cover mounting
fasteners. Remove the cover.
6 Manually activate the secondary boom drive
limit switch (LS4).
Result: The secondary boom drive limit switch
arm should move freely and spring return to
center. A distinct click should be felt and heard.
7 Manually activate the primary boom drive limit
switch (LS2).
Result: The primary boom drive limit switch arm
should move freely and spring return to center.
A distinct click should be felt and heard.
8 Install the rear counterweight cover and tighten
the mounting fasteners.
4 - 10 Genie Z-30/20N
First Edition • Third Printing
All models:
9 Turn the key switch to platform controls and pull
out the red Emergency Stop buttons to the ON
position at both the ground and platform
controls.
10 Press down the foot switch and slowly move the
drive control handle off center.
Result: The machine should move at normal
drive speeds.
11 Raise the primary boom approximately
5 feet / 1.5 m.
12 Slowly move the drive control handle off center.
Result: The machine should move at a reduced
drive speed.
13 Lower the primary boom to the stowed position.
14 Raise the secondary boom approximately
5 feet / 1.5 m.
15 Slowly move the drive control handle off center.
Result: The machine should move at a reduced
drive speed.
16 Lower the secondary boom to the stowed
position.
17 Extend the primary boom 12 inches / 30 cm.
18 Slowly move the drive control handle off center.
Result: The machine should move at a reduced
drive speed.
Drive speed, maximum
Raised or extended position 40 ft / 40 sec
12.2 m / 40 sec
Part No. 35532
First Edition • Third Printing Section 4 • Scheduled Maintenance Procedures

CHECKLIST A PROCEDURES

Drive Enable Limit Switch 7 Turn the key switch to platform control and pull
out the red Emergency Stop buttons to the ON
1 With the boom in the stowed position, locate the position at both the ground and platform
drive enable limit switch (LS3) under the controls.
turntable.
8 Rotate the turntable to the left until the primary
2 Visually inspect the drive enable limit switch for boom is past the left non-steer wheel.
the following:
Result: The drive enable indicator light should
· Broken or missing roller or arm
be ON. The drive function should not operate
· Missing fasteners until the drive enable toggle switch is activated.
· Loose wiring 9 Rotate the turntable to the right until the primary
boom is past the right non-steer wheel.
a
Result: The drive enable indicator light should be
b ON. The drive function should not operate until
the drive enable toggle switch is activated.
c

a turntable
b limit switch cam
c drive enable limit switch (LS3)
d drive chassis

3 Turn the key switch to ground controls and pull

out the red Emergency Stop buttons to the ON
position at both the ground and platform
controls.
4 Rotate the turntable to the left until the primary
boom is past the left non-steer wheel.
5 Manually activate the drive enable limit switch.
Result: The drive enable limit switch roller
should move freely and spring return to center.
A distinct click should be felt and heard.
6 Rotate the boom until it is centered between the
non-steer tires.

Part No. 35532 Genie Z-30/20N 4 - 11

Section 4 • Scheduled Maintenance Procedures
CHECKLIST A PROCEDURES
A-10
Perform 30 Day Service
The 30 day maintenance procedure 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 checklists for
continued scheduled maintenance.
1 Perform the following maintenance procedures:
· B-3 Inspect the Tires and Wheels
(including lug nut torque)
· B-19 Check the Turnable Rotation
Bearing Bolts
· B-20 Replace the Hydraulic Tank
Return Filter
4 - 12
First Edition • Third Printing
A-11
Grease the Turntable Rotation
Bearing and Worm Drive Gear
Genie specifications require that
this procedure be performed every
100 hours.
Frequent application of lubrication to the turntable
bearing and worm drive gear is essential to good
machine performance and service life. Continued
use of an insufficently greased gear will result in
component damage.
1 Locate the grease fitting on the tank side
turntable cover bulkhead.
2 Pump grease into the turntable rotation bearing.
Rotate the turntable in increments of 4 to 5
inches / 10 to 13 cm at a time and repeat this
step until the entire bearing has been greased.
3 Locate the 2 grease fittings on the worm drive
housing.
a grease fittings
4 Pump grease into the gear until you see it
coming out of the side of the gear housing.
5 Grease each tooth on the outside of the
turntable rotation bearing.
Lubricant specification
Type Multipurpose grease
Genie Z-30/20N Part No. 35532
First Edition • Third Printing Section 4 • Scheduled Maintenance Procedures

Checklist B Procedures
B-1 4 Remove the battery box cover retaining
fasteners. Remove the battery box cover.
Check the Batteries
5 Be sure that the battery cable connections are
free of corrosion.
6 Be sure that the battery hold down and cable
Proper battery condition is essential to good connections are tight.
machine performance and operational safety.
7 Remove the battery vent caps and check the
Improper fluid levels or damaged cables and
specific gravity of each battery cell with a
connections can result in engine component
hydrometer.
damage and hazardous conditions.
Result: If any battery cell displays a specific
Bodily injury hazard. Batteries
gravity of less than 1.026, the battery must be
contain acid. Avoid spilling or
replaced.
contacting battery acid. Neutralize
battery acid spills with baking soda 8 Check the battery acid level of the battery. If
and water. needed, replenish with distilled water to the
bottom of the battery fill tube. Do not overfill.
Electrocution hazard. Contact with
hot or live circuits could result in 9 Install the battery vent caps.
death or serious injury. Remove all
10 Check each battery pack and verify that the
rings, watches and other jewelry.
batteries are wired correctly.
Perform this test after fully
charging the batteries.
For a more accurate determination + -
of the battery condition, fully
charge the battery(s) and allow the
battery(s) to rest 24 hours before
performing this procedure to allow - +
-
+
the battery cells to equalize.
1 Put on protective clothing and eye wear.
2 Open the latch on the battery packs. Swing +
- -
+
open the battery packs.
3 Disconnect the battery pack from the machine.
11 Install the battery box cover and tighten the
retaining fasteners.
12 Connect the battery packs to the machine.
13 Close and latch the battery packs.

Part No. 35532 Genie Z-30/20N 4 - 13

Section 4 • Scheduled Maintenance Procedures First Edition • Third Printing

CHECKLIST B PROCEDURES

B-2 B-3
Inspect the Electrical Wiring Inspect the Tires and Wheels
(including lug nut torque)

Maintaining electrical wiring in good condition is

essential to safe operation and good machine Maintaining the tires and wheels in good
performance. Failure to find and replace burnt, condition is essential to safe operation and good
chafed, corroded or pinched wires could result in performance. Tire and/or wheel failure could result
unsafe operating conditions and may cause in a machine tip-over. Component damage may
component damage. also result if problems are not discovered and
Electrocution hazard. Contact with repaired in a timely fashion.
hot or live circuits could result in 1 Check the tire surface and sidewalls for cuts,
death or serious injury. Remove all cracks, and unusual wear.
rings, watches and other jewelry.
2 Check each wheel for damage, bends and
1 Inspect the following areas for burnt, chafed, cracked welds.
corroded and loose wires:
3 Check each lug nut for proper torque.
· Electrical power panel
· Electrical relay panel Tires and wheels
· Ground control panel
Lug nut torque, dry 125 ft-lbs
· Function manifold wiring 169.5 Nm
2 Turn the key switch to ground controls and pull
out the red Emergency Stop button to the ON Lug nut torque, lubricated 94 ft-lbs
position at both the ground and platform 127.4 Nm
controls.
3 Raise the secondary boom until the lower
mid-pivot is 10 feet / 3 m off the ground.
4 Inspect the turntable center area for burnt,
chafed and pinched cables.
5 Lower the boom to the stowed position and turn
the machine off.
6 Inspect the following areas for burnt, chafed,
corroded, pinched and loose wires:
· Cable track on the primary boom
· Primary boom to platform cable harness
· Inside of the platform control box

4 - 14 Genie Z-30/20N Part No. 35532

First Edition • Third Printing Section 4 • Scheduled Maintenance Procedures

CHECKLIST B PROCEDURES

B-4 B-5
Confirm the Proper Check the Oil Level
Brake Configuration in the Drive Hubs

Proper brake configuration is essential to safe
operation and good machine performance.
Hydraulically-released, spring-applied individual
wheel brakes can appear to operate normally when
they are actually not fully operational.
1 Check each drive hub disconnect cap to be sure
it is in the engaged position.
disengaged position
Failure to maintain proper drive hub oil levels may
cause the machine to perform poorly and continued
use may cause component damage.
1 Drive the machine to rotate the hub until one of
the plugs is located on top and the other is at
90 degrees.
a

engaged position

Before serial number 3447

After serial number 3446

a drive hub plugs

Part No. 35532 Genie Z-30/20N 4 - 15

Section 4 • Scheduled Maintenance Procedures First Edition • Third Printing

CHECKLIST B PROCEDURES

2 Remove the plug located at 90 degrees and B-6

check the oil level.
Result: The oil level should be even with the
bottom of the side plug hole.
3 If necessary, remove the top plug and add oil
until the oil level is even with the bottom of the
side plug hole.
4 Before serial number 3447: Apply pipe thread
sealant to the plugs. Install the plugs into the
drive hub.
After serial number 3446: Install the plugs into
the drive hub.
Test the Key Switch
Proper key switch action and response is essential
to safe machine operation. The machine can be
operated from the ground or platform controls and
the activation of one or the other is accomplished
with the key switch. Failure of the key switch to
activate the appropriate control panel could cause a
hazardous operating situation.
1 Pull out the red Emergency Stop button to the
ON position at both the ground and platform
controls.

5 Repeat this procedure for each drive hub. 2 Turn the key switch to platform controls.
3 Check the machine functions from the ground
Drive hub oil capacity specification controls.

35:1 Drive Hubs 17 fl oz Result: The machine functions should not

0.5 liters operate.
4 Turn the key switch to ground controls.
49:1 Drive Hubs 17 fl oz
0.5 liters 5 Check the machine functions from the platform
controls.
62.5:1 Drive Hubs 25.6 fl oz
0.76 liters Result: The machine functions should not
operate.
Type: SAE 90 multipurpose hypoid gear oil -
API service classification GL5 6 Turn the key switch to the OFF position.
Result: No function should operate. The
machine should stop.

4 - 16 Genie Z-30/20N Part No. 35532

First Edition • Third Printing
B-7
Test the Emergency Stop
A properly functioning Emergency Stop is essential
for safe machine operation. An improperly operating
red Emergency Stop button will 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 platform red
Emergency Stop button.
1 Turn the key switch to ground controls and pull
out the red Emergency Stop button to the ON
position at both the ground and platform
controls.
2 Push in the red Emergency Stop button to the
OFF position at the ground controls.
Result: No functions should operate.
3 Turn the key switch to platform controls and pull
out the red Emergency Stop button to the ON
position at both the ground and platform
controls.
4 Push in the platform Emergency Stop button
to the OFF position.
Result: No machine functions should operate.
The red Emergency Stop button at
the ground controls will stop all
machine operation, even if the key
switch is switched to platform
controls.
Part No. 35532 Genie Z-30/20N
Section 4 • Scheduled Maintenance Procedures
CHECKLIST B PROCEDURES
B-8
Test the Ground Control
Override
A properly functioning ground control override is
essential to safe machine operation. The ground
control override function is intended to allow ground
personnel to operate the machine from the ground
controls whether the red Emergency Stop button on
the platform controls is in the ON or OFF position.
This function is particularly useful if the operator at
the platform controls cannot return the boom to the
stowed position.
1 Push in the red Emergency Stop button at the
platform controls to the OFF position.
2 Turn the key switch to ground controls and pull
out the red Emergency Stop button to the ON
position.
3 Operate each boom function through a
partial cycle at the ground controls.
Result: All boom functions should operate.
4 - 17
Section 4 • Scheduled Maintenance Procedures
CHECKLIST B PROCEDURES
B-9
Test the Platform Self-leveling
Automatic platform self-leveling throughout
the full cycle of boom raising and lowering is
essential for safe machine operation. The
platform is maintained level by the platform leveling
slave cylinder which is controlled by the platform
leveling 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 controls and pull
out the red Emergency Stop button to the ON
position at both the ground and platform
controls.
2 Lower the boom to the stowed position.
3 Adjust the platform to a level position using the
platform leveling toggle switch.
4 Raise and lower the primary boom through
a full cycle.
Result: The platform should remain level at
all times to within ±5 degrees.
4 - 18 Genie Z-30/20N
First Edition • Third Printing
B-10
Test the Horn
A properly functioning horn is essential to safe
machine operation. The horn is activated at the
platform controls and sounds at the ground as a
warning to ground personnel. An improperly
functioning horn will prevent the operator from
alerting ground personnel of hazards or unsafe
conditions.
1 Turn the key switch to platform controls and
pull out the red Emergency Stop button to the
ON position at both the ground and platform
controls.
2 Push down the horn button at the platform
controls.
Result: The horn should sound.
If necessary, the horn can be
adjusted to obtain the loudest
volume by turning the adjustment
screw near the wire terminals on
the horn.
Part No. 35532
First Edition • Third Printing
B-11
Test the Foot Switch
A properly functioning foot switch is essential to
safe machine operation. Machine functions should
activate and operate smoothly as long as the foot
switch is pressed down, and promptly stop when
the foot switch is released. An improperly
functioning foot switch can cause an unsafe
working condition.
1 Turn the key switch to platform controls and pull
out the red Emergency Stop button to the ON
position at both the ground and platform
controls.
2 Do not press down the foot switch. Attempt to
operate the machine functions.
Result: The machine functions should not
operate.
3 Press down the foot switch and operate the
machine functions.
Result: The machine functions should operate.
Part No. 35532 Genie Z-30/20N
Section 4 • Scheduled Maintenance Procedures
CHECKLIST B PROCEDURES
B-12
Test the Drive Enable System
Proper drive enable system operation is
essential to safe machine operation. When the
primary boom is past the non-steering wheels, drive
movement is stopped and the indicator light turns
on. The drive enable toggle switch must be used
to reactivate drive function and should inform
the operator that the machine may move in the
opposite direction that the drive and steer controls
are moved. An improperly functioning drive enable
system may allow the machine to be moved into an
unsafe position.
Perform this test with the boom in
the stowed position.
1 Turn the key switch to platform controls and pull
out the red Emergency Stop button to the ON
position at both the ground and platform
controls.
2 Rotate the turntable until the boom moves past
one of the non-steering wheels.
Result: The drive enable
indicator light should come on
and remain on while the boom
is anywhere in the range
shown.
3 Slowly move the drive joystick off center.
Result: The drive function should not operate.
Collision hazard. Always use the
color-coded direction arrows on the
platform control panel and the drive
chassis to identify which direction
the machine will travel.
4 - 19
Section 4 • Scheduled Maintenance Procedures
CHECKLIST B PROCEDURES
4 Hold the drive enable toggle switch up or down
and slowly move the drive joystick off center.
Result: The drive function should operate.
5 Rotate the turntable until the boom moves past
the other non-steering wheel.
Result: The drive enable
indicator light should come on
and remain on while the
boom is anywhere in the
range shown.
6 Slowly move the drive joystick off center.
Result: The drive function should not operate.
Collision hazard. Always use the
color-coded direction arrows on the
platform control panel and the drive
chassis to identify which direction
the machine will travel.
7 Hold the drive enable toggle switch up or down
and slowly move the drive joystick off center.
Result: The drive function should operate.
4 - 20 Genie Z-30/20N
First Edition • Third Printing
B-13
Test the Drive Brakes
Proper brake action is essential to safe machine
operation. The drive brake function should operate
smoothly, free of hesitation, jerking and unusual
noise. Hydraulically-released individual wheel
brakes can appear to operate normally when they
are actually not fully operational.
Collision hazard. Be sure that the
machine is not in free-wheel or
partial free-wheel 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 Lower the boom to the stowed position.
3 Turn the key switch to platform controls.
4 Choose a reference point on the machine; i.e.,
contact patch of a tire, as a visual reference for
use when crossing the test line.
5 Bring the machine to top drive speed before
reaching the test line. Release the drive joystick
when your reference point on the machine
crosses the test line.
6 Measure the distance between the test line and
your machine reference point.
Braking distance, maximum
High range on paved surface 2 to 4 ft
0.6 to 1.2m
The brakes must be able to hold
the machine on any slope it is able
to climb.
Part No. 35532
First Edition • Third Printing Section 4 • Scheduled Maintenance Procedures

CHECKLIST B PROCEDURES

B-14 5 Bring the machine to maximum drive speed

before reaching the start line. Begin timing when
Test the Drive Speed - your reference point on the machine crosses the
Stowed Position start line.
6 Continue at full speed and note the time when
your machine reference point passes over the
finish line.
Proper drive function movement is essential to safe
machine operation. The drive function should Drive speed, maximum
respond quickly and smoothly to operator control. (before serial number 3447)
Drive performance should also be free of hesitation,
jerking and unusual noise over the entire 49:1 drive hubs 40 ft / 9.7 sec
proportionally controlled speed range. 12.2 m / 9.7 sec

Select a test area that is firm, level 35:1 drive hubs 40ft / 8.8 sec
and free of obstructions. 12.2 m / 8.8 sec

Be sure the boom is in the stowed Drive speed, maximum

position. (after serial number 3446)

1 Create start and finish lines by marking two lines 62.5:1 drive hubs 40 ft / 8.3 sec
on the ground 40 feet / 12.2 m apart. 12.2 m / 8.3 sec
2 Turn the key switch to platform control and pull
out the red Emergency Stop button to the ON
position at both the ground and platform
controls.
3 Choose a reference point on the machine; i.e.,
contact patch of a tire, as a visual reference for
use when crossing the start and finish lines.
4 Press down the foot switch and slowly move the
drive joystick to the full drive position.

Part No. 35532 Genie Z-30/20N 4 - 21

Section 4 • Scheduled Maintenance Procedures
CHECKLIST B PROCEDURES
B-15
Test the Drive Speed -
Raised or Extended Position
Proper drive function movement is essential to safe
machine operation. The drive function should
respond quickly and smoothly to operator control.
Drive performance should also be free of hesitation,
jerking and unusual noise over the entire
proportionally controlled speed range.
Select a test area that is firm, level
and free of obstructions.
1 Create start and finish lines by marking two lines
on the ground 40 feet / 12.2 m apart.
2 Turn the key switch to platform control and pull
out the red Emergency Stop button to the ON
position at both the ground and platform
controls.
3 Raise the primary boom more than
5 feet / 1.5 m.
4 Choose a reference point on the machine; i.e.,
contact patch of a tire, as a visual reference for
use when crossing the start and finish lines.
5 Press down the foot switch and slowly move the
drive joystick to the full drive position.
6 Bring the machine to maximum drive speed
before reaching the start line. Begin timing when
your reference point on the machine crosses the
start line.
7 Continue at full speed and note the time when
your machine reference point passes over the
finish line.
Drive speed, maximum
Raised or extended position 40 ft / 40 sec
12.2 m / 40 sec
4 - 22 Genie Z-30/20N
First Edition • Third Printing
B-16
Test the Alarm Package
(if equipped)
The alarm package includes:
· 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
ground controls side turntable cover.
1 Turn the key switch to ground controls and pull
out the red Emergency Stop buttons to the ON
position at both ground and platform controls.
Result: The flashing beacon should be ON and
flashing.
2 Before serial number 747: Move the primary
boom toggle switch to the down position, hold
for a moment then release it.
After serial number 746: Hold the function
enable toggle switch to either side, then move
the primary boom toggle switch to the down
position, hold for a moment then release it.
3 Before serial number 747: Move the
secondary boom toggle switch to the down
position, hold for a moment then release it.
After serial number 746: Hold the function
enable toggle switch to either side, then move
the secondary boom toggle switch to the down
position, hold for a moment then release it.
Result: The descent alarm should sound when
each control toggle switch is held down.
Part No. 35532
First Edition • Third Printing
4 Turn the key switch to platform controls.
Result: The flashing beacon should be ON
and flashing.
5 Press down the foot switch.
6 Move the primary boom toggle switch to the
down position, hold for a moment then release
it. Move the secondary boom toggle switch to
the down position, hold for a moment then
release it.
Result: The descent alarm should sound when
each control toggle switch is held down.
7 Press down the foot switch.
8 Move the drive joystick off center, hold for a
moment then release it. Move the drive joystick
off center in the opposite direction, hold for a
moment then release it.
Result: The travel alarm should sound when the
drive joystick is moved off center in either
direction.
Part No. 35532 Genie Z-30/20N
Section 4 • Scheduled Maintenance Procedures
CHECKLIST B PROCEDURES
B-17
Test the Turntable Rotation Stop
The turntable is capable of rotating the boom 359
degrees and is stopped midpoint between the
steering wheels by the rotation stop. Detecting a
rotation stop malfunction is essential to safe
operation and good machine performance. If the
turntable rotates past the rotation stop, component
damage may result.
1 Turn the key switch to platform controls and pull
out the red Emergency Stop buttons to the ON
position at both ground and platform controls.
2 Rotate the turntable to the left as far as it will
go.
Result: Movement should stop when the primary
boom reaches midpoint between the steer tires.
3 Rotate the turntable to the right as far as it will
go.
Result: Movement should stop when the primary
boom reaches mid-point between the steer tires.
4 - 23
Section 4 • Scheduled Maintenance Procedures
CHECKLIST B PROCEDURES
B-18
Check the Electrical Contactors
Maintaining the electrical contactors in good
condition is essential to safe machine operation.
Failure to locate a worn or damaged contactor could
result in an unsafe working condition and
component damage.
1 Remove the non-steer drive chassis cover and
locate the electrical contactors mounted on the
electrical component mounting panel.
2 Visually inspect the contact points of each
contactor for the following items:
· Excessive burns
· Excessive pitting
Electrocution hazard. Contact with
hot or live circuits could result in
death or serious injury. Remove all
rings, watches and other jewelry.
Replace the contactors if any
damage is found.
4 - 24 Genie Z-30/20N
First Edition • Third Printing
B-19
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 damage.
1 Raise the secondary boom and place a safety
chock on the secondary boom lift cylinder.
Carefully lower the boom onto the lift cylinder
safety chock.
Crushing hazard. Keep hands
away from the cylinder and all
moving parts when lowering the
secondary boom.
Lift cylinder safety chock
Genie part number 36555
Part No. 35532
First Edition • Third Printing Section 4 • Scheduled Maintenance Procedures

CHECKLIST B PROCEDURES

2 Check to verify that each turntable bearing bolt 5 Check to verify that each bearing mounting bolt
is torqued in specified order to under the drive chassis is torqued in specified
190 ft-lbs / 258 Nm. order to 190 ft-lbs / 258 Nm.
9 1
11 9 1
11
6 7 6 7
16 13 13

3 4 3 4

14 15 14 15

8 5 8 5
12 10 12 10
2 2

Bolt torque sequence Bolt torque sequence

(before serial number 3369) (before serial number 3369)

9 1 1
4 7 4 7

11

2 5 6 3

12

6 3 2 5
10
8 8
Bolt torque sequence Bolt torque sequence
(after serial number 3368) (after serial number 3368)

3 Raise boom and remove the safety chock.

Lower the boom to the stowed position.
4 Open the latch on the battery packs and swing
them out to expose the turntable bearing bolt
access hole.

Part No. 35532 Genie Z-30/20N 4 - 25

Section 4 • Scheduled Maintenance Procedures
CHECKLIST B PROCEDURES
B-20
Replace the Hydraulic Tank
Return Filter Element
Genie requires that this procedure
be performed quarterly or every
250 hours, whichever comes first.
Perform this procedure more often
if dusty conditions exist.
Replacement of the hydraulic return filter element is
essential for good machine performance and
service life. A dirty or clogged filter element may
cause the machine to perform poorly and continued
use may cause component damage. Extremely
dirty conditions may require that the filter element
be replaced more often.
Bodily injury hazard. Beware of hot
oil. Contact with hot oil may cause
severe burns.
The hydraulic return filter is located
on the bulkhead next to the
hydraulic power unit.
Before serial number 2008:
1 Clean the area around the oil filter housing, then
remove the filter element with an oil filter
wrench.
2 Apply a thin layer of fresh oil to the gasket on
the new oil filter element.
3 Install the new filter element and tighten it
securely by hand.
Hydraulic tank return filter
(before serial number 2008)
Genie part number 46014
4 - 26 Genie Z-30/20N
First Edition • Third Printing
4 Before serial number 747: Turn the key switch
to ground controls and pull out the red
Emergency Stop button to the ON position at the
ground controls. Move and hold the primary
boom toggle switch in the UP direction.
After serial number 746: Turn the key switch
to ground controls and pull out the red
Emergency Stop button to the ON position at the
ground controls. Move and hold the function
enable toggle switch to either side and move
and hold the primary boom toggle switch in the
UP direction.
5 Inspect the filter and related components to
be sure that there are no leaks. Clean up any oil
that may have spilled during the replacement
procedure. Properly discard the oil and oil filter.
After serial number 2007:
1 Clean the area around the oil filter housing cap
located on top of the reservoir.
2 Remove the oil filter housing cap fasteners.
Remove the cap.
3 Remove the oil filter element from the housing.
4 Clean the oil filter housing with a mild solvent.
5 Install the new oil filter element.
6 Install the housing cap and tighten the
fasteners.
Hydraulic tank return filter element
(from serial number 2008 to 4526)
Genie part number 58995
Hydraulic tank return filter element
(from serial number 4527 to 5522)
Genie part number 74346
Hydraulic tank return filter element
(after serial number 5522)
Genie part number 74634
Part No. 35532
First Edition • Third Printing Section 4 • Scheduled Maintenance Procedures

CHECKLIST B PROCEDURES

7 Turn the key switch to ground controls and pull

out the red Emergency Stop button to the ON
position. Move and hold the function enable
toggle switch to either side and move and hold
the primary boom toggle switch in the UP
direction.
8 Inspect the filter and related components to
be sure that there are no leaks.
9 Clean up any oil that may have spilled during the
replacement procedure.
10 Properly discard the oil and oil filter element.

B-21
Perform Hydraulic Oil Analysis

Replacement or testing of the hydraulic oil is

essential for good machine performance and
service life. Dirty oil and suction strainers may
cause the machine to perform poorly and continued
use may cause component damage. Extremely
dirty conditions may require oil changes to be
performed more often.
The machine uses Dexron
equivalent hydraulic oil. Before
replacing the hydraulic oil, the oil
may be tested by an oil distributor
for specific levels of contamination
to verify that changing the oil is
necessary. If the hydraulic oil
is not replaced at the two year
inspection, test the oil quarterly.
Replace the oil when it fails the
test. See D-1, Test or Replace the
Hydraulic Oil.

Part No. 35532 Genie Z-30/20N 4 - 27

Section 4 • Scheduled Maintenance Procedures
Checklist C Procedures
C-1
Check the Primary Boom
Wear Pads
Maintaining the primary boom wear pads in good
condition is essential to safe machine operation.
Wear pads are placed on boom tube surfaces to
provide a low friction, replaceable wear pad
between moving parts. Improperly shimmed wear
pads or continued use of worn out wear pads may
result in component damage and unsafe operating
conditions.
1 Turn the key switch to ground controls and pull
out the red Emergency Stop button to the ON
position at both the ground and platform
controls.
2 Extend the primary boom 10 inches / 25 cm.
3 Measure each wear pad. Replace the wear pad if
it is less than 0.41 inch / 1 cm thick. If the wear
pad is more than 0.41 inch / 1 cm thick, shim
as necessary to obtain zero clearance and zero
drag.
4 Extend and retract the primary boom 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.
Primary boom wear pad specification
Wear pad thickness, minimum 0.41 inch
1 cm
4 - 28 Genie Z-30/20N
First Edition • Third Printing
C-2
Check the Free-wheel
Configuration
Proper use of the free-wheel configuration is
essential to safe machine operation. The
free-wheel configuration is used primarily for towing.
A machine configured to free-wheel without operator
knowledge may cause death or serious injury and
property damage.
Collision hazard. Select a work site
that is firm and level.
Component damage hazard. If the
machine must be towed, do not
exceed 2 mph / 3.2 km/h.
1 Chock the steer wheels to prevent the machine
from rolling.
2 Center a lifting jack of ample capacity
(15000 lbs / 6804 kg) under the drive chassis
between the non-steer wheels.
3 Lift the wheels off the ground and then place
blocks under the drive chassis for support.
4 Disengage the drive hubs by turning over the
drive hub disconnect caps on each
non-steer wheel hub.
disengaged position
engaged position
Part No. 35532
First Edition • Third Printing
5 Manually rotate each non-steer wheel.
Result: Each non-steer wheel should rotate with
minimum effort.
6 Engage the drive hubs by turning over
the drive hub disconnect caps.
7 Carefully remove the blocks, lower the machine
and remove the jack.
Collision hazard. Failure to engage
the drive hubs could result in death
or serious injury and property
damage.
Part No. 35532 Genie Z-30/20N
Section 4 • Scheduled Maintenance Procedures
CHECKLIST C PROCEDURES
C-3
Replace the Drive Hub Oil
Replacing the drive hub oil is essential for good
machine performance and service life. Failure to
replace the drive hub oil at yearly intervals may
cause the machine to perform poorly and continued
use may cause component damage.
1 Select the drive hub to be serviced. Drive the
machine until one of the two plugs is at the
lowest point.
2 Remove both plugs and drain the oil.
3 Drive the machine until one plug is at the top
and the other is at 90 degrees.
Before serial number 3447
After serial number 3446
a drive hub plugs
4 - 29
Section 4 • Scheduled Maintenance Procedures First Edition • Third Printing

CHECKLIST C PROCEDURES

4 Fill the hub with oil from the top hole until the oil C-4
level is even with the bottom of the side plug
hole. Bleed the Platform Rotator
5 Before serial number 3447: Apply pipe thread
sealant to the plugs. Install the plugs into the
drive hub.
See Repair procedure 2-3, How to Bleed the
After serial number 3446: Install the plugs into Platform Rotator.
the drive hub.
6 Repeat this procedure for each drive hub.

Drive hub oil capacity specification

35:1 Drive Hubs 17 fl oz

0.5 liters

49:1 Drive Hubs 17fl oz

0.5 liters

62.5:1 Drive Hubs 25.6 fl oz

0.76 liters

Type: SAE 90 multipurpose hypoid gear oil -

API service classification GL5

4 - 30 Genie Z-30/20N Part No. 35532

First Edition • Third Printing
Checklist D Procedures
D-1
Test or Replace the Hydraulic
Oil
Replacement or testing of the hydraulic oil is
essential for good machine performance and
service life. Dirty oil and suction strainers may
cause the machine to perform poorly and continued
use may cause component damage. Extremely
dirty conditions may require that the oil be changed
more often.
The machine uses Dexron
equivalent hydraulic oil. Before
replacing the hydraulic oil, the oil
may be tested by an oil distributor
for specific levels of contamination
to verify that changing the oil is
necessary. If the hydraulic oil
is not replaced at the two year
inspection, test the oil quarterly.
Replace the oil when it fails the
test.
When removing a hose assembly
or fitting, the O-ring on the fitting
and/or hose end must be replaced
and then torqued to specification
during installation.
Refer to Section Two, Hydraulic
Hose and Fitting Torque
Specifications.
Perform this procedure with the
boom in the stowed position.
Part No. 35532 Genie Z-30/20N
Section 4 • Scheduled Maintenance Procedures
Before serial number 2008:
1 Remove the reservoir mounting fasteners.
Remove the reservoir from the power unit.
2 Completely drain the reservoir into a suitable
container. See capacity specifications.
3 Remove the suction strainer and the magnet and
then clean the reservoir with mild solvent.
4 Install the suction strainer.
5 Place the magnet inside the reservoir and install
the reservoir onto the power unit.
6 Fill the reservoir with hydraulic oil until the level
is within the top 2 inches / 5 cm of the hydraulic
oil decal. Do not overfill.
7 Clean up any oil that may have spilled.
After serial number 2007:
1 Close the hydraulic shutoff valve located at the
hydraulic tank.
Component damage hazard. The
machine must not be operated with
the hydraulic tank shutoff valve in
the CLOSED position or component
damage will occur. If the tank
valve is closed, remove the key
from the key switch and tag the
machine to inform personnel of the
condition.
2 Place a suitable container under the hydraulic
tank. See capacity specifications.
4 - 31
Section 4 • Scheduled Maintenance Procedures
CHECKLIST D PROCEDURES
3 Tag and disconnect and plug the hydraulic hose
from the hydraulic tank shutoff valve.
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 Open the valve on the hydraulic tank and drain
the oil into a suitable container.
Bodily injury hazard. Beware of hot
oil. Contact with hot oil may cause
severe burns.
5 Tag, disconnect and plug the hydraulic hoses
from the hydraulic tank filter. Cap the fittings on
the filter.
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.
Bodily injury hazard. Beware of hot
oil. Contact with hot oil may cause
severe burns.
6 Remove the hydraulic tank mounting fasteners.
Remove the hydraulic tank from the machine.
7 Remove the tank lid retaining fasteners and
remove the lid from the tank.
4 - 32 Genie Z-30/20N
First Edition • Third Printing
8 Clean the suction strainer using a mild solvent.
9 Rinse out the inside of the tank with a mild
solvent.
10 Install the lid onto the hydraulic tank.
11 Install the hydraulic tank on the machine. Install
the hydraulic tank mounting fasteners and
torque to 8 ft-lbs / 10.8 Nm.
Component damage hazard. The
hydraulic tank may become
damaged if the tank mounting
fasteners are over tightened.
12 Install the hydraulic hoses.
13 Fill the tank with hydraulic oil until the fluid is
within the FULL and ADD marks on the hydraulic
tank. Do not overfill.
14 Clean up any oil that may have spilled. Properly
discard of used oil.
15 Open the hydraulic tank shutoff valve.
Component damage hazard. Be
sure to open the hydraulic tank
shutoff valve after installing the
hydraulic tank.
Hydraulic oil type Dexron equivalent
Hydraulic oil capacity
Hydraulic tank 4 gallons
15.1 liters
Hydraulic system 6 gallons
(including tank) 22.7 liters
Part No. 35532
First Edition • Third Printing
D-2
Grease the Steer Axle Wheel
Bearings
Maintaining the steer axle wheel bearings is
essential for safe machine operation and service
life. Operating the machine with loose or worn
wheel bearings may cause an unsafe operating
condition and continued use may result in
component damage. Extremely wet or dirty
conditions or regular steam cleaning and pressure
washing of the machine may require that this
procedure be performed more often.
1 Loosen the wheel lug nuts. Do not remove them.
2 Block the non-steer wheels.
3 Center a lifting jack under the steer axle and
raise the machine 6 inches / 15 cm. Place
blocks under the drive chassis for support.
4 Remove the lug nuts. Remove the tire and wheel
assembly.
5 Check for wheel bearing wear by attempting to
move the wheel hub side to side, then up and
down.
Result: There should be no side to side or up
and down movement.
Skip to step 9 if there is no movement.
6 Remove the dust cap from the hub, then remove
the cotter pin from the castle nut.
Always use a new cotter pin when
installing a castle nut.
Part No. 35532 Genie Z-30/20N
Section 4 • Scheduled Maintenance Procedures
CHECKLIST D PROCEDURES
7 Tighten the castle nut to 35 ft-lbs / 47 Nm.
8 Check for wheel bearing wear by attempting to
move the wheel hub side to side, then up and
down.
Result: If there is side to side or up and down
movement, proceed to step 9 to replace the old
wheel bearings with new ones.
When replacing a wheel bearing,
both the inner and outer bearings,
including the pressed-in races,
must be replaced.
Result: If there is no side to side or up and down
movement, proceed to step 10 to grease the
wheel bearings.
9 Remove the dust cap from the hub, then remove
the cotter pin from the castle nut.
Always use a new cotter pin when
installing a castle nut.
10 Remove the castle nut.
11 Pull the hub off of the spindle. The washer and
outer bearing should fall loose from the hub.
12 Place the hub on a flat surface and gently pry
the grease seal out of the hub. Remove the
inner bearing.
13 Pack both bearings with clean, fresh grease.
14 Place the large inner bearing into the rear of the
hub.
15 Install a new bearing grease seal into the hub by
pressing it evenly into the hub until it is flush.
Always replace the bearing grease
seal when removing the hub.
Wheel hub grease seal
Genie part number 45110
4 - 33
Section 4 • Scheduled Maintenance Procedures First Edition • Third Printing

CHECKLIST D PROCEDURES

16 Slide the hub onto the spindle.

Component damage hazard. Do
not apply excessive force or
damage to the lip of the seal may
occur.
17 Place the outer bearing into the hub.
18 Install the washer and castle nut.
19 Tighten the castle nut to 35 ft-lbs / 47 Nm to
seat the bearings.
20 Loosen the castle nut, then tighten to
8 ft-lbs / 11 Nm.
21 Install a new cotter pin. Bend the cotter pin to
lock it in place.
Always replace the cotter pin with
a new one when removing the
castle nut or when checking the
torque of the castle nut.
22 Install the dust cap.
23 Install the tire and wheel assembly.
24 Lower the machine and remove the blocks.
25 Torque the wheel lug nuts to 125 ft-lbs /
169.5 Nm.
26 Repeat steps 9 through 22 for the other wheel
hub.

Tires and wheels

Lug nut torque, dry 125 ft-lbs

169.5 Nm

Lug nut torque, lubricated 94 ft-lbs

127.4 Nm

4 - 34 Genie Z-30/20N Part No. 35532

First Edition • Third Printing
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-30/20N Operator’s Manual
Be sure that all necessary tools and parts are
available and ready for use.
Read each procedure completely and adhere
to the instructions. Attempting shortcuts may
produce hazardous conditions.
Unless otherwise specified, perform each
repair procedure with the machine in the
following configuration:
· Machine parked on a firm, level surface
· Boom in stowed position
· Turntable rotated with the boom between
the non-steer wheels
· Key switch in the OFF position with the
key removed
· Wheels chocked
Part No. 35532 Genie Z-30/20N
Section 5 • Repair Procedures
Repair Procedures
About This Section
Most of the procedures in this section should only
be performed by a trained service professional
in a suitably equipped workshop. Select the
appropriate repair procedure after troubleshooting
the problem.
Perform disassembly procedures to the point where
repairs can be completed. Then to
reassemble, perform the disassembly steps in
reverse order.
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.
Red—used to indicate the
presence of an imminently
hazardous situation which, if not
avoided, will result in death or
serious injury.
Orange—used to indicate the
presence of a potentially
hazardous situation which, if not
avoided, could result in death or
serious injury.
Yellow with safety alert symbol—
used to indicate the presence of a
potentially hazardous situation
which, if not avoided, may cause
minor or moderate injury.
Yellow without safety alert
symbol—used to indicate the
presence of a potentially
hazardous situation which, if not
avoided, may result in property
damage.
Green—used to indicate operation
or maintenance information.
Indicates that a specific result is expected after
performing a series of steps.
5-1
Section 5 • Repair Procedures
Platform Controls
1-1
Controllers
The drive joystick is connected to the drive motor
controller, located under the drive chassis cover at
the non-steer end of the machine. Maintaining the
drive joystick and boom function speed controller at
the proper settings is essential to safe machine
operation. The drive joystick and boom function
speed controller should operate smoothly and
provide proportional speed control through its entire
range of motion. For further information or
assistance, contact the Genie Industries Service
Department.
The drive joystick is not adjustable
after serial number 3446.
a
b
d c
a boom function speed controller
b drive printed circuit board (before
serial number 747)
c drive joystick
d brake printed circuit board (before
serial number 747)
5-2 Genie Z-30/20N
First Edition • Third Printing
Drive Joystick Adjustments
(before serial number 747)
Electrocution hazard. Contact with
electrically charged circuits could
result in death or serious injury.
Remove all rings, watches and
other jewelry.
Do not adjust the drive joystick
and boom function speed controller
unless the static battery supply
voltage is above 24V DC.
This procedure will require the use
of two multi-meters. One will be
used for measuring amperage and
the other for DC voltage.
Individual trim potentiometers
(trimpots) are used to adjust
various output signals from the
drive joystick and boom function
speed controller. The trimpots will
be identified as the following:
• Max out trim potentiometer (max out trimpot)
• High range trim potentiometer (max out trimpot)
• Lo range trim potentiometer (lo range trimpot)
• Dual range trim potentiometer (lo range trimpot)
• Threshold trim potentiometer (threshold trimpot)
• Ramp rate trim potentiometer (ramp rate trimpot)
1 Block the steer wheels.
2 Center a lifting jack of ample capacity
(15000 lbs / 6804 kg) under the drive chassis
between the non-steer wheels.
Part No. 35532
First Edition • Third Printing Section 5 • Repair Procedures

PLATFORM CONTROLS

3 Lift the wheels off the ground 7 Locate the drive printed circuit board.
1 to 2 inches / 2.5 to 5 cm and place blocks
under the chassis for support. a

4 Open the platform control box lid and locate the b

brake printed circuit board. c

a e

b f

c g

d h

e i

f
Brake Drive

g
h b
Brake Drive
a not used
b not used
c terminal "X",
d terminal "-", ground
e terminal "+",
f terminal "A", proportional output
g threshold adjustable trimpot
h max-out adjustable trimpot
5 Disconnect the white/red wire from the "A"
terminal on the brake printed circuit board.
6 Connect the negative lead from a multi-meter
set to measure amperage to the white/red wire
that was removed from the brake circuit board.
Connect the positive lead of the multi-meter to
the "A" terminal on the brake printed circuit
board.
a high range adjustable trimpot
threshold adjustable trimpot
c terminal "A", proportional output
d not used
e terminal "-", ground
f terminal (blank)
g not used
h terminal "R", activates max-out
range
i dual (lo) range adjustable trimpot
8 Connect the positive lead from a multi-meter set
to measure DC voltage to the "A" terminal on
the drive joystick printed circuit board. Connect
the negative lead of the multi-meter to ground.
9 Turn the key switch to platform controls and pull
out the red Emergency Stop button out to the ON
position at both the ground and platform
controls.

Part No. 35532 Genie Z-30/20N 5-3

Section 5 • Repair Procedures
PLATFORM CONTROLS
10 Set the threshold on the brake circuit board:
Press down the foot switch and slowly move the
drive joystick off center until you hear the pump
motor turn ON. Adjust the amperage to 0.16A.
Turn the threshold trimpot adjustment screw
clockwise to increase the amperage or
counterclockwise to decrease the amperage.
11 Set the max out on the brake circuit board:
Press down the foot switch and slowly move the
drive joystick off center until you hear the pump
motor turn OFF. Adjust the amperage to 0.91A.
Turn the max out trimpot adjustment screw
clockwise to increase the amperage or
counterclockwise to decrease the amperage.
12 Set the threshold on the drive circuit board:
Press down the foot switch and slowly move the
drive joystick off center until you see 0.28A to
0.3A on the multi-meter. Adjust the threshold
trimpot on the drive circuit board to 0.8V DC to
0.9V DC. Turn the threshold trimpot adjustment
screw clockwise to increase the voltage or
counterclockwise to decrease the voltage.
13 Set the max out on the drive circuit board: Press
down the foot switch and slowly move the drive
joystick all the way to the FORWARD position.
Adjust the max out trimpot on the drive circuit
board to 5V DC to 5.2V DC. Turn the max out
trimpot adjustment screw clockwise to increase
the voltage or counterclockwise to decrease the
voltage.
14 Raise the primary boom approximately
2 feet / 0.6 m.
5-4 Genie Z-30/20N
First Edition • Third Printing
15 Set the lo range on the drive circuit board: Press
down the foot switch and move the drive
joystick all the way to the FORWARD position.
Adjust the lo range trimpot on the drive circuit
board to 2.4V DC to 2.7V DC. Turn the lo range
trimpot adjustment screw clockwise to increase
the voltage or counterclockwise to decrease the
voltage.
16 Lower the boom to the stowed position and
remove the blocks from under the chassis.
17 Raise the primary boom approximately
2 feet / 0.6 m.
18 Create start and finish lines by marking two lines
on the ground 40 feet / 12.2 m apart. Choose a
reference point on the machine as a visual
reference for use when crossing the start and
finish lines.
19 Bring the machine to top drive speed before
reaching the start line. Begin timing when your
reference point on the machine crosses the
start line.
20 Continue at full speed and note the time when
your reference point on the machine crosses the
finish line.
21 Adjust the lo range trimpot on the drive circuit
board to achieve a 44 second drive speed time.
Turn the lo range trimpot clockwise to decrease
the time or counterclockwise to increase the
time.
22 Lower the primary boom to the stowed position.
23 Bring the machine to top drive speed before
reaching the start line. Begin timing when your
reference point on the machine crosses the
start line.
Part No. 35532
First Edition • Third Printing Section 5 • Repair Procedures

PLATFORM CONTROLS

24 Continue at full speed and note the time when Drive Joystick Adjustments
your reference point on the machine crosses the
finish line. (from serial number 747 to 3446)
25 Adjust high range trimpot on the drive circuit Electrocution hazard. Contact with
board to achieve the specified drive speed time electrically charged circuits could
(refer to table below). Turn the high range result in death or serious injury.
trimpot clockwise to decrease the time or Remove all rings, watches and
counterclockwise to increase the time. other jewelry.
Do not adjust the drive joystick
Drive controller specifications
and boom function speed controller
Brake board unless the static battery supply
Threshold 0.16A when pump motor turns ON voltage is above 24V DC.
Max-out 0.91A when pump motor turns OFF This procedure will require the use
of two multi-meters. One will be
Drive board used for measuring amperage and
Threshold 0.8V DC to 0.9V DC the other for DC voltage.
when amperage output is 0.28A to 0.3A
1 Block the steer wheels.
Max-out 5V DC to 5.2V DC
when drive joystick is in full forward position 2 Center a lifting jack of ample capacity
(15000 lbs / 6804 kg) under the drive chassis
Lo range 2.4V DC to 2.7V DC
between the non-steer wheels.
when drive joystick is in full forward position
3 Lift the wheels off the ground
Drive speed, maximum
1 to 2 inches / 2.5 to 5 cm and place blocks
Stowed position (before serial number 3447) under the chassis for support.
35:1 drive hubs 3.1 mph
5 km/h
40ft / 8.8 sec
12.2 m / 8.8 sec

Stowed position (before serial number 3447)

49:1 drive hubs 2.8 mph
4.5 km/h
40 ft / 9.7 sec
12.2 m / 9.7 sec

Boom raised or extended 0.6 mph

1 km/h
40 ft / 44 sec
12.2 m / 44 sec

Part No. 35532 Genie Z-30/20N 5-5

Section 5 • Repair Procedures First Edition • Third Printing

PLATFORM CONTROLS

4 Open the platform control box lid and locate the 5 Disconnect the white/red wire from the "B"
printed circuit board on the drive joystick. terminal on the printed circuit board.
a

f
a g

b i

k
c

a terminal "R", activates max out range

a boom function speed controller b terminal "D", drive output
b drive and brake printed circuit board c terminal "X"
c drive joystick d terminal "-", ground
e terminal "+", positive
f terminal "B", brake output
g drive lo range trimpot
h drive threshold trimpot
i drive hi range trimpot
j brake threshold trimpot
k brake max-out trimpot

6 Connect the negative lead from a multi-meter

set to measure amperage to the white/red wire
that was removed from the circuit board.
Connect the positive lead of the mult-meter to
the "B" terminal on the printed circuit board.
7 Connect the positive lead from a multi-meter set
to read DC voltage to the "D" terminal on the
drive controller printed circuit board. Connect
the negative lead to ground.

5-6 Genie Z-30/20N Part No. 35532

First Edition • Third Printing
8 Turn the key switch to platform control and pull
out the red Emergency Stop button to the ON
position at both the ground and platform
controls.
9 Set the brake threshold on the circuit board:
Press down the foot switch and slowly move the
drive joystick off center until you hear the pump
motor turn ON. Adjust the amperage to 0.16A.
Turn the threshold trimpot adjustment screw
clockwise to increase the amperage or
counterclockwise to decrease the amperage.
10 Set the brake max out on the circuit board:
Press down the foot switch and slowly move the
drive joystick off center until you hear the pump
motor turn OFF. Adjust the amperage to 0.91A.
Turn the max out trimpot adjustment screw
clockwise to increase the amperage or
counterclockwise to decrease the amperage.
11 Set the drive threshold on the circuit board:
Press down the foot switch and slowly move the
drive joystick off center until you see 0.28A to
0.3A on the multi-meter. Hold the drive joystick
in this position and adjust the drive threshold
trimpot on the circuit board to 0.8V DC to
0.9V DC. Turn the threshold trimpot adjustment
screw clockwise to increase the voltage or
counterclockwise to decrease the voltage.
12 Set the drive max out on the circuit board: Press
down the foot switch and slowly move the drive
joystick all the way to the FORWARD position.
Adjust the max out trimpot on the circuit board
to 5V DC to 5.2V DC. Turn the max out trimpot
adjustment screw clockwise to increase the
voltage or counterclockwise to decrease the
voltage.
Part No. 35532 Genie Z-30/20N
Section 5 • Repair Procedures
PLATFORM CONTROLS
13 Raise the primary boom approximately
2 feet / 0.6 m to activate the drive limit switch.
14 Set the drive lo range on the circuit board: Press
down the foot switch and move the drive
joystick all the way in the direction indicated by
the blue arrow on the platform control panel and
on the chassis. Adjust the drive lo range trimpot
on the circuit board to 2.4V DC to 2.7V DC.
Turn the lo range trimpot adjustment screw
clockwise to increase the voltage or
counterclockwise to decrease the voltage.
15 Lower the boom to the stowed position and
remove the blocks from under the chassis.
16 Raise the primary boom off the drive limit
switch.
17 Create start and finish lines by marking two lines
on the ground 40 feet / 12.2 m apart. Choose a
reference point on the machine as a visual
reference for use when crossing the start and
finish lines.
18 Bring the machine to top drive speed before
reaching the start line. Begin timing when your
reference point on the machine crosses the
start line.
19 Continue at full speed and note the time when
your reference point on the machine crosses the
finish line.
20 Adjust the drive lo range trimpot on the circuit
board to achieve a 44 second drive speed time.
Turn the lo range trimpot clockwise to decrease
the time or counterclockwise to increase the
time.
5-7
Section 5 • Repair Procedures First Edition • Third Printing

PLATFORM CONTROLS

21 Lower the primary boom to the stowed position.
22 Bring the machine to top drive speed before
reaching the start line. Begin timing when your
reference point on the machine crosses the
start line.
23 Continue at full speed and note the time when
your reference point on the machine crosses the
finish line.
24 Adjust drive max out trimpot on the circuit board
to achieve a 10 second drive speed time. Turn
the max out trimpot clockwise to decrease the
time or counterclockwise to increase the time.
Refer to the chart below.
Drive joystick specifications
Brake
Threshold 0.16A when pump motor turns ON
Boom Function Speed
Controller Adjustments
(before serial number 3750)
Electrocution hazard. Contact with
electrically charged circuits could
result in death or serious injury.
Remove all rings, watches and
other jewelry.
Do not adjust the boom function
speed controller unless the static
battery supply voltage is above
24V DC.
1 Turn the key switch to platform controls and pull
out the red Emergency Stop button to the ON
position at both the ground and platform
controls.

Max out 0.91A when pump motor turns OFF 2 Open the platform control box lid and locate the
boom function speed controller.
Drive
Threshold 0.8V DC to 0.9V DC a
f
when amperage output is 0.28A to 0.3A
e b
Max out 5V DC to 5.2V DC
when drive joystick is in full forward position c

Lo range 2.4 to 2.7V DC

when drive joystick is in full forward position
d
Drive speed, maximum

Stowed position (before serial number 3447)

35:1 drive hubs 3.1 mph a black wire
5 km/h b diode
c white/red wire
40ft / 8.8 sec
d boom function speed controller
12.2 m / 8.8 sec e threshold trimpot
f max out trimpot
Stowed position (before serial number 3447)
49:1 drive hubs 2.8 mph
4.5 km/h
40 ft / 9.7 sec
12.2 m / 9.7 sec

Boom raised or extended 0.6 mph

1 km/h
40 ft / 44 sec
12.2 m / 44 sec

5-8 Genie Z-30/20N Part No. 35532

First Edition • Third Printing Section 5 • Repair Procedures

PLATFORM CONTROLS

3 Locate the diode between the black wire from
the boom function speed controller and the
white/red wire. Disconnect the white/red wire
from the diode on the black wire.
4 Connect the negative lead from a multi-meter
set to measure amperage to the wire connector
of the white/red wire. Connect the positive lead
of the multi-meter to the diode on the black wire.
5 Turn the boom function speed controller to the
CREEP position.
6 Set the threshold: Press down the foot switch
and move the primary boom toggle switch to the
DOWN position. Adjust the amperage to 0 to
0.12A. Turn the threshold trimpot adjustment
screw clockwise to increase the amperage or
counterclockwise to decrease the amperage.
7 Turn the boom function speed controller to
the 9 position.
8 Set the max out: Press down the foot switch
and move the primary boom toggle switch to the
DOWN position. Adjust the amperage to 0.72A to
0.75A. Turn the max out trimpot adjustment
screw clockwise to increase the amperage or
counterclockwise to decrease the amperage.
Boom Function Speed
Controller Adjustments
(after serial number 3749)
Electrocution hazard. Contact with
electrically charged circuits could
result in death or serious injury.
Remove all rings, watches and
other jewelry.
Do not adjust the boom function
speed controller unless the static
battery supply voltage is above
24V DC.
1 Turn the key switch to platform controls and pull
out the red Emergency Stop button to the ON
position at both the ground and platform
controls.
2 Open the platform control box lid and locate the
boom function speed controller.
g a
b
f
c

Boom function speed

controller specifications d
Threshold 0 to 0.12A e
(controller turned to "CREEP")
a black wire
Max out 0.72A to 0.75A b diode
(controller turned to "9") c white/red wire
d boom function speed controller
e ramp rate trimpot
f threshold trimpot
g max out trimpot

Part No. 35532 Genie Z-30/20N 5-9

Section 5 • Repair Procedures First Edition • Third Printing

PLATFORM CONTROLS

3 Locate the diode between the black wire from 10 Set the ramp rate: Turn the ramp rate trimpot to
the boom function speed controller and the obtain a 2 second delay from 0 to 0.65A. Turn
white/red wire. Disconnect the white/red wire the trimpot clockwise to increase the time or
from the diode on the black wire. counterclockwise to decrease the time.
4 Connect the negative lead from a multi-meter 11 Disconnect the leads from the multi-meter and
set to measure amperage to the wire connector connect the white/red wire to the diode on the
of the white/red wire. Connect the positive lead black wire.
of the multi-meter to the diode on the black wire.
Boom function speed
5 Turn the boom function speed controller to the controller specifications
CREEP position.
Threshold 0.28A
6 Set the threshold: Press down the foot switch (controller turned to "CREEP")
and move the primary boom toggle switch to the
up position. Adjust the amperage to 0.28A. Turn Max out 0.65A
the threshold trimpot adjustment screw (controller turned to "9")
clockwise to increase the amperage or Ramp rate 2 seconds
counterclockwise to decrease the amperage.
7 Turn the boom function speed controller to
the 9 position.
8 Set the max out: Press down the foot switch
and move the primary boom toggle switch to the
1-2
DOWN position. Adjust the amperage to 0.65A. Diodes
Turn the max out trimpot adjustment screw
clockwise to increase the amperage or How to Test a Diode
counterclockwise to decrease the amperage.
1 Connect the leads from an ohmmeter to each
9 Start a timer and simultaneously press down the
end of the diode. Note the ohms.
foot switch and move the primary boom toggle
switch in the DOWN direction. Note how long it 2 Reverse the leads from the ohmmeter. The
takes to reach 0.65A. resistance of the diode should be high in one
direction and low in the other direction.

5 - 10 Genie Z-30/20N Part No. 35532

First Edition • Third Printing Section 5 • Repair Procedures

PLATFORM CONTROLS

1-3 Test Desired result

Foot Switch red to black continuity
(zero W)
How to Test the Foot Switch red to white no continuity
1 Before serial number 4083: Turn the key (infinite W)
switch to the OFF position and separate the foot black to white no continuity
switch wiring quick disconnect plug from the (infinite W)
platform toeboard.
After serial number 4082: Remove the
Before serial number 4083: Do
platform control box lid retaining fasteners.
not use the color of the connector
Open the platform control box and locate the
as a guide for these tests. Use the
foot switch wiring.
actual wire color to identify which
2 Do not press down the foot switch. Connect the connector to use for testing.
leads from an ohmmeter or continuity tester to
3 Press down the foot switch. Connect the leads
each wire combination listed below and check
from an ohmmeter or continuity tester to each
for continuity.
wire combination listed below and check for
continuity.

Test Desired result

red to black no continuity

(infinite W)
N.O. N.C. C N.O. N.C. C
red to white no continuity
(infinite W)
red
black black
white white
brown
black to white continuity
(zero W)
ground

Before serial number 4083 After serial number 4082

Part No. 35532 Genie Z-30/20N 5 - 11

Section 5 • Repair Procedures First Edition • Third Printing

PLATFORM CONTROLS

1-4 Test Desired result

Toggle Switches Left position

Toggle switches used for single function switching terminal 1 to 2, 3, 4, 5 and 6 no continuity
are single pole double throw (SPDT) toggle (infinite W)
switches. Dual function switching requires a double terminal 2 to 3 continuity
pole double throw (DPDT) toggle switch. (zero W)

How to Test a Toggle Switch terminal 2 to 4, 5 and 6 no continuity

(infinite W)
Continuity is the equivalent of 0 to
3 ohms. A simple continuity tester terminal 3 to 4, 5 and 6 no continuity
may not accurately test the toggle (infinite W)
switch. terminal 4 to 5 and 6 no continuity
(infinite W)
This procedure covers fundamental
toggle switch testing and does not terminal 5 to 6 continuity
specifically apply to all varieties of (zero W)
toggle switches.
Center position There are no terminal
1 Turn the key switch to the OFF position. Tag combinations that will
and disconnect all wiring from the toggle switch produce continuity
to be tested. (infinite W)

2 Connect the leads of an ohmmeter to the switch Right position

terminals in the following combinations listed to
terminal 1 to 2 continuity
check for continuity. (zero W)

Left Center Right terminal 1 to 3, 4, 5 and 6 no continuity

(infinite W)

terminal 2 to 3, 4, 5 and 6 no continuity

(infinite W)

terminal 3 to 4, 5 and 6 no continuity

(infinite W)

terminal 4 to 5 continuity
(zero W)
1 3 1 3 1 3
Single pole 2 2 2 terminal 4 to 6 no continuity
double throw
(infinite W)
(SPDT)
1 2 3 1 2 3 1 2 3 terminal 5 to 6 no continuity
Double pole
4 5 6 4 5 6 4 5 6 (infinite W)
double throw
(DPDT)

1 2 3 1 2 3 1 2 3

5 - 12 Genie Z-30/20N Part No. 35532

First Edition • Third Printing
Platform Components
2-1
Platform
How to Remove the Platform
(before serial number 4416)
1 Separate the foot switch wiring quick disconnect
plug from the platform toeboard.
2 Remove the platform control box mounting
fasteners and lower the control box.
If your machine is equipped with
an air line to platform option, the
air line must be disconnected
before removal of the platform.
3 Place blocks under the platform for support and
carefully rest the platform on the blocks.
4 Remove the platform mounting fasteners and
remove the platform.
Component damage hazard.
Platform can be damaged if the
mounting fasteners are
overtightened.
Part No. 35532 Genie Z-30/20N
Section 5 • Repair Procedures
How to Remove the Platform
(after serial number 4415)
1 Remove the fasteners from the power to
platform cover.
2 Remove the power to platform box from the
platform. Do not disconnect the wiring.
Electrocution hazard. Contact with
electrically charged circuits could
result in death or serious injury.
Remove all rings, watches and
other jewelry.
3 Remove the platform control box lid retaining
fasteners. Open the control box lid.
4 Tag and disconnect the black foot switch wire
from the red Emergency Stop button that
originates at the foot switch.
Electrocution hazard. Contact with
electrically charged circuits could
result in death or serious injury.
Remove all rings, watches and
other jewelry.
5 Tag and disconnect the white foot switch wire
from terminal #6 on the drive joystick.
6 Loosen the squeeze connector for the foot
switch wiring and pull the wiring out through the
bottom of the squeeze connector.
7 Remove the platform control box mounting
fasteners and lower the control box.
If your machine is equipped with
an air line to platform option, the
air line must be disconnected
before removal of the platform.
8 Remove the platform mounting fasteners and
carefully remove the platform.
Component damage hazard.
Platform can be damaged if the
mounting fasteners are
overtightened.
5 - 13
Section 5 • Repair Procedures
PLATFORM COMPONENTS
2-2
Platform Leveling Slave
Cylinder
The slave cylinder and the rotator pivot are the
two primary supports for the platform. The slave
cylinder keeps the platform level through the
entire range of primary boom motion. It operates in
a closed loop hydraulic circuit with the master
cylinder. The slave cylinder is equipped with
counterbalance valves to prevent platform
movement in the event of a hydraulic line failure.
How to Remove the Slave
Cylinder
Before cylinder removal is
considered, bleed the slave
cylinder to be sure there is no
air in the closed loop hydraulic
circuit.
When removing a hose assembly
or fitting, the O-ring on the fitting
and/or hose end must be replaced
and then torqued to specification
during installation.
Refer to Section Two, Hydraulic
Hose and Fitting Torque
Specifications.
1 Extend the boom until the slave cylinder
barrel-end pivot pin is accessible.
2 Raise the boom slightly and place blocks under
the platform for support. Lower the boom until
the platform is resting on the blocks.
5 - 14 Genie Z-30/20N
First Edition • Third Printing
3 Remove the pin retaining fastener from
the rod-end pivot pin. Do not remove the pin.
4 Remove the external snap ring from the barrel-
end pivot pin.
5 Place a block of wood under the barrel of the
slave cylinder.
6 Use a soft metal drift to remove the rod-end
pivot pin.
7 Use a soft metal drift to drive out the barrel-end
pivot pin.
8 Carefully pull the cylinder out of the boom.
Crushing hazard. The slave
cylinder will fall if not properly
supported.
9 Tag and disconnect the hydraulic hoses from
the slave cylinder and connect them together
with a connector. 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.
How to Bleed the Slave Cylinder
1 Raise the jib boom to a horizontal position.
2 Move the platform level toggle switch up and
down through two platform leveling cycles to
remove any air that might be in the system.
Part No. 35532
First Edition • Third Printing
2-3
Platform Rotator
The platform rotator is a hydraulically activated
helical gear assembly used to rotate the platform
180 degrees.
How to Remove the
Platform Rotator
When removing a hose assembly
or fitting, the O-ring on the fitting
and/or hose end must be replaced
and then torqued to specification
during installation.
Refer to Section Two, Hydraulic
Hose and Fitting Torque
Specifications.
1 Remove the platform. See 2-1,
How to Remove the Platform.
2 Tag, disconnect and plug the hydraulic hoses
from the platform rotate manifold.
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.
3 Support the platform mounting weldment. Do not
apply any lifting pressure.
4 Remove the six mounting bolts from the
platform mounting weldment. Remove the
center bolt and slide the platform mounting
weldment off of the platform rotator.
5 Support the platform rotator with a suitable lifting
device. Do not apply any lifting pressure.
Part No. 35532 Genie Z-30/20N
Section 5 • Repair Procedures
PLATFORM COMPONENTS
6 Remove the pin retaining fasteners from the jib
boom and leveling links to platform rotator pivot
pins. Do not remove the pins.
7 Support the jib boom, jib boom cylinder and
leveling links with an overhead crane.
8 Use a soft metal drift to drive both pins out, then
remove the platform rotator from the machine.
Crushing hazard. The platform
rotator will fall when the pins are
removed if not properly supported.
How to Bleed the Platform
Rotator
This procedure will require two
people.
1 Turn the key switch to ground controls and pull
out the red Emergency Stop buttons to the ON
position at both the ground and platform
controls.
2 Before serial number 747: Move the primary
boom toggle switch in the up direction until the
platform is approximately 6 feet / 1.8 m off the
ground.
After serial number 746: Hold the function
enable toggle switch to either side and move the
primary boom toggle switch in the up direction
until the platform is approximately
6 feet / 1.8 m off the ground.
3 Connect a clear hose to the top bleed valve.
Place the other end of the hose in a container to
collect any discharge. Open the top bleed valve,
but do not remove it.
5 - 15
Section 5 • Repair Procedures
PLATFORM COMPONENTS
4 Before serial number 747: Move and hold the
platform rotate toggle switch to the right for
approximately 5 seconds, then release it.
Repeat three times.
After serial number 746: Move and hold the
function enable toggle switch to either side and
move and hold the platform rotate toggle switch
to the right for approximately 5 seconds, then
release it. Repeat three times.
Crushing hazard. Keep hands and
head clear of the platform pivot
weldment during rotation.
a
b weldment during rotation.
c 7 Rotate the platform to the right until the platform
d
a clear hose
b top bleed valve
c bottom bleed valve
d container
5 - 16 Genie Z-30/20N
First Edition • Third Printing
5 Before serial number 747: Move and hold the
platform rotate toggle switch to the left for
approximately 5 seconds, then release it.
Repeat three times.
After serial number 746: Move and hold the
function enable switch to either side and move
and hold the platform rotate toggle switch to the
left for approximately 5 seconds, then release it.
Repeat three times.
6 Fully rotate the platform to the left and continue
holding the platform rotate toggle switch until air
stops coming out of the bleed valve.
Immediately release the platform rotate toggle
switch and close the bleed valve.
Crushing hazard. Keep hands and
head clear of the platform pivot
is centered.
8 Connect the clear hose to the bottom bleed
valve and open the valve.
9 Rotate the platform to the right and continue
holding the platform rotate toggle switch until air
stops coming out of the bleed valve.
Crushing hazard. Keep hands and
head clear of the platform pivot
weldment during rotation.
10 Close the bleed valve and remove the hose.
11 Rotate the platform full left and right and inspect
the bleed valves for leaks.
12 Turn the key switch to the OFF position and clean
up any hydraulic oil that may have spilled.
Part No. 35532
First Edition • Third Printing
Jib Boom Components
3-1
Jib Boom
How to Remove the Jib Boom
Perform this procedure with the
boom in the stowed position.
When removing a hose assembly
or fitting, the O-ring on the fitting
and/or hose end must be replaced
and then torqued to specification
during installation.
Refer to Section Two, Hydraulic
Hose and Fitting Torque
Specifications.
1 Remove the platform. See 2-1,
How to Remove the Platform.
2 Remove the platform mounting weldment
and the platform rotator. See 2-3, How to
Remove the Platform Rotator.
3 Tag, disconnect and plug the jib boom lift
cylinder hydraulic hoses. Cap the fittings on the
jib boom lift 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.
4 Remove the cable cover from the side of the
jib boom.
Part No. 35532 Genie Z-30/20N
Section 5 • Repair Procedures
5 Remove the mounting fasteners from the jib
boom/platform rotate manifold. Do not remove
the hoses.
Component damage hazard. Hoses
and cables can be damaged if
they are twisted or kinked.
6 Attach a lifting strap from an overhead crane to
the jib boom.
7 Models without rotating jib boom: Remove
the pin retaining fastener from the jib boom pivot
pin at the jib boom bellcrank. Use a soft metal
drift to remove the pin, then remove the jib
boom from the jib boom bellcrank.
Crushing hazard. The jib boom will
fall when the pin is removed
if not properly supported by the
overhead crane.
Models with rotating jib boom: Remove the
pin retaining fastener from the jib boom pivot pin
at the jib boom rotator. Use a soft metal drift to
remove the pin, then remove the jib boom from
the jib boom rotator.
Crushing hazard. The jib boom will
fall when the pin is removed
if not properly supported by the
overhead crane.
8 Remove the pin retaining fasteners from the jib
boom lift cylinder rod-end pivot pin. Do not
remove the pin.
5 - 17
Section 5 • Repair Procedures
JIB BOOM COMPONENTS
9 Models without rotating jib boom: Remove
both of the jib boom leveling links from the bell
crank.
Models with rotating jib boom: Remove both
of the jib boom leveling links from the jib boom
rotator.
10 Attach a lifting strap from an overhead crane to
the rod-end of the jib boom lift cylinder.
11 Models without rotating jib boom: Use a soft
metal drift to remove the jib boom lift cylinder
rod-end pivot pin. Remove the jib boom lift
cylinder from the bell crank.
Models with rotating jib boom: Use a soft
metal drift to remove the jib boom lift cylinder
rod-end pivot pin. Remove the jib boom lift
cylinder from the jib boom rotator.
Crushing hazard. The jib boom
lift cylinder will fall when the pin
is removed if not properly
supported by the overhead crane.
5 - 18 Genie Z-30/20N
First Edition • Third Printing
3-2
Jib Boom Bell Crank
(models without rotating
jib boom)
How to Remove the Jib Boom
Bell Crank
Perform this procedure with the
boom in the stowed position.
When removing a hose assembly
or fitting, the O-ring on the fitting
and/or hose end must be replaced
and then torqued to specification
during installation.
Refer to Section Two, Hydraulic
Hose and Fitting Torque
Specifications.
1 Remove the Jib Boom, See 3-1, How to Remove
the Jib Boom.
2 Support and secure the jib boom bell crank to an
appropriate lifting device.
3 Remove the pin retaining fasteners from the
slave cylinder rod-end pivot pin. Do not remove
the pin.
4 Remove the pin retaining fasteners from the jib
boom bell crank at the extension boom. Use a
soft metal drift to remove the pin.
5 Use a soft metal drift to remove the slave
cylinder rod-end pivot pin.
6 Remove the jib boom bell crank from the
extension boom.
Crushing hazard. The jib boom bell
crank could become unbalanced
and fall when the pins are removed
if not properly supported and
secured to the lifting device.
Part No. 35532
First Edition • Third Printing
3-3
Jib Boom Rotator
(models with rotating jib boom)
How to Remove the Jib Boom
Rotator
Perform this procedure with the
boom in the stowed position.
When removing a hose assembly
or fitting, the O-ring on the fitting
and/or hose end must be replaced
and then torqued to specification
during installation.
Refer to Section Two, Hydraulic
Hose and Fitting Torque
Specifications.
1 Remove the Jib Boom, See 3-1, How to Remove
the Jib Boom.
2 Tag, disconnect and plug the jib boom rotator
hydraulic hoses. Cap the fittings on the rotator.
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.
3 Support and secure the jib boom rotator to an
appropriate lifting device.
4 Remove the eight mounting bolts from the jib
boom rotator mount.
Part No. 35532 Genie Z-30/20N
Section 5 • Repair Procedures
JIB BOOM COMPONENTS
5 Remove the center bolt. Carefully remove the jib
boom rotator from the machine.
Crushing hazard. The jib boom
rotator could become unbalanced
and fall when removed from the
machine if not properly supported
and secured to the lifting device.
How to Bleed the Jib Boom
Rotator
This procedure will require two
people.
1 Turn the key switch to ground controls and pull
out the red Emergency Stop buttons to the ON
position at both the ground and platform
controls.
2 Connect a clear hose to the top bleed valve.
Place the other end of the hose in a container to
collect any discharge. Open the top bleed valve,
but do not remove it.
a
b
c
d
a top bleed valve
b clear hose
c container
d bottom bleed valve
5 - 19
Section 5 • Repair Procedures
JIB BOOM COMPONENTS
3 Move and hold the function enable toggle switch
to either side and move and hold the jib boom
rotate toggle switch to the right for
approximately 5 seconds, then release it.
Repeat three times.
Crushing hazard. Keep hands and
head clear of the platform pivot
weldment during rotation.
4 Move and hold the function enable switch to
either side and move and hold the jib boom
rotate toggle switch to the left for approximately
5 seconds, then release it. Repeat three times.
5 Fully rotate the jib boom to the left and continue
holding the jib boom rotate toggle switch until air
stops coming out of the bleed valve.
Immediately release the platform rotate toggle
switch and close the bleed valve.
Crushing hazard. Keep hands and
head clear of the platform pivot
weldment during rotation.
6 Rotate the jib boom to the right until the jib boom
is centered.
7 Connect the clear hose to the bottom bleed
valve and open the valve.
8 Rotate the jib boom to the right and continue
holding the platform rotate toggle switch until air
stops coming out of the bleed valve.
Crushing hazard. Keep hands and
head clear of the jib boom during
rotation.
5 - 20 Genie Z-30/20N
First Edition • Third Printing
9 Close the bleed valve and remove the hose.
10 Rotate the jib boom full left and right and inspect
the bleed valves for leaks.
Crushing hazard. Keep hands and
head clear of the platform pivot
weldment during rotation.
11 Turn the key switch to the OFF position and clean
up any hydraulic oil that may have spilled.
3-4
Jib Boom Lift Cylinder
How to Remove the Jib Boom
Lift Cylinder
Perform this procedure with the
boom in the stowed position.
When removing a hose assembly
or fitting, the O-ring on the fitting
and/or hose end must be replaced
and then torqued to specification
during installation.
Refer to Section Two, Hydraulic
Hose and Fitting Torque
Specifications.
1 Raise the jib boom slightly and place blocks
under the platform mounting weldment for
support. Lower the jib boom until the platform is
resting on the blocks.
Part No. 35532
First Edition • Third Printing Section 5 • Repair Procedures

JIB BOOM COMPONENTS

2 Tag, disconnect and plug the jib boom lift

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.
3 Remove the pin retaining fasteners from the jib
boom lift cylinder rod-end pivot pin. Do not
remove the pin.
4 Use a soft metal drift to tap the rod-end pivot pin
half way out and lower one of the leveling links
to the ground. Tap the pin the other direction
and lower the opposite leveling link. Do not
remove the pin.
5 Attach a lifting strap from an overhead crane to
the rod end of the jib boom lift cylinder.
6 Remove the pin retaining fasteners from the jib
boom lift cylinder barrel-end pivot pin. Use a
soft metal drift to remove the barrel-end pivot
pin.
7 Use a soft metal drift to remove the jib boom lift
cylinder rod-end pivot pin. Remove the jib boom
lift cylinder from the machine.
Crushing hazard. The jib boom lift
cylinder could fall when the pins
are removed if not properly
supported by the overhead crane.

Part No. 35532 Genie Z-30/20N 5 - 21

Section 5 • Repair Procedures First Edition • Third Printing

Primary Boom Components

4-1
Plastic Cable Track
The primary boom cable track guides the cables
and hoses running up the boom. It can be repaired
link by link without removing the cables and hoses
that run through it. Removing the entire primary
boom cable track is only necessary when
performing major repairs that involve removing the
primary boom.
How to Repair the Plastic Cable
Track
Component damage hazard. The
primary boom cable track can be
damaged if it is twisted.
a
b
4-2
Primary Boom
How to Shim the Primary Boom
Measure each wear pad. Replace
the pad if it is less than
0.41 inch / 1 cm thick. If the pad is
more than 0.41 inch / 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
cycle. Check for tight spots that could cause
scraping or binding.
Always maintain squareness
between the outer and inner boom
tubes.

a link separation point

b lower clip

1 Use a slotted screwdriver to pry down on the

lower clip.
2 Repeat step 1 for each link.
3 To remove a single link, open the lower clip.
Use a screwdriver to pry the link to the side.

5 - 22 Genie Z-30/20N Part No. 35532

First Edition • Third Printing
How to Remove the
Primary Boom
Bodily injury hazard. This
procedure requires specific repair
skills, lifting equipment and a
suitable workshop. Attempting this
procedure without these skills and
tools could result in death or
serious injury and significant
component damage. Dealer
service is strongly recommended.
Perform this procedure with the
boom in the stowed position.
When removing a hose assembly
or fitting, the O-ring on the fitting
and/or hose end must be replaced
and then torqued to specification
during installation.
Refer to Section Two, Hydraulic
Hose and Fitting Torque
Specifications.
1 Remove the platform. See 2-1,
How to Remove the Platform.
2 Remove the platform rotator. See 2-3, How to
Remove the Platform Rotator.
3 Remove the jib boom. See 3-1,
How to Remove the Jib Boom.
4 Models without rotating jib boom: Remove
the jib boom bellcrank. See 3-2, How to Remove
the Jib Boom Bellcrank.
Models with rotating jib boom: Remove the
jib boom rotator. See 3-3, How to Remove the
Jib Boom Rotator.
Part No. 35532 Genie Z-30/20N
Section 5 • Repair Procedures
PRIMARY BOOM COMPONENTS
5 Tag, disconnect and cap the slave cylinder
hydraulic hoses at the union. Plug the hoses
from the slave 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.
6 Remove the upper cable track mounting
fasteners from the platform end of the boom.
7 Remove the cable track mounting fasteners,
then remove the cable track from the boom and
lay it flat on the ground.
Component damage hazard.
Cables and hoses can be damaged
if they are kinked or pinched.
8 Raise the secondary boom until the primary
boom lift cylinder rod-end pivot pin is accessible
above the mid-pivot weldment.
9 Remove all the hose and cable clamps from the
underside of the primary boom and at the pivot
end of the primary boom.
10 Attach a lifting strap of ample capacity from an
overhead 5 ton crane to the primary boom.
11 Locate the cables from the primary boom cable
track to the platform control box. Number each
cable and its entry location at the platform
control box.
12 Open the platform conrol box.
5 - 23
Section 5 • Repair Procedures First Edition • Third Printing

PRIMARY BOOM COMPONENTS

13 Tag and disconnect each wire from the cables in 22 Remove the pin retaining fastener from the
the platform control box. primary boom lift cylinder rod-end pivot pin. Use
a soft metal drift to remove the pin.
Electrocution hazard. Contact with
electrically charged circuits could Crushing hazard. The primary
result in death or serious injury. boom lift cylinder will fall when it is
Remove all rings, watches and removed from the machine if not
other jewelry. properly supported.
14 Pull all the cables out of the platform control 23 Lower the rod end of the primary boom lift
box. cylinder onto support blocks. Protect the
cylinder rod from damage.
15 Remove the front counterweight cover.
24 Remove the pin retaining fastener from the
16 Remove the extension boom drive limit switch
primary boom pivot pin.
from the side of the primary boom at the pivot
end. Do not disconnect the wiring. 25 Remove the primary boom pivot pin with a soft
metal drift. Carefully remove the primary boom
17 Pull all the electrical cables and hydraulic hoses
assembly from the machine.
out of the plastic cable track.
Crushing hazard. The primary
18 Remove the pin retaining fastener from the
boom assembly could become
master cylinder rod-end pivot pin. Use a soft
unbalanced and fall when it is
metal drift to remove the pivot pin. Pull the
removed from the machine if not
cylinder back and secure it from moving.
properly supported by the overhead
19 Tag, disconnect and plug the extension cylinder crane.
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.
20 Attach a lifting strap from an overhead crane to
the primary boom lift cylinder.
21 Place 2 x 4 x 18 inch / 5 x 10 x 46 cm support
blocks under the cylinder, across the secondary
boom.

5 - 24 Genie Z-30/20N Part No. 35532

First Edition • Third Printing
How to Disassemble
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 4-4, How to Remove
the Extension Cylinder.
1 Remove the boom. See 4-2,
How to Remove the Primary Boom.
2 Place blocks under the extension cylinder for
support.
3 Remove the retaining fasteners from the
extension cylinder barrel-end pivot pin. Use a
soft metal drift to remove the pin.
4 Remove and label the location of the wear pads
from the top side of the boom tube at the
platform end of the boom.
Pay careful attention to the
location and amount of shims used
with each wear pad.
5 Support the extension tube with an overhead
crane at the platform end of the boom.
Crushing hazard. The boom
extension tube will fall when they
are removed from the boom if they
are not properly supported.
Part No. 35532 Genie Z-30/20N
Section 5 • Repair Procedures
PRIMARY BOOM COMPONENTS
6 Support and slide the extension tube out of the
primary boom tube. Place the extension tube on
blocks for support.
During removal, the overhead
crane strap will need to be
carefully adjusted for proper
balancing.
7 Models without rotating jib boom: Support
the jib boom bellcrank with a suitable lifting
device.
Models with rotating jib boom: Support the jib
boom rotator mount with a suitable lifting
device.
8 Remove the pin retaining fasteners from the
slave cylinder rod-end pivot pin.
9 Use a soft metal drift to remove the slave
cylinder rod-end pivot pin.
10 Models without rotating jib boom: Remove
the pin retaining fasteners from the bellcrank
pivot pin. Use a soft metal drift to remove the
pin and remove the bellcrank from the extension
boom tube.
Models with rotating jib boom: Remove the
pin retaining fasteners from the jib boom rotator
mountbellcrank pivot pin. Use a soft metal drift
to remove the pin and remove the jib boom
rotator mount from the extension boom tube.
Crushing hazard. The bellcrank or
jib boom rotator mount could fall
when removed from the extension
boom if not properly supported.
5 - 25
Section 5 • Repair Procedures
PRIMARY BOOM COMPONENTS
11 Remove the external snap rings from the slave
cylinder barrel-end pivot pin.
12 Use a soft metal drift and drive the slave
cylinder barrel-end pivot pin out.
13 Remove the slave cylinder from the primary
extension boom tube.
14 Remove the external snap rings from the
extension cylinder rod-end pivot pins at the
platform end of the extension tube. Use a soft
metal drift to remove the pins.
15 Support and slide the extension cylinder out of
the pivot end of the boom extension tube. Place
the extension cylinder on blocks for support.
During removal, the overhead
crane strap will need to be
carefully adjusted for proper
balancing.
16 Remove and label the wear pads from the
extension cylinder.
Pay careful attention to the
location of each wear pad.
5 - 26 Genie Z-30/20N
First Edition • Third Printing
4-3
Primary Boom Lift Cylinder
The primary boom lift cylinder raises and lowers the
primary boom. The primary boom lift cylinder is
equipped with counterbalance valves to prevent
movement in the event of a hydraulic line failure.
How to Remove the Primary
Boom Lift Cylinder
Bodily injury hazard. This
procedure requires specific repair
skills, lifting equipment and a
suitable workshop. Attempting this
procedure without these skills and
tools could result in death or
serious injury and significant
component damage. Dealer
service is strongly recommended.
When removing a hose assembly
or fitting, the O-ring on the fitting
and/or hose end must be replaced
and then torqued to specification
during installation.
Refer to Section Two, Hydraulic
Hose and Fitting Torque
Specifications.
1 Raise the secondary boom enough to access
the primary boom lift cylinder barrel-end
pivot pin.
2 Raise the primary boom enough to access the
primary boom lift cylinder rod-end pivot pin.
Part No. 35532
First Edition • Third Printing
3 Place a block of wood across the upper
secondary boom to support the cylinder when
the rod-end pin is removed. Support the primary
boom lift cylinder with a suitable lifting device.
4 Attach an overhead crane to the primary boom
at the platform end for support. Do not lift it.
5 Remove the front counterweight cover fasteners.
Remove the front counterweight cover from the
machine.
6 Place a block of wood between the
counterweight plate on the leveling link and the
cross member of the upper secondary boom.
Carefully lower the secondary boom onto the
block.
Crushing hazard. Keep hands
away from the block and all
moving parts when lowering the
secondary boom onto the block.
7 Remove the pin retaining fasteners from the
primary boom lift cylinder rod-end pivot pin. Use
a soft metal drift to remove the pin.
8 Lower the rod end of the cylinder onto the blocks
that were placed on the upper secondary boom.
9 Remove the pin retaining fastener from the
ground control side upper secondary leveling
link pivot pin at the upper pivot (same side of
machine as the primary boom lift cylinder barrel-
end pivot pin retainer).
10 Place a rod through the upper secondary
leveling link pivot pin at the upper pivot and
twist to remove the pin.
Part No. 35532 Genie Z-30/20N
Section 5 • Repair Procedures
PRIMARY BOOM COMPONENTS
11 Swing the leveling link up out of the way and
secure it from moving.
12 Tag, disconnect and plug the primary boom lift
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.
13 Support the barrel end of the primary boom lift
cylinder with straps or ropes to restrict it from
swinging freely.
14 Remove the pin retaining fastener from the
primary boom lift cylinder barrel-end pivot pin.
Do not remove the pivot pin.
15 Place a rod through the barrel-end pivot pin and
twist to remove the pin.
Crushing hazard. When the barrel-
end pivot pin is removed, the
primary boom lift cylinder will fall if
not properly supported.
5 - 27
Section 5 • Repair Procedures
PRIMARY BOOM COMPONENTS
16 Attach an overhead crane or similar lifting
device to the lug on the rod-end of the primary
boom lift cylinder. Carefully loosen the straps
and allow the primary boom lift cylinder to
slowly swing down.
17 Carefully remove the cylinder from the machine.
Crushing hazard. The primary
boom lift cylinder will fall if not
properly supported when it is
removed from the machine.
5 - 28 Genie Z-30/20N
First Edition • Third Printing
4-4
Extension Cylinder
The extension cylinder extends and retracts the
primary boom extension tube. The extension
cylinder is equipped with counterbalance valves to
prevent movement in the event of a hydraulic line
failure.
How to Remove the
Extension Cylinder
Bodily injury hazard. This
procedure requires specific repair
skills, lifting equipment and a
suitable workshop. Attempting this
procedure without these skills and
tools could result in death or
serious injury and significant
component damage. Dealer
service is strongly recommended.
When removing a hose assembly
or fitting, the O-ring on the fitting
and/or hose end must be replaced
and then torqued to specification
during installation.
Refer to Section Two, Hydraulic
Hose and Fitting Torque
Specifications.
1 Raise the primary boom to the horizontal
position. Extend the boom 3 to 4 feet /
0.9 to 1.2 m until the extension cylinder rod-end
pivot pins are accessible.
Part No. 35532
First Edition • Third Printing Section 5 • Repair Procedures

PRIMARY BOOM COMPONENTS

2 Remove the external snap rings from the 9 Remove the retaining fastener from the
extension cylinder rod-end pivot pins. Use a soft extension cylinder barrel-end pivot pin. Use a
metal drift to remove the pins. soft metal drift to remove the pin.
3 Remove the front counterweight cover fasteners. 10 Carefully pull out and properly support the
Remove the front counterweight cover from the extension cylinder from the primary boom.
machine.
Crushing hazard. The cylinder will
4 Raise the secondary boom until the master fall if not properly supported when
cylinder rod-end pivot pin is accessible. it is pulled out of the extension
tube.
5 Remove the primary boom extend drive limit
switch from the pivot end of the primary boom. To make installation of the
Do not disconnect the wiring. extension cylinder easier, be sure
that the cylinder rod is extended
6 Remove the retaining fastener from the master
3 to 4 feet / 0.9 to 1.2 m.
cylinder rod-end pivot pin. Use a soft metal drift
to remove the pin.
7 Manually retract the master cylinder and push it
toward the platform end of the boom to obtain
enough clearance for extension cylinder
removal.
8 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 slowly to allow
the oil pressure to dissipate
gradually. Do not allow oil to squirt
or spray.

Part No. 35532 Genie Z-30/20N 5 - 29

Section 5 • Repair Procedures
PRIMARY BOOM COMPONENTS
4-5
Platform Leveling Master
Cylinder
The platform leveling master cylinder acts as a
pump for the slave cylinder. It is part of the closed-
loop hydraulic circuit that keeps the platform level
through the entire range of primary boom motion.
The platform leveling master cylinder is located
inside the upper mid-pivot at the pivot end of the
primary boom.
How to Remove the Platform
Leveling Master Cylinder
Bodily injury hazard. This
procedure requires specific repair
skills, lifting equipment and a
suitable workshop. Attempting this
procedure without these skills and
tools could result in death or
serious injury and significant
component damage. Dealer
service is strongly recommended.
When removing a hose assembly
or fitting, the O-ring on the fitting
and/or hose end must be replaced
and then torqued to specification
during installation.
Refer to Section Two, Hydraulic
Hose and Fitting Torque
Specifications.
Before cylinder removal is
considered, bleed the cylinder to
be sure that there is no air in the
closed loop. See 2-2, How to Bleed
the Slave Cylinder.
1 Remove the rear counterweight cover.
2 Raise the secondary boom until the master
cylinder barrel-end pivot pin is above the
turntable counterweights.
5 - 30 Genie Z-30/20N
First Edition • Third Printing
3 Raise the primary boom until the master cylinder
rod-end pivot pin is accessible.
4 Attach an overhead crane to the pivot end of the
primary boom. Do not lift it.
5 Secure the upper secondary boom to the pivot
end of the primary boom with a strap (this will
prevent the upper secondary boom from falling
when the master cylinder barrel-end pivot pin is
removed from the cylinder).
6 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.
7 Attach a lifting strap from an overhead crane to
the lug on the rod end of the master cylinder,
then secure the strap to the primary boom (use
this strap to lower the master cylinder out of the
upper mid-pivot).
8 Remove the pin retaining fastener from the
master cylinder rod-end pivot pin. Use a soft
metal drift to remove the pin.
9 Remove the pin retaining fastener from the
master cylinder barrel-end pivot pin. Use a soft
metal drift to remove the pin from the cylinder.
Do not remove the pin from the upper mid-pivot.
Push the pin to one side, only far enough to
remove the cylinder. The pin should remain in
one side of the upper secondary boom and
upper mid-pivot.
Crushing Hazard. The upper
secondary boom and the upper
mid-pivot will fall if the pivot pin is
completely removed.
10 Use the strap around the rod-end lug to lower the
cylinder out of the machine.
Part No. 35532
First Edition • Third Printing Section 5 • Repair Procedures

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Part No. 35532 Genie Z-30/20N 5 - 31

Section 5 • Repair Procedures First Edition • Third Printing

Secondary Boom Components

h
c

f
d

e
Secondary Boom
a upper pivot
b upper compression arm
c mid-pivot
d compression link
e lower secondary boom
f lower compression arm
g turntable pivot
h upper secondary boom

5 - 32 Genie Z-30/20N Part No. 35532

First Edition • Third Printing
5-1
Secondary Boom
How to Disassemble the
Secondary Boom
Bodily injury hazard. The
procedures in this section require
specific repair skills, lifting
equipment and a suitable
workshop. Attempting this
procedure without these skills and
tools could 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. Reassemble the secondary
boom by following the disassembly
steps in reverse order.
When removing a hose assembly
or fitting, the O-ring on the fitting
and/or hose end must be replaced
and then torqued to specification
during installation.
Refer to Section Two, Hydraulic
Hose and Fitting Torque
Specifications.
1 Fully raise the secondary boom.
2 Remove the front counterweight cover.
3 Remove the counterweight from the lower
compression arm.
Part No. 35532 Genie Z-30/20N
Section 5 • Repair Procedures
SECONDARY BOOM COMPONENTS
4 Lower the boom to the stowed position.
5 Place a lifting device under the front of the
platform.
6 Disconnect the battery packs from the machine.
7 Remove the cable cover from the side of the jib
boom.
8 Remove the wire loom from the cables at the
platform control box.
9 Locate the 4 cables from the primary boom
cable track to the platform control box. Number
each cable and its entry location at the platform
control box.
10 Open the platform control box.
11 Label and disconnect each wire from the 4
cables in the platform control box.
Electrocution hazard. Contact with
electrically charged circuits could
result in death or serious injury.
Remove all rings, watches and
other jewelry.
12 Pull the cables out of the platform control box.
13 Pull all of the electrical cables out of the plastic
cable track. Do not pull out the hydraulic hoses.
14 Remove the hose clamps from the bottom side
of the primary boom.
5 - 33
Section 5 • Repair Procedures
SECONDARY BOOM COMPONENTS
15 Tag, disconnect and plug the platform rotator
hydraulic hoses at the union located on the
bottom side of the primary boom. Cap the
fittings on the union.
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.
16 Remove the hose clamp from the side of the
primary boom at the pivot end.
17 Remove the primary boom extend drive speed
limit switch (LS1) mounted on the side of the
pivot end of the primary boom. Do not
disconnect the wiring.
18 Attach a lifting strap from an overhead crane to
the pivot end of the primary boom.
19 Carefully lift the secondary and primary boom
assembly until the master cylinder and primary
boom lift cylinder hydraulic hoses are
accessible.
20 Remove the cable covers from the top of the
upper secondary boom.
21 Tag, disconnect and plug the primary boom lift
cylinder and master cylinder hydraulic hoses.
Cap the fittings on the cylinders.
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.
5 - 34 Genie Z-30/20N
First Edition • Third Printing
22 Lower the booms to the fully stowed position.
23 Pull all the cables and hoses through the upper
mid-pivot.
Component damage hazard.
Cables and hoses can be damaged
if they are kinked or pinched.
24 Position the strap from the overhead crane
approximately 2 feet / 0.6 m from the platform
end of the primary boom. Measure from the
platform end of the primary boom tube.
25 Remove the pin retaining fasteners from the
upper mid-pivot to upper secondary
compression arm pivot pins. Use a soft metal
drift to remove the pins.
26 Swing the compression arms down and out of
the way. Secure them from moving.
27 Remove the pin retaining fasteners from the
upper mid-pivot to the upper secondary boom
pivot pin. Use a soft metal drift to remove the
pin.
28 Carefully remove the entire primary boom
assembly from the machine (primary boom
assembly, jib boom assembly, platform, master
cylinder, primary lift cylinder and upper mid-
pivot).
Crushing hazard. The primary
boom assembly could become
unbalanced and fall when removed
from the machine if not properly
supported by the overhead crane.
Do not remove the assembly from
the machine until it is properly
balanced.
Part No. 35532
First Edition • Third Printing
29 Place the entire assembly onto a structure
capable of supporting it.
30 Remove the pin retaining fasteners from the
upper secondary compression arm pivot pins.
Do not remove the pins.
31 Position the lifting strap from an overhead crane
at the center of the control box side upper
secondary leveling link and remove the link from
the machine. Repeat this step for the hydraulic
tank side upper secondary leveling link.
Crushing hazard. The upper
secondary leveling link could
become unbalanced and fall when
removed from the machine if not
properly supported by the overhead
crane.
32 Remove the pin retaining fastener from the rod
end of the secondary boom lift cylinder. Use a
soft metal drift to remove the pin. Secure the
cylinder from moving.
33 Remove the pin retaining fastener from the lower
pivot pin on the compression link. Use a soft
metal drift to remove the pin.
34 Attach a lifting strap from an overhead crane to
the upper secondary boom.
35 Remove the pin retaining fastener from the
upper secondary boom to the lower mid-pivot
pivot pin. Use a soft metal drift to remove the
pin.
Part No. 35532 Genie Z-30/20N
Section 5 • Repair Procedures
SECONDARY BOOM COMPONENTS
36 Remove the upper secondary boom with leveling
link from the machine.
Crushing hazard. The upper
secondary boom with leveling link
could become unbalanced and fall
when removed from the machine if
not properly supported by the
overhead crane.
37 Remove the cable covers from the top of the
lower secondary boom. Pull all the cables and
hoses towards the counterweight end of the
turntable.
38 Remove the mounting fasteners from the
counterweight attached to the lower leveling
link.
39 Attach a lifting strap from an overhead crane to
the counterweight. Remove the counterweight
from the lower leveling link.
Tip-over hazard. The counterweight
is critical to machine stability. If
the counterweight is not installed
during re-assembly of the machine,
the machine will become unstable
and tip over.
40 Before serial number 747: Remove the drive
speed limit switch (LS2) mounted on the inside
of the lower mid-pivot. Do not disconnect the
wiring.
41 Remove the mounting fasteners from the
function manifold and slide the function manifold
to the side. This will allow access to the barrel
end mounting pin.
5 - 35
Section 5 • Repair Procedures
SECONDARY BOOM COMPONENTS
42 Remove the retaining fasteners from the
secondary boom lift cylinder barrel-end pivot
pins.
43 Attach a lifting strap from an overhead crane to
the lug on the rod end of the secondary boom
lift cylinder.
44 Tag, disconnect and plug the hydraulic hoses
from the secondary boom lift 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 to squirt
or spray.
45 Use a slide hammer to remove the barrel-end
pins (access the pins from the access holes in
the bulkheads, one on each side). Remove the
secondary boom lift cylinder from the machine.
Crushing hazard. The secondary
boom lift cylinder could become
unbalanced and fall when removed
from the machine if not properly
supported by the overhead crane.
46 Attach a lifting strap from an overhead crane to
the mid-pivot.
47 Remove the pin retaining fasteners from the
mid-pivot to the lower secondary leveling link
pivot pins. Use a slide hammer and remove the
pins.
5 - 36 Genie Z-30/20N
First Edition • Third Printing
48 Remove the pin retaining fasteners from the
mid-pivot to the lower secondary boom pivot
pin. Use a soft metal drift to remove the pins.
49 Remove the mid-pivot from the machine.
Crushing hazard. The mid-pivot
could become unbalanced and fall
when it is removed from the
machine if not properly supported
by the overhead crane.
50 After serial number 746: Remove the
secondary boom drive speed limit switch (LS4)
mounted on the turntable on the ground controls
side. Do not disconnect the wiring.
51 Attach a lifting strap from an overhead crane to
the ground control side lower secondary leveling
link.
52 Remove the pin retaining fastener from the lower
secondary leveling link to the turntable pivot pin.
53 Use a slide hammer and remove the pin.
Remove the leveling link from the machine.
Repeat for the hydraulic tank side lower
secondary leveling link.
Crushing hazard. The lower
secondary leveling link could
become unbalanced and fall when
removed from the machine if not
properly supported by the overhead
crane.
54 Attach a strap from an overhead crane to the
lower secondary boom.
Part No. 35532
First Edition • Third Printing
55 Remove the pin retaining fastener from the lower
secondary boom to the turntable pivot pin. Use
a soft metal drift to remove the pin.
56 Remove the lower secondary boom from the
machine.
Crushing hazard. The lower
secondary boom could become
unbalanced and fall when removed
from the machine if not properly
supported by the overhead crane.
Part No. 35532 Genie Z-30/20N
Section 5 • Repair Procedures
SECONDARY BOOM COMPONENTS
5-2
Secondary Boom Lift Cylinder
The secondary boom lift cylinder raises and
lowers the secondary boom. The secondary
boom lift cylinder is equipped with counterbalance
valves to prevent movement in the event of a
hydraulic line failure.
How to Remove the Secondary
Boom Lift Cylinder
Bodily injury hazard. This
procedure requires specific repair
skills, lifting equipment and a
suitable workshop. Attempting this
procedure without these skills and
tools could result in death or
serious injury and significant
component damage. Dealer
service is strongly recommended.
When removing a hose assembly
or fitting, the O-ring on the fitting
and/or hose end must be replaced
and then torqued to specification
during installation.
Refer to Section Two, Hydraulic
Hose and Fitting Torque
Specifications.
1 Rotate the turntable to either side until the boom
is centered between the steer and non-steer
tires.
2 Raise the primary boom to full height. Do not
extend it.
5 - 37
Section 5 • Repair Procedures
SECONDARY BOOM COMPONENTS
3 Swing out the battery pack that is directly below
the secondary boom lift cylinder.
4 Disconnect the battery packs from the machine.
5 Open the hydraulic tank side turntable cover.
6 Tag and disconnect the power cables on the
auxiliary power unit.
7 Tag and disconnect and plug the hydraulic hose
from the hydraulic tank shutoff valve.
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.
8 Open the valve on the hydraulic tank and drain
the oil into a suitable container.
Bodily injury hazard. Beware of hot
oil. Contact with hot oil may cause
severe burns.
9 Tag, disconnect and plug the hydraulic hoses
from the hydraulic tank filter. Cap the fittings on
the filter.
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.
Bodily injury hazard. Beware of hot
oil. Contact with hot oil may cause
severe burns.
5 - 38 Genie Z-30/20N
First Edition • Third Printing
10 Remove the hydraulic tank mounting fasteners.
Remove the hydraulic tank from the machine.
11 Open the ground controls side turntable cover.
12 Remove the terminal strip cover retaining
fasteners. Remove the cover.
13 Remove the terminal strip retaining fasteners.
Do not disconnect the wiring.
14 Remove the plastic plug in the bulkhead to
access the secondary boom lift cylinder rod-end
pivot pin.
15 Remove the mounting fasteners from the
function manifold and slide the manifold to the
side This will allow access to the hydraulic tank
side barrel-end pivot pin.
16 Attach a lifting strap from an overhead crane to
the lug on the rod end of the secondary boom
lift cylinder.
17 From the bottom side of the cylinder, remove
the retaining fasteners from the secondary
boom lift cylinder barrel-end pivot pins.
18 Remove the hose clamp under the lower
secondary boom.
19 Use a slide hammer to remove both barrel-end
pivot pins (access the pins from the access
holes in the bulkheads, one on each side).
20 Remove the pin retaining fastener from the
secondary boom lift cylinder rod-end pivot pin.
21 Use a soft metal drift to remove the secondary
boom rod-end pivot pin.
Part No. 35532
First Edition • Third Printing Section 5 • Repair Procedures

SECONDARY BOOM COMPONENTS

22 Carefully lower the cylinder down through the

secondary boom, enough to access the
hydraulic hoses. Do not pinch the hoses.
Component damage hazard. Hoses
can be damaged if they are kinked
or pinched.
23 Tag, disconnect and plug the hydraulic hoses
from the secondary boom lift 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 to squirt
or spray.
24 Remove the cylinder through the top of the
secondary boom.
Crushing hazard. The secondary
boom lift cylinder could become
unbalanced and fall when removed
from the machine if not properly
supported by the overhead crane.

Part No. 35532 Genie Z-30/20N 5 - 39

Section 5 • Repair Procedures First Edition • Third Printing

Ground Controls
6-1 Test Desired result
Control Relays terminal 7 to 8 640 to 650W

terminal 1 to 2, 3, 4 and 6 no continuity

How to Test a Double Pole (infinite W)
Double Throw Relay
terminal 2 to 3, 4 and 5 no continuity
Relays used for dual function switching are double (infinite W)
pole double throw (DPDT) relays.
terminal 3 to 6 no continuity
Electrocution hazard. Contact with (infinite W)
electrically charged circuits could terminal 2 to 6 continuity
result in death or serious injury. (zero W)
Remove all rings, watches and
other jewelry. terminal 1 to 5 continuity
(infinite W)
This procedure covers fundamental
relay testing and does not
specifically apply to all varieties 4 Connect 24V DC to terminal 8 and a ground wire
of relays. to terminal 7, then test the following terminal
combinations.
1 Turn the key switch to the OFF position and
remove the key.
Test Desired result
2 Label and then disconnect all the wiring from the
terminal 1 to 2, 4, 5 and 6 no continuity
relay to be tested. (infinite W)
3 Connect the leads from an ohmmeter to each
terminal 2 to 3, 5 and 6 no continuity
terminal combination and check for continuity. (infinite W)
Terminals 7 and 8 represent the coil and should
not be tested in any other combination. terminal 1 to 3 continuity
(zero W)
2
terminal 2 to 4 continuity
1
(zero W)
4
3

6 5

8
7

Bubble number represents the terminal number

Relay Schematic

5 - 40 Genie Z-30/20N Part No. 35532

First Edition • Third Printing Section 5 • Repair Procedures

GROUND CONTROLS

How to Test a Single Pole 4 Connect 24V DC to terminal 85 and a ground

wire to terminal 86. Test the following terminal
Double Throw Relay combinations.
Relays used for single function switching are single
Test Desired result
pole double throw (SPDT) relays.
terminal 87a to 87 and 30 no continuity
Electrocution hazard. Contact with (infinite W)
electrically charged circuits could
result in death or serious injury. terminal 87 to 30 continuity
Remove all rings, watches and (zero W)
other jewelry.
This procedure covers fundamental
relay testing and does not
specifically apply to all varieties
of relays.
85 87 87a
1 Turn the key switch to the OFF position and
remove the key. Relay deactivated
2 Label and then disconnect all the wiring from the
86 30
relay to be tested.
3 Connect the leads from an ohmmeter to each
terminal combination and check for continuity.
Terminals 85 and 86 represent the coil and
should not be tested in any other combination.
85 87 87a

Test Desired result

Relay activated
terminal 85 to 86 85 to 95W
86 30
terminal 87 to 87a and 30 no continuity
(infinite W)

terminal 87a to 30 continuity

(zero W) 87

87a
86 85
30

Terminal numbers

terminal no. 87a - N.C.

terminal no. 85 - ground
terminal no. 30 - common
terminal no. 86 - coil
terminal nol 87 - N.O.

Part No. 35532 Genie Z-30/20N 5 - 41

Section 5 • Repair Procedures First Edition • Third Printing

GROUND CONTROLS

6-2 6-3
Toggle Switches Wago® Components
See 1-4, Toggle Switches. How to Remove a Wago®
Component
Electrocution hazard. Contact with
electrically charged circuits could
result in death or serious injury.
Remove all rings, watches and
other jewelry.
1 Label the wiring from the component to be
removed.
2 Use a small screwdriver to push in and release
the wire from the component.
3 Locate the removal tab on the bottom or top of
the component.
4 Use a small screwdriver to gently pry up on the
tab of the component and remove it.

5 - 42 Genie Z-30/20N Part No. 35532

First Edition • Third Printing
7-1
Auxiliary Pump
How to Test the Auxiliary Pump
1 Disconnect and plug the high pressure hydraulic
hose from the auxiliary pump.
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.
When removing a hose assembly
or fitting, the O-ring on the fitting
and/or hose end must be replaced
and then torqued to specification
during installation.
Refer to Section Two, Hydraulic
Hose and Fitting Torque
Specifications.
2 Connect a 0 to 5000 psi / 0 to 350 bar pressure
gauge to the high pressure port on the pump.
3 Turn the key switch to ground control and pull
out the red Emergency Stop button to the ON
position at both the ground and platform
controls.
Part No. 35532 Genie Z-30/20N
Section 5 • Repair Procedures
Hydraulic Pumps
4 Activate any function using auxiliary power.
Result: If the pressure gauge reads
2800 psi / 193 bar, immediately stop. The pump
is good.
Result: If pressure fails to reach
2800 psi / 193 bar, the pump is bad and will
need to be serviced or replaced.
5 Remove the pressure gauge and reconnect the
hydraulic hose.
How to Remove the Auxiliary
Pump
1 Tag, disconnect and plug the hydraulic hoses
from the pump. Cap the fittings on the pump.
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 pump mounting bolts. Carefully
remove the pump.
5 - 43
Section 5 • Repair Procedures
HYDRAULIC PUMPS
7-2
Function Pump
How to Test the Function Pump
1 Disconnect and plug the high pressure hydraulic
hose from the function pump.
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.
When removing a hose assembly
or fitting, the O-ring on the fitting
and/or hose end must be replaced
and then torqued to specification
during installation.
Refer to Section Two, Hydraulic
Hose and Fitting Torque
Specifications.
2 Connect a 0 to 5000 psi / 0 to 350 bar pressure
gauge to the high pressure port on the pump.
3 Turn the key switch to ground control and pull
out the red Emergency Stop button to the ON
position at both the ground and platform
controls.
5 - 44 Genie Z-30/20N
First Edition • Third Printing
4 Before serial number 747: Move and hold any
boom function toggle switch at the ground
controls.
After serial number 746: Move and hold the
function enable switch to either side and move
and hold any boom function toggle switch at the
ground controls.
Result: If the pressure gauge reads
2800 psi / 193 bar, immediately stop. The pump
is good.
Result: If pressure fails to reach
2800 psi / 193 bar,
Before serial number 996: the external relief
valve setting is incorrect or the pump is faulty
and will need to be serviced or replaced.
From serial number 996 to 2007: the internal
relief valve setting is incorrect or the pump is
faulty and will need to be serviced or replaced.
After serial number 2007: the relief valve
setting on the function manifold is incorrect or
the pump is faulty and will need to be serviced
or replaced.
5 Remove the pressure gauge and reconnect the
hydraulic hose.
Part No. 35532
First Edition • Third Printing Section 5 • Repair Procedures

HYDRAULIC PUMPS

How to Remove the Function

Pump
Before serial number 2008:

1 Remove the support angle from the side of the

hydraulic power unit.
2 Remove the mounting fasteners from the
hydraulic reservoir. Remove the the hydraulic
reservoir from the power unit.
3 Remove the pump mounting bolts. Carefully
remove the pump.
After serial number 2007:

1 Tag, disconnect and plug the hoses from the

function pump.
2 Remove the pump mounting bolts from the
pump. Carefully remove the pump from the
electric motor.

Part No. 35532 Genie Z-30/20N 5 - 45

Section 5 • Repair Procedures First Edition • Third Printing

Manifolds
8-1
Function Manifold Components (before serial number 3447)
The function manifold is locate behind the ground controls turntable cover.
Index Schematic
No. Description Item Function Torque
1 Flow regulator valve .......................... A ........... Differential sensing circuit ................ 10-12 ft-lbs / 14-16 Nm
2 Relief valve, 2800 psi / 193 bar ........ B ........... System relief ..................................... 25-30 ft-lbs / 34-41 Nm
3 Solenoid valve, 2 position 3 way ..... C ........... Boom retract ....................................... 8-10 ft-lbs / 11-14 Nm
4 Solenoid valve, 2 position 3 way ..... D ........... Primary boom up ................................ 8-10 ft-lbs / 11-14 Nm
5 Solenoid valve, 2 position 3 way ...... E ........... Secondary boom up ........................... 8-10 ft-lbs / 11-14 Nm
6 Solenoid valve, 2 position 3 way ...... F ........... Turntable rotate left ............................. 8-10 ft-lbs / 11-14 Nm
7 Solenoid valve, 2 position 3 way ..... G ........... Platform level up ................................. 8-10 ft-lbs / 11-14 Nm
8 Solenoid valve, 2 position 3 way ..... H ........... Boom extend ...................................... 8-10 ft-lbs / 11-14 Nm
9 Solenoid valve, 2 position 3 way ...... I ............ Primary boom down ........................... 8-10 ft-lbs / 11-14 Nm
10 Solenoid valve, 2 position 3 way ...... J ............ Secondary boom down ...................... 8-10 ft-lbs / 11-14 Nm
11 Solenoid valve, 2 position 3 way ...... K ........... Turntable rotate right .......................... 8-10 ft-lbs / 11-14 Nm
12 Solenoid valve, 2 position 3 way ...... L ........... Platform level down ............................ 8-10 ft-lbs / 11-14 Nm
13 Orifice, 0.050 inch / 1.27 mm ........... M ........... Turntable rotate circuit
14 Counterbalance valve ...................... N ........... Platform level down .......................... 35-40 ft-lbs / 47-54 Nm
15 Counterbalance valve ...................... O ........... Platform level up ............................... 35-40 ft-lbs / 47-54 Nm
16 Relief valve, 1750 psi / 121 bar ........ P ........... Turntable rotate left ........................... 25-30 ft-lbs / 34-41 Nm
17 Relief valve, 1750 psi / 121 bar ....... Q ........... Turntable rotate right ........................ 25-30 ft-lbs / 34-41 Nm
18 Relief valve, 1600 psi / 110 bar ....... R ........... Secondary boom down .................... 25-30 ft-lbs / 34-41 Nm
19 Relief valve, 1400 psi / 97 bar ......... S ........... Primary boom down ......................... 25-30 ft-lbs / 34-41 Nm
20 Relief valve, 1800 psi / 124 bar ........ T ........... Boom extend .................................... 25-30 ft-lbs / 34-41 Nm
21 Proportional solenoid valve ............. U ........... System Flow regulating circuit ......... 10-12 ft-lbs / 14-16 Nm
22 Diagnostic fitting ............................................... Testing

Plug Torque Specifications Valve Coil Resistance

Specification
Description Hex Size Torque

SAE No. 2 1/8 50 in-lbs / 6 Nm Description Specification

SAE No. 4 3/16 13 ft-lbs / 18 Nm Proportional solenoid valve, 24V DC 19.5 W

(schematic items C through L)
SAE No. 6 1/4 18 ft-lbs / 24 Nm
Solenoid valve, 2 position 3 way, 20V DC 23.5 W
SAE No. 8 5/16 50 ft-lbs / 68 Nm (schematic item U)

5 - 46 Genie Z-30/20N Part No. 35532

First Edition • Third Printing Section 5 • Repair Procedures

MANIFOLDS

1 2

A
22

C
3

21 U
D
4

E
5

T F
20 6

S
19 G
7
R H
18
8
Q
17
I

P 9
16

J
M
O 10
N
K

L 11

15 14 13 12

Part No. 35532 Genie Z-30/20N 5 - 47

Section 5 • Repair Procedures First Edition • Third Printing

MANIFOLDS

8-2
Function Manifold Components (after serial number 3446)
The function manifold is locate behind the ground controls turntable cover.
Index Schematic
No. Description Item Function Torque
1 Solenoid valve, 3 position 4 way .... HH .......... Platform level up/down ..................... 10-12 ft-lbs / 14-16 Nm
2 Counterbalance valve ....................... II ............ Platform level down .......................... 35-40 ft-lbs / 47-54 Nm
3 Counterbalance valve ...................... JJ ........... Platform level up ............................... 35-40 ft-lbs / 47-54 Nm
4 Relief valve, 1100 psi / 75.8 bar ..... KK .......... Turntable rotate left/right .................. 25-30 ft-lbs / 34-41 Nm
5 Relief valve, 1600 psi / 110 bar ....... LL .......... Secondary boom down .................... 25-30 ft-lbs / 34-41 Nm
6 Relief valve,
(before serial number 5398)
1400 psi / 97 bar ............................. MM ......... Primary boom down ......................... 25-30 ft-lbs / 34-41 Nm
Relief valve,
(after serial number 5397)
1600 psi / 110 bar ........................... MM ......... Primary boom down ......................... 25-30 ft-lbs / 34-41 Nm
7 Relief valve, 1800 psi / 124 bar ...... NN .......... Primary boom extend ....................... 25-30 ft-lbs / 34-41 Nm
8 Proportional solenoid valve ............ OO .......... System flow regulating circuit ........... 10-12 ft-lbs / 14-16 Nm
9 Check valve ..................................... PP .......... Brake circuit ...................................... 25-30 ft-lbs / 34-41 Nm
10 Solenoid valve, 3 position 4 way .... QQ .......... Steer left/right .................................... 10-12 ft-lbs / 14-16 Nm
11 Solenoid valve, 3 position 4 wa ...... RR .......... Primary boom extend/retract ............ 10-12 ft-lbs / 14-16 Nm
12 Pressure switch ............................... SS .......... Brake circuit
13 Solenoid valve, N.C. poppet ............ TT .......... Brake circuit ...................................... 25-30 ft-lbs / 34-41 Nm
14 Orifice, 0.045 inch / 1.02 mm .......... UU .......... Brake circuit

This list continues. Please turn the page.

Valve Coil Resistance

Specification
Description Specification

Plug Torque Specifications Proportional solenoid valve, 24V DC 19.5 W

(schematic item OO)
Description Hex Size Torque
Solenoid valve, 3 position 4 way, 20V DC 22 W
SAE No. 2 1/8 50 in-lbs / 6 Nm (schematic items HH, QQ and RR)

SAE No. 4 3/16 13 ft-lbs / 18 Nm Solenoid valve, N.C. poppet, 20V DC 23.5 W
(schematic item TT)
SAE No. 6 1/4 18 ft-lbs / 24 Nm
Solenoid valve, N.O. poppet, 20V DC 23.5 W
SAE No. 8 5/16 50 ft-lbs / 68 Nm (schematic item WW)

5 - 48 Genie Z-30/20N Part No. 35532

First Edition • Third Printing Section 5 • Repair Procedures

MANIFOLDS

Part No. 35532 Genie Z-30/20N 5 - 49

Section 5 • Repair Procedures First Edition • Third Printing

MANIFOLDS

Function Manifold Components

(after serial number 3446), continued
The function manifold is locate behind the ground controls turntable cover.
Index Schematic
No. Description Item Function Torque
15 Orifice,
(before serial number 4083)
0.060 inch / 1.5 mm ......................... VV .......... Brake and steer circuit
Orifice,
(after serial number 4082)
0.045 inch / 1.02 mm ....................... VV .......... Brake and steer circuit
16 Solenoid valve, N.O. poppet .......... WW ......... Brake circuit ...................................... 25-30 ft-lbs / 34-41 Nm
17 Differential sensing valve ................ XX .......... Differential sensing circuit ................ 10-12 ft-lbs / 14-16 Nm
18 Relief valve, 2800 psi / 193 bar ...... YY .......... System relief ..................................... 25-30 ft-lbs / 34-41 Nm
19 Diagnostic fitting ............................... ZZ .......... Testing
20 Solenoid valve, 3 position 4 way .... AB .......... Secondary boom up/down ............... 10-12 ft-lbs / 14-16 Nm
21 Solenoid valve, 3 position 4 way .... AC .......... Primary boom up/down .................... 10-12 ft-lbs / 14-16 Nm
22 Flow regulator valve,
1.5 gpm / 5.7 L/min .......................... AD .......... Turntable rotate circuit ...................... 10-12 ft-lbs / 14-16 Nm
23 Flow regulator valve,
0.8 gpm / 3 L/min ............................. AE .......... Jib boom/platform rotate circuit ........ 10-12 ft-lbs / 14-16 Nm
24 Solenoid valve, 3 position 4 way .... AF .......... Turntable rotate left/right .................. 10-12 ft-lbs / 14-16 Nm

Valve Coil Resistance

Specification
Description Specification

Plug Torque Specifications Proportional solenoid valve, 24V DC 23.5 W

(schematic item OO)
Description Hex Size Torque
Solenoid valve, 3 position 4 way, 20V DC 19.5 W
SAE No. 2 1/8 50 in-lbs / 6 Nm (schematic items HH, QQ and RR)

SAE No. 4 3/16 13 ft-lbs / 18 Nm Solenoid valve, N.C. poppet, 20V DC 19.5 W
(schematic item TT)
SAE No. 6 1/4 18 ft-lbs / 24 Nm
Solenoid valve, N.O. poppet, 20V DC 19.5 W
SAE No. 8 5/16 50 ft-lbs / 68 Nm (schematic item WW)

5 - 50 Genie Z-30/20N Part No. 35532

First Edition • Third Printing Section 5 • Repair Procedures

MANIFOLDS

Part No. 35532 Genie Z-30/20N 5 - 51

Section 5 • Repair Procedures
MANIFOLDS
8-3
Valve Adjustments -
Function Manifold
How to Adjust the System Relief
Valve
Perform this procedure with the
boom in the stowed position.
1 Connect a 0 to 5000 psi / 0 to 345 bar pressure
gauge to the test port on the function manifold.
2 Turn the key switch to ground control and pull
out the red Emergency Stop button to the ON
position.
3 Before serial number 747: Move and hold the
primary boom extend/retract toggle switch in the
retract direction with the primary boom fully
retracted. Observe the pressure reading on the
pressure gauge.
After serial number 746: Move and hold the
function enable toggle switch to either side and
move and hold the primary boom extend/retract
toggle switch in the retract direction with the
primary boom fully retracted. Observe the
pressure reading on the pressure gauge.
System relief valve specifications
Pressure 2800 psi
193 bar
4 Turn the machine off. Hold the system relief
valve with a wrench and remove the cap
(item B or YY).
5 - 52 Genie Z-30/20N
First Edition • Third Printing
5 Adjust the internal hex socket. Turn it clockwise
to increase the pressure or counterclockwise to
decrease the pressure. Install the relief valve
cap.
Tip-over hazard. Do not adjust
the relief valve higher than
specified.
6 Repeat steps 2 and 3 to confirm the relief valve
pressure setting.
How to Adjust the Primary 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 pull
out the red Emergency Stop button to the ON
position.
3 Before serial number 747: Move and hold the
primary boom up/down toggle switch in the
down direction with the primary boom fully
lowered. Observe the pressure reading on the
pressure gauge.
After serial number 746: Move and hold the
function enable toggle switch to either side and
move and hold the primary boom up/down
toggle switch in the down direction with the
primary boom fully lowered. Observe the
pressure reading on the pressure gauge.
Primary boom down relief valve specifications
Pressure
(before serial number 5398) 1400 psi
97 bar
(after serial number 5397) 1600 psi
110 bar
Part No. 35532
First Edition • Third Printing Section 5 • Repair Procedures

MANIFOLDS

4 Turn the machine off. Hold the primary down
relief valve with a wrench and remove the cap
(item S or MM).
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 valve higher than
specified.
6 Repeat steps 2 and 3 to confirm the relief valve
pressure setting.
4 Turn the machine off. Hold the secondary boom
down relief valve with a wrench and remove the
cap (item R or LL).
5 Adjust the internal hex socket. Turn it clockwise
to increase the pressure or counterclockwise to
decrease the pressure. Install the relief valve
cap.
Tip-over hazard. Do not adjust
the relief valve higher than
specified.
6 Repeat steps 2 and 3 to confirm the relief valve
pressure setting.

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 pull
out the red Emergency Stop button to the ON
position.
3 Before serial number 747: Move and hold the
secondary boom up/down toggle switch in the
down direction with the secondary boom fully
lowered. Observe the pressure reading on the
pressure gauge.
After serial number 746: Move and hold the
function enable toggle switch to either side and
move and hold the secondary boom up/down
toggle switch in the down direction with the
secondary boom fully lowered. Observe the
pressure reading on the pressure gauge.

Secondary boom down relief valve specifications

Pressure 1600 psi

110 bar

Part No. 35532 Genie Z-30/20N 5 - 53

Section 5 • Repair Procedures
MANIFOLDS
How to Adjust the Primary Boom
Extend 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 pull
out the red Emergency Stop button to the ON
position.
3 Before serial number 747: Move and hold the
primary boom extend/retract toggle switch in the
extend direction with the primary boom fully
extended. Observe the pressure reading on the
pressure gauge.
After serial number 746: Move and hold the
function enable toggle switch to either side and
move and hold the primary boom extend/retract
toggle switch in the extend direction with the
primary boom fully extended. Observe the
pressure reading on the pressure gauge.
Primary boom extend relief valve specifications
Pressure
Models with rotating jib boom 1800
124
Models without rotating jib boom 2800
193
4 Turn the machine off. Hold the primary booom
extend relief valve with a wrench and remove
the cap (item T or NN).
5 - 54 Genie Z-30/20N
First Edition • Third Printing
5 Adjust the internal hex socket. Turn it clockwise
to increase the pressure or counterclockwise to
decrease the pressure. Install the relief valve
cap.
Tip-over hazard. Do not adjust
the relief valves higher than
specified.
6 Repeat steps 2 and 3 to confirm the relief valve
pressure setting.
How to Adjust the Turntable
Rotate Relief Valve(s)
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 pull
out the red Emergency Stop button to the ON
position.
3 Before serial number 747: Move and hold the
turntable rotate toggle switch in the RIGHT
direction until turntable stops against the
rotation stop. Observe the pressure reading on
psi the pressure gauge.
bar After serial number 746: Move and hold the
psi
function enable toggle switch to either side and
bar
move and hold the turntable rotate toggle switch
in the RIGHT direction (until turntable stops
against the rotation stop). Observe the pressure
reading on the pressure gauge.
Turntable rotate relief valve specifications
Pressure
before serial number 3447 1750 psi
121 bar
after serial number 3446 1100 psi
75.8 bar
Part No. 35532
First Edition • Third Printing Section 5 • Repair Procedures

MANIFOLDS

4 Turn the machine off. Hold the turntable relief

valve(s) with a wrench and remove the cap
(item Q or KK).
5 Adjust the internal hex socket. Turn it clockwise
to increase the pressure or counterclockwise to
decrease the pressure. Install the relief valve
cap.
Tip-over hazard. Do not adjust
the relief valve(s) higher than
specified.
6 Repeat steps 2 and 3 to confirm the relief valve
pressure setting.
Before serial number 3446:

7 Turn the key switch to ground control and pull

out the red Emergency Stop button to the ON
position.
8 Before serial number 747: Move and hold the
turntable rotate toggle switch in the LEFT
direction until turntable stops against the
rotation stop. Observe the pressure reading on
the pressure gauge.
After serial number 746: Move and hold the
function enable toggle switch to either side and
move and hold the turntable rotate toggle switch
in the LEFT direction (until turntable stops against
the rotation stop). Observe the pressure reading
on the pressure gauge.
9 Turn the machine off. Hold the turntable rotate
left relief valve with a wrench and remove the
cap (item P).
10 Adjust the internal hex socket. Turn it clockwise
to increase the pressure or counterclockwise to
decrease the pressure. Install the relief valve
cap.
Tip-over hazard. Do not adjust
the relief valve higher than
specified.
11 Repeat steps 2 and 3 to confirm the relief valve
pressure setting.

Part No. 35532 Genie Z-30/20N 5 - 55

Section 5 • Repair Procedures
MANIFOLDS
8-4
Valve Coils
How to Test a Coil
A properly functioning coil provides an
electromotive force which operates the solenoid
valve. Critical to normal operation is continuity
within the coil that provides this force field.
Electrocution hazard. Contact with
electrically charged circuits could
result in death or serious injury.
Remove all rings, watches and
other jewelry.
1 Tag and disconnect the wiring from the coil to be
tested.
2 Test the coil resistance.
Coils with 2 terminals: Connect the leads from
the ohmmeter to the valve coil terminals.
Coils with 1 terminal: Connect the positive
lead from the ohmmeter to the valve coil
terminal, then connect the negative lead from
the ohmmeter to the internal ring of the valve
coil.
Result: The resistance should be within
specification, plus or minus 30%.
Result: If the resistance is not within
specification, plus or minus 30%, replace the
coil.
5 - 56 Genie Z-30/20N
First Edition • Third Printing
Valve Coil Resistance Specification
Description Specification
Solenoid valve, 3 position 4 way, 20V DC 22 W
(schematic item G)
Proportional solenoid valve, 24V DC 19.5 W
(schematic item H and AD)
Solenoid valve, N.C. poppet, 20V DC 23.5 W
(schematic item AH)
Solenoid valve, N.O. poppet 20V DC 23.5 W
(schematic items BA and BB)
Solenoid valve, 2 position 3 way 20V 23.5 W
(schematic items BI and BJ)
How to Test a Coil Diode
Genie incorporates spike suppressing diodes in all
of its valve coils. Properly functioning coil diodes
protect the electrical circuit by suppressing voltage
spikes. Voltage spikes naturally occur within a
function circuit following the interruption of electrical
current to a coil. Faulty diodes can fail to protect
the electrical system, resulting in a tripped circuit
breaker or component damage.
Electrocution hazard. Contact with
electrically charged circuits could
result in death or serious injury.
Remove all rings, watches and
other jewelry.
1 Test the coil for resistance. See 8-4, How to
Test a Coil.
Part No. 35532
First Edition • Third Printing Section 5 • Repair Procedures

MANIFOLDS

2 Connect a 10W resistor to the negative terminal 4 Connect the negative lead to the other terminal
of a known good 9V DC battery. Connect the on the coil.
other end of the resistor to a terminal on the
If testing a single-terminal coil,
coil.
connect the negative lead to the
The battery should read 9V DC or internal metallic ring at either end
more when measured across the of the coil.
terminals.
5 Momentarily connect the positive lead from the
Resistor, 10W multimeter to the positive terminal on the 9V
Genie part number 27287 battery. Note and record the current reading.
6 At the battery or coil terminals, reverse the
connections. Note and record the current
reading.
a
COIL AMMETER Result: Both current readings are greater than
e 0 mA and are different by a minimum of 20%.
The coil is good.
b

d - c
Result: If one or both of the current readings are
0 mA, or if the two current readings do not differ
by a minimum of 20%, the coil and/or its
+

10 W 9V internal diode are faulty and the coil should be

RESISTOR BATTERY
replaced.
d
c
+

a multimeter
b diode
c 9V battery
d 10W resistor
e coil

Note: Dotted lines in illustration indicate a

reversed connection as specified in
step 6

3 Set a multimeter to read DC current.

The multimeter, when set to read
DC current, should be capable of
reading up to 800 mA.

Part No. 35532 Genie Z-30/20N 5 - 57

Section 5 • Repair Procedures First Edition • Third Printing

MANIFOLDS

8-5
Jib Boom / Platform Rotate Manifold Components
(before serial number 4083)
The jib boom/platform rotate manifold is mounted to the jib boom.

Index Schematic
No. Description Item Function Torque
1 Solenoid valve, 2 position 3 way ..... U ........... Jib boom up ........................................ 8-10 ft-lbs / 11-14 Nm
2 Solenoid valve, 2 position 3 way ...... V ........... Platform rotate right ............................ 8-10 ft-lbs / 11-14 Nm
3 Orifice plug, 0.030 inch / 0.76 mm
(before serial number 3447) ............ W ........... Platform rotate circuit
Orifice plug, 0.025 inch / 0.64 mm
(after serial number 3446) ............... W ........... Platform rotate circuit
4 Solenoid valve, 2 position 3 way ...... X ........... Platform rotate left ............................... 8-10 ft-lbs / 11-14 Nm
5 Solenoid valve, 2 position 3 way ...... Y ........... Jib boom down ................................... 8-10 ft-lbs / 11-14 Nm

U 2
V
5

4
Y X
W 3

Valve Coil Resistance

Specifications
Plug Torque Specifications
Valve coil specification
Description Hex Size Torque
3 position 4 way valve, 20V DC 22 to 25W
SAE No. 4 3/16 13 ft-lbs / 18 Nm (schematic items U, V, X and Y)

5 - 58 Genie Z-30/20N Part No. 35532

First Edition • Third Printing Section 5 • Repair Procedures

MANIFOLDS

8-6
Jib Boom and Platform / Jib Boom Rotate Manifold Components
(after serial number 4082)
The jib boom and jib boom/platform rotate manifold is mounted to the jib boom.

Index Schematic
No. Description Item Function Torque
1 Solenoid valve, 3 position 4 way .... BA .......... Jib boom rotate left/right ..................... 8-10 ft-lbs / 11-14 Nm
2 Solenoid valve, 3 position 4 way .... BB .......... Platform rotate left/right ....................... 8-10 ft-lbs / 11-14 Nm
3 Solenoid valve, 3 position 4 way .... BC .......... Jib boom up/down .............................. 8-10 ft-lbs / 11-14 Nm
4 Orifice plug, 0.025 inch / 0.64 mm .. BD .......... Jib boom rotate circuit
5 Flow regulator valve,
0.3 gpm / 1.14 L/min ........................ BE .......... Platform rotate circuit ........................ 10-12 ft-lbs / 14-16 Nm

1
2
BA

BB 3

BC

5 BE BD 4

Valve Coil Resistance

Specifications
Plug Torque Specifications
Valve coil specification
Description Hex Size Torque
3 position 4 way valve, 20V DC 22 to 25W
(schematic items BA, BB and BC) SAE No. 4 3/16 13 ft-lbs / 18 Nm

Part No. 35532 Genie Z-30/20N 5 - 59

Section 5 • Repair Procedures First Edition • Third Printing

MANIFOLDS

8-7
Steer / Brake Manifold Components (before serial number 3447)
Index Schematic
No. Description Item Function Torque
1 Check valve ....................................... Z ........... Brake circuit ...................................... 25-30 ft-lbs / 34-41 Nm
2 Normally open poppet valve ........... AA .......... Brake circuit ...................................... 25-30 ft-lbs / 34-41 Nm
3 Solenoid valve, 3 position 4 way .... BB .......... Steer left/right .................................... 10-12 ft-lbs / 14-16 Nm
4 Orifice, 0.040 inch / 1.02 mm .......... CC .......... Brake circuit
5 Pressure switch ............................... DD .......... Brake circuit
6 Normally closed poppet valve ........ EE .......... Brake circuit ...................................... 25-30 ft-lbs / 34-41 Nm
7 Orifice - Washer,
0.052 inch / 1.32 mm ........................ FF .......... Brake circuit
8 Proportional solenoid valve ............ GG .......... Brake circuit ...................................... 10-12 ft-lbs / 14-16 Nm

8 1
GG

Z
2
AA

FF

6
EE BB 3

5
DD

4
CC

5 - 60 Genie Z-30/20N Part No. 35532

First Edition • Third Printing Section 5 • Repair Procedures

Turntable Rotation Components

9-1
Turntable Rotation Hydraulic
Motor
The turntable rotation hydraulic motor is the only
serviceable component of the turntable rotation
assembly. The worm gear must not be removed
from the housing. In order to remove the housing,
the turntable has to be removed.

How to Remove the Turntable

Rotation Motor
When removing a hose assembly
or fitting, the O-ring on the fitting
and/or hose end must be replaced
and then torqued to specification
during installation.
Refer to Section Two, Hydraulic
Hose and Fitting Torque
Specifications.
1 Tag, disconnect and plug the hydraulic hoses
from the turntable rotation motor. Cap the
fittings on the motor.
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 turntable rotation motor mounting
bolts. Remove the motor from the machine.

Part No. 35532 Genie Z-30/20N 5 - 61

Section 5 • Repair Procedures First Edition • Third Printing

Steering Axle Components

10-1 5 Remove the retaining fasteners from the upper
and lower yoke pivot pins. Do not remove the
Yoke and Hub pins.
6 Support and secure the yoke/hub assembly to a
How to Remove the Yoke lifting jack.
and Hub
7 Place a rod through the yoke pivot pins and
1 Loosen the wheel lug nuts. Do not remove them. twist to remove the pins.
2 Block the non-steer wheels. Crushing hazard. The yoke/hub
Center a lifting jack under the steering axle and assembly may become
raise the machine 6 inches / 15 cm. Place unbalanced and fall when the yoke
blocks under the drive chassis for support. pivot pins are removed if not
properly supported and secured to
3 Remove the lug nuts. Remove the tire and
the lifting jack.
wheel assembly.
Always use a new cotter pin when
4 Before serial number 4526: Remove the cotter
installing a clevis pin.
pins from the clevis pins at each end of the tie
rod. Remove the clevis pins from both the steer Torque specifications
cylinder and tie rod.
Lug nut torque, dry 125 ft-lbs
After serial number 4525: Remove the 169.5 Nm
retaining rings from the clevis pins at each end
of the tie rod. Remove the clevis pins from both Lug nut torque, lubricated 94 ft-lbs
the steer cylinder and tie rod. 127.4 Nm

h b

g c

f d

f e

a axle
b retaining fastener
c yoke pivot pin
d yoke
e hub
f clevis pin and cotter pin
g steer cylinder
h tie rod

5 - 62 Genie Z-30/20N Part No. 35532

First Edition • Third Printing
How to Remove the
Hub and Bearings
1 Loosen the wheel lug nuts. Do not remove them.
2 Block the non-steer wheels and place a lifting
jack under the steer axle.
3 Raise the machine. Place blocks under
the drive chassis for support.
4 Remove the lug nuts. Remove the tire
and wheel assembly.
5 Remove the dust cap, cotter pin and
castle nut.
Always use a new cotter pin when
installing a castle nut.
6 Pull the hub off the yoke spindle. The washer
and outer bearing should fall loose from the hub.
7 Place the hub on a flat surface and gently pry
the inner bearing seal out of the hub. Remove
the inner bearing.
When removing a bearing, always
use a new inner bearing seal.
Part No. 35532 Genie Z-30/20N
Section 5 • Repair Procedures
STEERING AXLE COMPONENTS
How to Install the
Hub and Bearings
When replacing a wheel bearing,
both the inner and outer bearings,
including the pressed-in races,
must be replaced.
1 Be sure that both bearings are packed
with grease.
2 Place the large inner bearing into the rear
of the hub.
3 Press the inner bearing seal evenly into the hub
until it is flush.
4 Apply a small amount of grease onto the yoke
spindle.
5 Slide the hub onto the yoke spindle.
Component damage hazard.
Damage to the lip of the seal may
occur if excessive force is applied.
6 Place the outer bearing into the hub.
7 Install the washer and castle nut.
8 Torque the castle nut to 35 ft-lbs / 47 Nm.
9 Loosen the castle nut, then torque the castle nut
to 8 ft-lbs / 11 Nm.
10 Install a new cotter pin. Bend the cotter pin
to lock it. Install the dust cap.
11 Install the tire and wheel assembly. Torque the
wheel lug nuts to 125 ft-lbs / 169.5 Nm.
Torque specifications
Lug nut torque, dry 125 ft-lbs
169.5 Nm
Lug nut torque, lubricated 94 ft-lbs
127.4 Nm
5 - 63
Section 5 • Repair Procedures First Edition • Third Printing

STEERING AXLE COMPONENTS

10-2 10-3
Steer Cylinder Tie Rod

How to Remove a Steer Cylinder How to Remove the Tie Rod

When removing a hose assembly 1 Before serial number 4526: Remove the cotter
or fitting, the O-ring on the fitting pins from the clevis pins at each end of the tie
and/or hose end must be replaced rod. Remove the clevis pins.
and then torqued to specification
After serial number 4525: Remove the
during installation.
retaining rings from the clevis pins at each end
Refer to Section Two, Hydraulic
of the tie rod. Remove the clevis pins.
Hose and Fitting Torque
Specifications. 2 Remove the tie rod from the machine.
1 Remove the drive chassis cover fasteners from Always use a new cotter pin when
the steer end of the machine. Remove the drive installing a clevis pin.
chassis cover.
2 Tag, disconnect and plug the hydraulic hoses
from the steer 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 to
squirt or spray.
3 Before serial number 4526: Remove the cotter
pins from the clevis pin from each end of the
steer cylinder. Remove the clevis pins.
After serial number 4525: Remove the cotter
pins from the clevis pin from each end of the
steer cylinder. Remove the clevis pins.
4 Remove the steering cylinder from the machine.
Always use a new cotter pin when
installing a clevis pin.

5 - 64 Genie Z-30/20N Part No. 35532

First Edition • Third Printing
Non-steering Axle Components
11-1
Drive Motor
How to Remove a Drive Motor
A drive motor can only be removed
from the inside of the drive
chassis.
1 Disconnect the battery packs from the machine.
2 Remove the drive chassis cover fasteners from
the non-steer end of the machine. Remove the
drive chassis cover.
3 Tag and disconnect the power cables from the
drive motor.
Electrocution hazard. Contact with
electrically charged circuits could
result in death or serious injury.
Remove all rings, watches and
other jewelry.
4 Remove the drive motor mounting fasteners.
5 Guide the drive motor shaft out of the brake and
remove the drive motor from the machine.
Part No. 35532 Genie Z-30/20N
Section 5 • Repair Procedures
11-2
Drive Hub
How to Remove a Drive Hub
The drive motor must be removed
in order to access the drive hub
mounting bolts.
When removing a hose assembly
or fitting, the O-ring on the fitting
and/or hose end must be replaced
and then torqued to specification
during installation.
Refer to Section Two, Hydraulic
Hose and Fitting Torque
Specifications.
1 Remove the drive motor. See 11-1,
How to Remove a Drive Motor.
2 Disconnect and plug the hydraulic hose from the
brake. Remove the hydraulic fitting and the
bleed valve from 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.
3 Chock the steer wheels.
4 Loosen the wheel lug nuts on the wheel of the
drive hub to be removed. Do not remove them.
5 - 65
Section 5 • Repair Procedures First Edition • Third Printing

NON-STEERING AXLE COMPONENTS

5 Center a lifting jack under the non-steer end of

the machine. Raise the machine and place
blocks under the chassis for support.
6 Remove the wheel lug nuts. Remove the tire and
wheel assembly.
7 Place a second lifting jack under the drive
hub for support. Secure the drive hub to the
lifting jack.
8 Remove the brake mounting bolts. Remove the
brake from the drive hub and set to the side.
Component damage hazard. Hoses
can be damaged if they are kinked
or pinched.
9 Remove the drive hub mounting bolts. Remove
the drive hub.
Crushing hazard. The drive
hub may become unbalanced and
fall when the mounting fasteners
are removed if not properly
supported and secured to the lifting
jack.

Torque specifications

Lug nut torque, dry 125 ft-lbs

169.5 Nm

Lug nut torque, lubricated 94 ft-lbs

127 Nm

Drive hub bolt torqe, dry 210 ft-lbs

285 Nm

Drive hub bolt torque, lubricated 94 ft-lb

127 Nm

5 - 66 Genie Z-30/20N Part No. 35532

First Edition • Third Printing Section 5 • Repair Procedures

12-1
Motor Controller
(after serial number 3446)
The drive motor controller is located under the non-
steer end drive chassis cover. The drive motor
controller can recognize machine drive
malfunctions and display motor controller fault
codes by flashing an LED at the ground controls
and on the motor controller. See the
Troubleshooting section of this manual for a list of
fault codes and additional information. There are no
adjustments needed on the drive joystick. For
further information or assistance, consult the Genie
Industries Service Department.
Motor Controller
4 Tag and disconnect all power cables from the
motor controller.
5 Press the release tab on the motor controller
harness connector and remove the motor
controller harness connector from the motor
controller.
6 Connect the leads from an ohmmeter to test
each motor controller terminal combination
listed below. Check for resistance.
Result: All desired results must be 500 kilohms
or more. If any test has a result of less than
500 kilohms, replace the motor controller.
Test Desired result
(in kilohms)

How to Test the Motor Controller F1 to F2 (500k W or more)

Use the following procedure to test F1 to B- (500k W or more)

the motor controller. If the motor
F1 to M- (500k W or more)
controller is found to be faulty,
note which test failed and which F1 to B+ (500k W or more)
fault code (if any) was present at
the time of failure. F2 to B- (500k W or more)

1 Turn the key switch to the OFF position. F2 to M- (500k W or more)

Disconnect the battery packs from the machine. F2 to B+ (500k W or more)
2 Remove the drive chassis cover fasteners from B- to M- (500k W or more)
the non-steer end of the machine. Remove the
drive chassis cover. M- to B+ (500k W or more)

3 Discharge the capacitors inside the motor Pin 17 to B- (500k W or more)

controller by connecting a 10-50 Wresistor or
the coil of a 24V DC relay between the B+ and Pin 20 to B- (500k W or more)
B- terminals of the motor controller. Hold for
approximately 5-10 seconds.
Electrocution hazard. Contact with
electrically charged circuits could
result in death or serious injury.
Remove all rings, watches and
other jewelry.

Part No. 35532 Genie Z-30/20N 5 - 67

Section 5 • Repair Procedures First Edition • Third Printing

This page intentionally left blank.

5 - 68 Genie Z-30/20N Part No. 35532

First Edition • Third Printing
Troubleshooting Flow Charts
Observe and Obey:
Troubleshooting and 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.
Unless otherwise specified, perform each
repair procedure with the machine in the
following configuration:
· Machine parked on a flat level surface
· Boom in stowed position
· Turntable rotated with the boom between
the non-steering wheels
· Key switch in the OFF position with the
key removed
· Wheels chocked
Part No. 35532
Section 6 • Troubleshooting Flow Charts
Before Troubleshooting:
Read, understand and obey the safety rules
and operating instructions printed in the
Genie Z-30/20N Operator’s Manual.
Be sure that all necessary tools and test
equipment are available and ready for use.
Read each appropriate flow chart thoroughly.
Attempting shortcuts may produce hazardous
conditions.
Be aware of the following hazards and follow
generally accepted safe workshop practices.
Crushing hazard. When testing
or replacing any hydraulic
component, always support
the structure and secure it
from movement.
Electrocution hazard. Contact
with electrically charged circuits
could result in death or serious
injury. Remove all rings, watches
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.
Genie Z-30/20N 6-1
Section 6 • Troubleshooting Flow Charts First Edition • Third Printing

TROUBLESHOOTING FLOW CHARTS

About This Section General Repair Process

When a malfunction is discovered, the flow charts

in this section will help a service professional Malfunction Identify Troubleshoot
pinpoint the cause of the problem. To use this discovered symptoms
section, basic hand tools and certain pieces of test
equipment are required—voltmeter, ohmmeter,
pressure gauges. problem
still exists
The location of terminals mentioned in this section
can be found on the appropriate electrical or Return to Inspect Perform
hydraulic schematics provided in Section 7, service problem and test repair
Schematics. solved

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, refer to the
flow chart which most closely describes the
problem.

Tip-over hazard. When adjusting On machines after serial number 3446, an LED
the raised drive speed settings, will flash a fault code to aid in troubleshooting.
the maximum raised drive speed This LED is mounted on the tilt level sensor
must not exceed 0.6 mph / 1Km/h mounting bracket, located behind the cover on
or 40 feet/45 seconds / the ground controls side.
12.2 meters / 45 seconds. If the
machine is allowed to drive faster
than specification, the machine
may become unstable and tip-over.
Additional troubleshooting of the
fault codes may by accomplished
by using the hand-held pendant
motor controller programmer
(Genie part number 56303).
When using the hand-held pendant
motor controller programmer, the
M1 MAX SPEED needs to be set
to 33. If needed, adjust the M1
MAX SPEED higher or lower to
achieve the maximum raised drive
speed of 0.6 mph / 1Km/h or
40 feet / 45 seconds /
12.2 meters / 45 seconds.

6-2 Genie Z-30/20N Part No. 35532

First Edition • Third Printing Section 6 • Troubleshooting Flow Charts

Fault Code Chart

(after serial number 3446)
Fault codes are two digits. The Fault Indicator Light will blink the first digit of a two digit code, pause for 1
second, and then blink the second digit. There will be a 2 second pause between codes. For example: the
Fault Indicator Light blinks 4 consecutive times, pauses for 1 second, and then blinks 1 time. That would
indicate Fault Code 41.

Programmer
Fault Code Condition Possible Causes Solution
Diagnostic Display

Turn the ground control

Emergency Stop button
The key switch or
to the OFF position and
Fault Indicator Machine will not drive. Emergency Stop
wait for 5 seconds. Pull
Controller fault indicator button(s) was cycled on
Light is OFF or COMMUNICATION out the ground control
light may or may not be and off faster than 5
is ON but not ERROR Emergency Stop button
on at the platform seconds OR controller
blinking to the ON position. If
controls. sensed an internal error
problem persists,
during start up.
replace the motor
controller.

01 Normal operation.
Machine will not drive.
Controller fault indicator The motor controller Replace the motor
12 HW FAILSAFE 1-2-3
light on at the platform failed self test. controller.
controls.
Machine will not drive. The motor controller
Test the motor
Controller fault indicator has a internal short
13 M- SHORTED
light on at the platform between M- and B-
controller. See Repair
Section.
controls. terminals.
Check for loose or open
connections at the drive
Machine will not drive. Motor wiring is loose motors and motor
Controller fault indicator OR motor is defective controller OR replace
FIELD OPEN
light on at the platform OR motor controller has the defective drive
controls. an internal short. motor OR test the motor
controller. See Repair
Section.
Machine will not drive.
Controller fault indicator Defective motor Replace the motor
ARM SENSOR
light on at the platform controller. controller.
controls.
Machine will not drive.
Controller fault indicator Defective motor Replace the motor
FLD SENSOR
light on at the platform controller. controller.
controls.

Part No. 35532 Genie Z-30/20N 6-3

Section 6 • Troubleshooting Flow Charts First Edition • Third Printing

FAULT CODE CHART (AFTER SERIAL NUMBER 3446)

Programmer
Fault Code Condition Possible Causes Solution
Diagnostic Display

Open in wht/red wire

#32 at pin 14 or red/wht
wire #29 at pin 16 on
the motor controller
Machine will not drive. going from drive joystick
Controller fault indicator to pins 14 and 16 at the
21 THROTTLE FAULT 1
light on at the platform motor controller OR pin
See Chart 29A
controls. 14 is internally shorted
to power or ground OR
the potentiometer on
the drive joystick is
defective.

Pin 14 (wht/red #32) is

Machine will not drive. shorted to power or
Controller fault indicator ground OR the
THROTTLE FAULT 2 See Chart 29A
light on at the platform potentiometer on the
controls. drive joystick is
defective.

Machine will not drive. Main contactor (PR1) Replace main contactor
Controller fault indicator coil defective OR brake PR1 or brake release
31 CONT DRVR OC
light on at the platform release relay CR5 relay CR5 OR replace
controls. defective. the motor controller.

Main contactor (PR1)

contacts stuck closed
OR grn wire at pin 17 on
Machine will not drive.
motor controller shorted
Controller fault indicator
32 MAIN CONT WELDED
light on at the platform
to ground OR open in See Chart 29B
motor armature wiring
controls.
OR motor controller has
an internal short to
ground.

6-4 Genie Z-30/20N Part No. 35532

First Edition • Third Printing Section 6 • Troubleshooting Flow Charts

FAULT CODE CHART (AFTER SERIAL NUMBER 3446)

Programmer
Fault Code Condition Possible Causes Solution
Diagnostic Display
Repair short between
B+ terminal on motor
controller and ground
External short between
Machine will not drive. OR replace motor
B+ terminal on motor
Controller fault indicator controller.
33 PRECHARGE FAULT
light on at the platform
controller and ground
Note: Short can be on
OR motor controller is
controls. any part of circuit
defective.
connected to the B+
terminal on the motor
controller.

Machine will not drive. Motor controller does

Controller fault indicator not detect the main
34 MISSING CONTACTOR
light on at the platform contactor PR1 or brake
See Chart 29C
controls. release relay CR5.

Main contactor PR1 or

brake release relay CR5
Machine will not drive. did not close OR open
Controller fault indicator in org/red wire to PR1
MAIN CONT DNC See Chart 29C
light on at the platform and/or CR5 OR main
controls. contactor and/or brake
release relay is
defective.

Completely charge
batteries OR check
Machine will not drive.
Battery supply voltage battery cable condition
LOW BATTERY Controller fault indicator
41 VOLTAGE light on at the platform
to motor controller less OR check for corrosion
than 32V. or loose connections at
controls.
battery terminals and
motor controller.

Part No. 35532 Genie Z-30/20N 6-5

Section 6 • Troubleshooting Flow Charts First Edition • Third Printing

FAULT CODE CHART (AFTER SERIAL NUMBER 3446)

Programmer
Fault Code Condition Possible Causes Solution
Diagnostic Display

Battery supply voltage

Be sure the battery
Machine will not drive. to motor controller more
charger is disconnected
Controller fault indicator than 55V OR machine
42 OVERVOLTAGE
light on at the platform is being operated with
OR check for loose
battery cables or poor
controls. the battery charger
connections.
plugged in.

Operate machine within

Machine being operated
specified temperature
outside of temperature
limits OR check for
range of -13°F to
Machine will not drive. debris around motor
185°F (-25°C to 85°C)
Controller fault indicator controller preventing
43 THERMAL CUTBACK
light on at the platform
OR machine being
proper cooling of the
driven under excessive
controls. controller OR check for
load OR motor
mechanical restrictions
controller is not being
causing excessive load
cooled sufficently.
on the machine.

6-6 Genie Z-30/20N Part No. 35532

First Edition • Third Printing
All Functions
Will Not
Operate
Be sure key switch is in
the appropriate position.
Be sure the Emergency
Stop buttons are pulled
out to the ON position.
Be sure the circuit
breaker and fuses are
not tripped or blown.
Be sure the battery
packs are properly
connected and fully
charged.
If the Error Indicator
light is on at the platform
controls, please refer to
the specific chart that
relates to the error code
that is displayed on the
ECM.
Part No. 35532
Section 6 • Troubleshooting Flow Charts
Chart 1
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Genie Z-30/20N 6-7
Section 6 • Troubleshooting Flow Charts First Edition • Third Printing

CHART 1

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6-8 Genie Z-30/20N Part No. 35532

First Edition • Third Printing Section 6 • Troubleshooting Flow Charts

CHART 1

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Part No. 35532 Genie Z-30/20N 6-9

Section 6 • Troubleshooting Flow Charts First Edition • Third Printing

Chart 2
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6 - 10 Genie Z-30/20N Part No. 35532

First Edition • Third Printing Section 6 • Troubleshooting Flow Charts

CHART 2

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Part No. 35532 Genie Z-30/20N 6 - 11

Section 6 • Troubleshooting Flow Charts First Edition • Third Printing

CHART 2

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6 - 12 Genie Z-30/20N Part No. 35532

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Part No. 35532 Genie Z-30/20N
Section 6 • Troubleshooting Flow Charts
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Section 6 • Troubleshooting Flow Charts First Edition • Third Printing

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6 - 14 Genie Z-30/20N Part No. 35532

First Edition • Third Printing Section 6 • Troubleshooting Flow Charts

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Part No. 35532 Genie Z-30/20N 6 - 15

Section 6 • Troubleshooting Flow Charts
Chart 3
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6 - 16 Genie Z-30/20N
First Edition • Third Printing
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Section 6 • Troubleshooting Flow Charts
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6 - 17
Section 6 • Troubleshooting Flow Charts First Edition • Third Printing

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6 - 18 Genie Z-30/20N Part No. 35532

First Edition • Third Printing Section 6 • Troubleshooting Flow Charts

Chart 4
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Part No. 35532 Genie Z-30/20N 6 - 19

Section 6 • Troubleshooting Flow Charts First Edition • Third Printing

Chart 5
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6 - 20 Genie Z-30/20N Part No. 35532

First Edition • Third Printing
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Part No. 35532 Genie Z-30/20N
Section 6 • Troubleshooting Flow Charts
CHART 5
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6 - 21
Section 6 • Troubleshooting Flow Charts First Edition • Third Printing

CHART 5

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ZNK]NZXKJ ]OXKGZ \GR\K

:(

'LZKXYKXOGRT[SHKX

 .URJZNKL[TIZOUT

KTGHRKZUMMRKY]OZINZU

KOZNKXYOJKGTJSU\K

GT_HUUSL[TIZOUT

ZUMMRKY]OZINGTJINKIQ

\URZGMKUTZNK]NZXKJ 8KVGOXUVKTOT]NZXKJ

]OXKGZ:( ]OXKIOXI[OZ]OZNJOUJK

LXUS:(ZUZNKHRQXKJ

]OXKGZZNKHUUS

L[TIZOUTYVKKJIUTZXURRKX

58XKVRGIKJOUJK58
<
ZXU[HRKYNUUZMXU[TJGTJ

VRGZLUXSIUTZXUR

L[TIZOUTYYKVGXGZKR_

XKLKXZUINGXZYGTJ

58IUTY[RZ-KTOK

/TJ[YZXOKY9KX\OIK

*KVGXZSKTZ

6 - 22 Genie Z-30/20N Part No. 35532

First Edition • Third Printing Section 6 • Troubleshooting Flow Charts

Chart 6
Ground )NKIQ\URZGMKGZZNKXKJ 8KVGOXUVKTOTZNKXKJ

Controls ]OXKUTZNKOTV[ZYOJKUL

ZNKMXU[TJIUTZXURY <
]OXKIOXI[OZLXUSZNK

+SKXMKTI_9ZUVH[ZZUT

Inoperative, IUTZGIZULZNKQK_Y]OZIN

ZNOY]OXKYNU[RJ
ZUZNKOTV[ZYOJKULZNK

MXU[TJIUTZXURYIUTZGIZ

Platform UXOMOTGZKGZZNK

+SKXMKTI_9ZUV
ULZNKQK_Y]OZIN

Controls H[ZZUT

Operate <

Normally
:[XTQK_Y]OZINZU
<
Be sure key switch is in MXU[TJIUTZXURYGTJV[RR
)NKIQZUYKKOLZNKQK_ 8KVRGIKZNKQK_Y]OZIN
_KY
Y]OZINOTZKXTGRIGSOY IUTZGIZLUXMXU[TJ

HUZN+SKXMKTI_9ZUV GIZO\GZOTMZNKMXU[TJ IUTZXURY

the appropriate position. H[ZZUTYU[ZZUZNK 54 IUTZXURYIUTZGIZ

VUYOZOUT)NKIQ\URZGMK

Be sure the Emergency GZZNKU[ZV[ZYOJKUL TU

Stop buttons are pulled MXU[TJIUTZXURYIUTZGIZ

ULZNKQK_Y]OZIN 8KVRGIKZNKQK_Y]OZIN
out to the ON position.
<
Be sure the battery
packs are properly
(KLUXKYKXOGRT[SHKX )NKIQZNK\URZGMKUT 8KVGOXUVKTOTXKJ]OXK
connected and fully  .URJZNKYKIUTJGX_ < ZNKXKJ]OXKGZIKTZKX < IOXI[OZY[VVR_OTM<ZU

charged. HUUSZUMMRKY]OZIN ZKXSOTGRULKGINMXU[TJ ZNKIKTZKXZKXSOTGRUL

:9OTZNK ;6 IUTZXURZUMMRKY]OZIN KGINMXU[TJIUTZXUR

JOXKIZOUTGTJINKIQ ZUMMRKY]OZIN

\URZGMKGZ:(
<
'LZKXYKXOGRT[SHKX

 3U\KZNKL[TIZOUT

KTGHRKZUMMRKY]OZINZU 8KVGOXUVKTOT]NZXKJ

KOZNKXYOJKGTJNURJZNK ]OXKIOXI[OZ]OZNJOUJK

YKIUTJGX_HUUSZUMMRK LXUS:9ZU:(58

Y]OZIN XKVRGIKZNKJOUJK

(KLUXKYKXOGRT[SHKX

 :9

'LZKXYKXOGRT[SHKX

 :9

;6JOXKIZOUTGTJ
OTZNK

INKIQ\URZGMKGZ:(

<

3U\KZNKL[TIZOUT 8KVGOXUVKTOTMXT]NZ

KTGHRKZUMMRKY]OZINZU ]OXKIOXI[OZ]OZNJOUJK
<
KOZNKXYOJKGTJNURJZNK LXUSHUUSL[TIZOUT

YKIUTJGX_HUUSZUMMRK ZUMMRKY]OZINKYZU:(

;6
Y]OZINOTZNK 58XKVRGIKZNKJOUJK

JOXKIZOUT)NKIQ\URZGMK

GZ:(

<

)UTY[RZ-KTOK/TJ[YZXOKY

9KX\OIK*KVGXZSKTZ

Part No. 35532 Genie Z-30/20N 6 - 23

Section 6 • Troubleshooting Flow Charts First Edition • Third Printing

Chart 7
Platform :[XTQK_Y]OZINZU 8KVGOXUVKTOTZNKXKJ
VRGZLUXSIUTZXURYGTJ ]OXKIOXI[OZLXUSZNK
Controls V[RRHUZN+SKXMKTI_ < +SKXMKTI_9ZUVH[ZZUT
Inoperative, 9ZUVH[ZZUTYU[ZZUZNK ZUZNKOTV[ZYOJKULZNK
54VUYOZOUT)NKIQ VRGZLUXSIUTZXURYIUTZGIZ
Ground \URZGMKGZZNKXKJ]OXK ULZNKQK_Y]OZIN
UTZNKOTV[ZYOJKULZNK
Controls VRGZLUXSIUTZXURYIUTZGIZ
ULQK_Y]OZINZNOY]OXK
Operate YNU[RJUXOMOTGZKGZZNK
+SKXMKTI_9ZUV
Normally H[ZZUT
(before serial <UXSUXK
number 3447)
)NKIQ\URZGMKGZZNK )NKIQZUYKKOLZNKQK_ _KY 8KVRGIKZNKQK_Y]OZIN
Be sure key switch is in U[ZV[ZYOJKULVRGZLUXS < Y]OZINOTZKXTGRIGSOY IUTZGIZLUXVRGZLUXS
the appropriate position. IUTZXURYIUTZGIZULZNK GIZO\GZOTMZNKVRGZLUXS IUTZXURY
QK_Y]OZIN IUTZXURYIUTZGIZ
Be sure the Emergency
Stop buttons are pulled TU
out to the ON position.
<UXSUXK 8KVRGIKZNKQK_Y]OZIN
Be sure the battery
packs are properly
connected and fully <
charged. )NKIQ\URZGMKGZ:( 8KVGOXUVKTOTHRQ 
]OXKIOXI[OZLXUSQK_
Y]OZINZU:(
<UXSUXK

)NKIQ\URZGMKGZZNK 8KVGOXUVKTOTHRQ
OTV[ZYOJKULZNKVRGZLUXS < ]OXKIOXI[OZLXUS:(ZU
+SKXMKTI_9ZUVH[ZZUT VRGZLUXS+SKXMKTI_
IUTZGIZ 9ZUVH[ZZUT58XKVGOX
UVKTOTMXU[TJ]OXK
IOXI[OZLXUSVRGZLUXS
IUTZXURYZUMXU[TJ
<UXSUXK

)NKIQ\URZGMKGZZNK < )NKIQZUYKKOLZNK _KY 8KVRGIKZNKVRGZLUXS

U[ZV[ZYOJKULVRGZLUXS +SKXMKTI_9ZUVH[ZZUT +SKXMKTI_9ZUVH[ZZUT
+SKXMKTI_9ZUVH[ZZUT OYGIZO\GZOTMZNKIUTZGIZ IUTZGIZ
IUTZGIZ
TU

<UXSUXK 8KVRGIKZNKVRGZLUXS
+SKXMKTI_9ZUVH[ZZUT

)UTZOT[KJUTZNKTK^Z
VGMK

6 - 24 Genie Z-30/20N Part No. 35532

First Edition • Third Printing
)UTZOT[KJLXUSZNK
VXK\OU[YVGMK
Part No. 35532
Section 6 • Troubleshooting Flow Charts
CHART 7
)NKIQZNK\URZGMKGZZNK 8KVGOXUVKTOTZNK]OXK
OTV[ZYOJKULZNKLUUZ < IOXI[OZLXUSZNKVRGZLUXS
Y]OZIN +SKXMKTI_9ZUVH[ZZUT
6ZULUUZY]OZIN
<UXSUXK
6XKYYJU]TLUUZY]OZIN < 8KVRGIKLUUZY]OZIN
GTJINKIQ\URZGMKUT IUTZGIZY58XKVRGIKZNK
(KLUXKYKXOGRT[SHKX LUUZY]OZIN
 ZNK]NZ]OXKGZZNK
LUUZY]OZIN
'LZKXYKXOGRT[SHKX
 ZNKHR[]NZ]OXKGZ
ZNKLUUZY]OZIN
<UXSUXK
6XKYYJU]TLUUZY]OZIN < 8KVGOXUVKTOTZNK
GTJINKIQ\URZGMKGZ HR[]NZ]OXKIOXI[OZ
:( LXUSLUUZY]OZINZU:(
<UXSUXK
6XKYYJU]TLUUZY]OZIN < 8KVGOXUVKTOTZNK
GTJINKIQ\URZGMKGZ HRQ ]OXKIOXI[OZLXUS
HRQ ]OXKUT29 :(ZU29
<UXSUXK
<
6XKYYJU]TLUUZY]OZIN 8KVRGIK29
GTJINKIQ\URZGMKGZ
XKJ ]OXKUT29
<UXSUXK
6XKYYJU]TLUUZY]OZIN < 8KVGOXUVKTOTXKJ 
GTJINKIQ\URZGMKGZ ]OXKLXUS29ZU:(
:(
<UXSUXK
)UTZOT[KJUTZNKTK^Z
VGMK
Genie Z-30/20N 6 - 25
Section 6 • Troubleshooting Flow Charts
CHART 7
6XKYYJU]TLUUZY]OZIN
)UTZOT[KJLXUSZNK <
VXK\OU[YVGMK GTJINKIQ\URZGMKGZ
ZKXSOTGRUTZNKJXO\K
IUTZXURRKX
<UXSUXK
:[XTZNKHUUSL[TIZOUT
YVKKJIUTZXURRKXZU
VXKYYJU]TLUUZY]OZIN <
GTJSU\KGT_HUUS
L[TIZOUTZUMMRKY]OZIN
GTJINKIQZNK\URZGMKGZ
ZNKXKJ]OXKUTZNK
HUUSL[TIZOUTYVKKJ
IUTZXURRKX
<UXSUXK
6XKYYJU]TLUUZY]OZIN
GTJSU\KGT_HUUS
L[TIZOUTZUMMRKY]OZIN <
GTJINKIQZNK\URZGMKGZ
ZNKHRQXKJ]OXKUTZNK
HUUSL[TIZOUTYVKKJ
IUTZXURRKX
<UXSUXK
6XKYYJU]TLUUZY]OZIN
GTJSU\KGT_HUUS <
L[TIZOUTZUMMRKY]OZIN
GTJINKIQ\URZGMKGZ
:(
<UXSUXK
)UTZOT[KJUTZNKTK^Z
VGMK
6 - 26 Genie Z-30/20N
First Edition • Third Printing
(KLUXKYKXOGRT[SHKX
 8KVGOXUVKTOTZNK
UXMXKJ]OXKIOXI[OZ
LXUS:(ZUZKXSOTGR
UTZNKJXO\K
IUTZXURRKX
'LZKXYKXOGRT[SHKX
 8KVGOXUVKTOTZNK
UXMXKJ]OXKIOXI[OZ
LXUS:(ZU)858
XKVGOXUXXKVRGIK)8
58XKVGOXUVKTOTZNK
HXTMXU[TJ]OXKIOXI[OZ
LXUS)8ZUMXU[TJ
8KVGOXUVKTOTZNK
VU]KXY[VVR_IOXI[OZ
LXUSKGINOTJO\OJ[GR
HUUSZUMMRKY]OZINZU
ZNKHUUSL[TIZOUTYVKKJ
IUTZXURRKX
'JP[YZHUUSL[TIZOUT
YVKKJIUTZXURRKX58
XKVRGIKHUUSL[TIZOUT
YVKKJIUTZXURRKX58
IUTY[RZ-KTOK/TJ[YZXOKY
9KX\OIK*KVGXZSKTZ
8KVGOXUVKTOT]OXK
IOXI[OZ]OZNJOUJKLXUS
ZNKHUUSL[TIZOUTYVKKJ
IUTZXURRKXZU:(58
XKVRGIKJOUJK
Part No. 35532
First Edition • Third Printing
)UTZOT[KJLXUSZNK
VXK\OU[YVGMK
Part No. 35532
Section 6 • Troubleshooting Flow Charts
CHART 7
=OZNZNKHUUSL[TIZOUT 8KVGOXUVKTOT]NZXKJ
YVKKJIUTZXURRKXZ[XTKJ < ]OXKIOXI[OZLXUS
ZUVXKYYJU]TLUUZ VXUVUXZOUTGR\GR\KIUORZU
Y]OZINGTJSU\KGT_ :(
HUUSL[TIZOUTZUMMRK
Y]OZINGTJINKIQ
\URZGMKGZZNK]NZXKJ
]OXKUTZNKVXUVUXZOUTGR
\GR\KIUOR
(KLUXKYKXOGRT[SHKX
 OZKS;
'LZKXYKXOGRT[SHKX

OZKS55
<UXSUXK
UX
*OYIUTTKIZZNK]OXKZU OTLOTOZK
ZNKVXUVUXZOUTGR\GR\K UNSY
IUOR:KYZZNKXKYOYZGTIK 8KVRGIKVXUVUXZOUTGR
ULZNK\GR\KIUOR9KK \GR\KIUOR
8KVGOX9KIZOUT
ZUUNSY
(KLUXKYKXOGRT[SHKX
 8KVGOXUVKTOTZNK
HR[]NZ]OXKIOXI[OZLXUS
ZNKVXUVUXZOUTGR\GR\K
IUORZU:(ZUZNKHUUS
L[TIZOUTYVKKJIUTZXURRKX
58XKVRGIKVXUVUXZOUTGR
\GR\KOZKS;58
ZXU[HRKYNUUZROLZGTJ
JXO\KL[TIZOUTY
OTJO\OJ[GRR_58IUTY[RZ
-KTOK/TJ[YZXOKY9KX\OIK
*KVGXZSKTZ
'LZKXYKXOGRT[SHKX
 8KVGOXUVKTOTHXT
MXU[TJ]OXKIOXI[OZLXUS
VXUVUXZOUTGR\GR\KZU
MXU[TJ58XKVRGIK
VXUVUXZOUTGR\GR\KOZKS
;58ZXU[HRKYNUUZROLZ
GTJJXO\KL[TIZOUTY
OTJO\OJ[GRR_58IUTY[RZ
-KTOK/TJ[YZXOKY9KX\OIK
*KVGXZSKTZ
Genie Z-30/20N 6 - 27
Section 6 • Troubleshooting Flow Charts First Edition • Third Printing

Chart 8
Platform :[XTQK_Y]OZINZU 8KVGOXUVKTOTXKJ]OXK

Controls VRGZLUXSIUTZXURYGTJ

V[RRHUZN+SKXMKTI_
< IOXI[OZLXUS+SKXMKTI_

9ZUVH[ZZUTZUZNKQK_

Inoperative, 9ZUVH[ZZUTYU[ZZUZNK

54VUYOZOUT)NKIQ
Y]OZIN

Ground \URZGMKGZZNKXKJ]OXK

UTZNKOTV[ZYOJKULZNK

Controls VRGZLUXSIUTZXURYIUTZGIZ

ULZNKQK_Y]OZINZNOY

Operate ]OXKYNU[RJUXOMOTGZKGZ

+SKXMKTI_9ZUVH[ZZUT

Normally 6

(after serial <

number 3446)
)NKIQ\URZGMKUTZNK )NKIQZUYKKOLZNKQK_ 8KVRGIKZNKQK_Y]OZIN
_KY
Be sure key switch is in U[ZV[ZYOJKULZNK < Y]OZINOTZKXTGRIGSOY IUTZGIZLUXVRGZLUXS

VRGZLUXSIUTZXURYIUTZGIZ GIZO\GZOTMZNKVRGZLUXS IUTZXURY

the appropriate position. UTZNKQK_Y]OZIN IUTZXURYIUTZGIZ

Be sure the Emergency TU

Stop buttons are pulled
out to the ON position. <
8KVRGIKZNKQK_Y]OZIN

Be sure the battery

packs are properly
<
connected and fully )NKIQ\URZGMKGZ:( 8KVGOXUVKTOTHRQ 

charged. ]OXKIOXI[OZLXUSQK_

Y]OZINZU:(

<

)NKIQ\URZGMKGZZNK 8KVGOXUVKTOTHRQ

OTV[ZYOJKULZNKVRGZLUXS < ]OXKIOXI[OZLXUS:(ZU

+SKXMKTI_9ZUVH[ZZUT ZNKVRGZLUXS+SKXMKTI_

IUTZGIZ 9ZUVH[ZZUT58XKVGOX

UVKTOTHXTMXU[TJ]OXK

IOXI[OZLXUS:(ZUZNK

VRGZLUXS

<

)NKIQ\URZGMKGZZNK )NKIQZUYKKOLZNK 8KVRGIKZNKVRGZLUXS

< _KY
U[ZV[ZYOJKULVRGZLUXS +SKXMKTI_9ZUVH[ZZUT +SKXMKTI_9ZUVH[ZZUT

+SKXMKTI_9ZUVH[ZZUT OYGIZO\GZOTMZNKIUTZGIZ IUTZGIZ

IUTZGIZ

TU

8KVRGIKZNKVRGZLUXS
<
+SKXMKTI_9ZUVH[ZZUT

)UTZOT[KJUTZNKTK^Z

VGMK

6 - 28 Genie Z-30/20N Part No. 35532

First Edition • Third Printing Section 6 • Troubleshooting Flow Charts

CHART 8

:[XTQK_Y]OZINZU < :KYZZNKLUUZY]OZIN9KK MUUJ 8KVGOXUVKTOT]NZ,9

)UTZOT[KJLXUSZNK
VRGZLUXSIUTZXURYGTJ 8KVGOX9KIZOUT ]OXKIOXI[OZLXUSLUUZ
VXK\OU[YVGMK
V[RRHUZN+SKXMKTI_ Y]OZINZUZNKIKTZKX

9ZUVH[ZZUTYU[ZZUZNK ZKXSOTGRUL:9ZU
HGJ
54VUYOZOUT6XKYYJU]T ZKXSOTGRUTZNKJXO\K

ZNKLUUZY]OZINGTJ IUTZXURRKX

INKIQ\URZGMKGZ 8KVRGIKZNKLUUZY]OZIN

ZKXSOTGRUTZNKJXO\K

IUTZXURRKX

<

6XKYYJU]TZNKLUUZ 6XKYYJU]TZNKLUUZ 8KVGOXUVKTOTXKJ]OXK

Y]OZINGTJINKIQ < Y]OZINGTJINKIQ < IOXI[OZLXUSZKXSOTGRZU

\URZGMKGZZNKIKTZKX \URZGMKGZZNKZKXSOTGR ZKXSOTGRUTZNKJXO\K

ZKXSOTGRULKGINL[TIZOUT UTZNKJXO\KIUTZXURRKX IUTZXURRKXZUKGIN

ZUMMRKY]OZIN L[TIZOUTZUMMRKY]OZIN

<

8KVRGIKZNKJXO\K

IUTZXURRKXUXIUTY[RZ

< -KTOK/TJ[YZXOKY9KX\OIK

*KVGXZSKTZ

6XKYYJU]TZNKLUUZ 8KVGOXUVKTOTVU]KX

Y]OZINGTJSU\KGT_ Y[VVR_IOXI[OZZUHUUS

HUUSL[TIZOUTZUMMRK < L[TIZOUTYVKKJIUTZXURRKX

Y]OZINGTJINKIQ LXUSKGINOTJO\OJ[GR

\URZGMKGZZNKXKJ]OXK HUUSL[TIZOUTZUMMRK

UTZNKHUUSL[TIZOUT Y]OZIN58IUTY[RZ-KTOK

YVKKJIUTZXURRKX /TJ[YZXOKY9KX\OIK

*KVGXZSKTZ

<

=OZNZNKHUUSL[TIZOUT 'JP[YZHUUSL[TIZOUT
RKYY
YVKKJIUTZXURRKXYKZZU YVKKJIUTZXURRKXYKK
ZNGT
VXKYYJU]TZNKLUUZ 8KVGOX9KIZOUT58
<
Y]OZINGTJSU\KGT_ XKVRGIKHUUSL[TIZOUT

HUUSL[TIZOUTZUMMRK YVKKJIUTZXURRKX58

Y]OZINGTJINKIQ IUTY[RZ-KTOK/TJ[YZXOKY

\URZGMKGZZNKHRQXKJ 9KX\OIK*KVGXZSKTZ

]OXKUTHUUSL[TIZOUT

YVKKJIUTZXURRKX

<UXSUXK

)UTZOT[KJUTZNKTK^Z

VGMK

Part No. 35532 Genie Z-30/20N 6 - 29

Section 6 • Troubleshooting Flow Charts First Edition • Third Printing

CHART 8

6XKYYJU]TZNKLUUZ
)UTZOT[KJLXUSZNK
Y]OZINGTJSU\KGT_
VXK\OU[YVGMK <
HUUSL[TIZOUTZUMMRK
8KVRGIKZNKJOUJKUT
ZNKHRQXKJ]OXKUTHUUS
L[TIZOUTYVKKJIUTZXURRKX

Y]OZINGTJINKIQ 58XKVGOXUVKTOT]NZ

\URZGMKGZ:( XKJ]OXKIOXI[OZLXUS

HUUSL[TIZOUTYVKKJ

IUTZXURRKXZU:(

<UXSUXK

6XKYYJU]TZNKLUUZ 8KVGOXUVKTOT]NZXKJ
<
Y]OZINGTJSU\KGT_ ]OXKLXUS:(ZUZNK

HUUSL[TIZOUTZUMMRK VXUVUXZOUTGR\GR\K

Y]OZINGTJINKIQ

\URZGMKGZZNK]NZXKJ

]OXKUTZNKVXUVUXZOUTGR

\GR\KOZKS55

<UXSUXK

8KVGOXUVKTOTHXT

MXU[TJ]OXKIOXI[OZZUZNK

VXUVUXZOUTGR\GR\K

58ZXU[HRKYNUUZROLZGTJ

JXO\KL[TIZOUTY

OTJO\OJ[GRR_58IUTY[RZ

-KTOK/TJ[YZXOKY9KX\OIK

*KVGXZSKTZ

6 - 30 Genie Z-30/20N Part No. 35532

First Edition • Third Printing Section 6 • Troubleshooting Flow Charts

Chart 9
Primary Boom :[XTQK_Y]OZINZU (KLUXKYKXOGRT[SHKX 8KVGOXUVKTOTZNK

Up Function MXU[TJIUTZXURYGTJV[RR

HUZN+SKXMKTI_9ZUV
 3U\KZNKVXOSGX_

HUUSZUMMRKY]OZINOT
]NZXKJ ]OXKIOXI[OZ

LXUS:(ZUZNKHUUS

54 ;6JOXKIZOUTGTJ
Inoperative H[ZZUTYU[ZZUZNK

VUYOZOUT
ZNK

INKIQ\URZGMKGZ:( <
L[TIZOUTVXUVUXZOUTGR

\GR\KIUOR58XKVGOX

(KLUXKYKXOGRT[SHKX 'LZKXYKXOGRT[SHKX UVKTOTZNKHXTMXU[TJ

Be sure key switch is in  3U\KZNKVXOSGX_
<
 .URJZNKL[TIZOUT ]OXKIOXI[OZLXUSZNK

the appropriate position. HUUSZUMMRKY]OZIN KTGHRKZUMMRKY]OZINZU HUUSL[TIZOUT

:9OTZNK;6JOXKIZOUT KOZNKXYOJKGTJSU\KZNK VXUVUXZOUTGR\GR\KIUORZU

GTJINKIQ\URZGMKUT VXOSGX_HUUSZUMMRK MXU[TJ

Be sure the Emergency
ZNK]NZXKJ ]OXKGZ Y]OZINOTZNK[VJOXKIZOUT
Stop buttons are pulled ZNKHUUSL[TIZOUT GTJINKIQ\URZGMKGZ

out to the ON position. VXUVUXZOUTGR\GR\KIUOR :(

OZKS;

Be sure the battery ,XUSYKXOGRT[SHKX <

ZU .URJZNK
packs are properly L[TIZOUTKTGHRKZUMMRK :[XTQK_Y]OZINZU 8KVGOXUVKTOTZNKHRQ
<
connected and fully Y]OZINZUKOZNKXYOJKGTJ VRGZLUXSIUTZXURYGTJ XKJ]OXKZUZNK]NZXKJ

SU\KZNKVXOSGX_HUUS V[RRHUZN+SKXMKTI_ ]OXKZU:(

charged.
ZUMMRKY]OZIN:9OT 9ZUVH[ZZUTYU[ZZUZNK

;6JOXKIZOUTGTJ
ZNK 54VUYOZOUT=OZNZNK
INKIQ\URZGMKUTZNK HUUSL[TIZOUTYVKKJ

]NZXKJ ]OXKGZZNK IUTZXURRKXZ[XTKJZU

HUUSL[TIZOUT VXKYYJU]TZNKLUUZ

VXUVUXZOUTGR\GR\KIUOR Y]OZINGTJSU\KZNK

OZKS; VXOSGX_HUUSZUMMRK

'LZKXYKXOGRT[SHKX Y]OZIN

 .URJZNKL[TIZOUT (KLUXKYKXOGRT[SHKX

KTGHRKZUMMRKY]OZINZU  :9

KOZNKXYOJKGTJSU\KZNK 'LZKXYKXOGRT[SHKX

VXOSGX_HUUSZUMMRK  :9

Y]OZIN:9OTZNK ;6 OTZNK ;6JOXKIZOUT

JOXKIZOUTGTJINKIQ )NKIQ\URZGMKGZ:(

\URZGMKUTZNK]NZXKJ

]OXKGZZNKHUUS
<
L[TIZOUTVXUVUXZOUTGR

\GR\KIUOROZKS55
6XKYYJU]TZNKLUUZ 8KVGOXUVKTOTZNK]OXK

Y]OZINGTJSU\KZNK IOXI[OZZNXU[MNZNKHUUS

VXOSGX_HUUSZUMMRK < L[TIZOUTZUMMRKY]OZINKY

Y]OZINOTZNK ;6 ZUZNKXKJ]OXKUTZNK

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Section 6 • Troubleshooting Flow Charts First Edition • Third Printing

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6 - 36 Genie Z-30/20N Part No. 35532

First Edition • Third Printing
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Section 6 • Troubleshooting Flow Charts First Edition • Third Printing

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6 - 38 Genie Z-30/20N Part No. 35532

First Edition • Third Printing
)UTZOT[KJLXUSZNK
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Part No. 35532
Section 6 • Troubleshooting Flow Charts
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Genie Z-30/20N 6 - 39
Section 6 • Troubleshooting Flow Charts First Edition • Third Printing

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6 - 40 Genie Z-30/20N Part No. 35532

First Edition • Third Printing Section 6 • Troubleshooting Flow Charts

CHART 12

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Part No. 35532 Genie Z-30/20N 6 - 41

Section 6 • Troubleshooting Flow Charts First Edition • Third Printing

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6 - 42 Genie Z-30/20N Part No. 35532

First Edition • Third Printing
Primary Boom
Extend
Function
Inoperative
(before serial
number 5398)
Be sure key switch is in
the appropriate position.
Be sure the Emergency
Stop buttons are pulled
out to the ON position.
Be sure the battery
packs are properly
connected and fully
charged.
Part No. 35532
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Genie Z-30/20N
Section 6 • Troubleshooting Flow Charts
Chart 13
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6 - 43
Section 6 • Troubleshooting Flow Charts First Edition • Third Printing

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6 - 44 Genie Z-30/20N Part No. 35532

First Edition • Third Printing
)UTZOT[KJLXUSVGMK
Part No. 35532
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6 - 45
Section 6 • Troubleshooting Flow Charts First Edition • Third Printing

CHART 13

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6 - 46 Genie Z-30/20N Part No. 35532

First Edition • Third Printing Section 6 • Troubleshooting Flow Charts

Primary Boom
Extend
Function
Inoperative
(after serial
number 5397)
Be sure key switch is in
the appropriate position.
Be sure the Emergency
Stop buttons are pulled
out to the ON position.
Be sure the battery
packs are properly
connected and fully
charged.
:[XTQK_Y]OZINZU
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Part No. 35532 Genie Z-30/20N 6 - 47

Section 6 • Troubleshooting Flow Charts First Edition • Third Printing

CHART 14

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6 - 48 Genie Z-30/20N Part No. 35532

First Edition • Third Printing
)UTZOT[KJLXUSZNK
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Part No. 35532
Section 6 • Troubleshooting Flow Charts
CHART 14
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Genie Z-30/20N 6 - 49
Section 6 • Troubleshooting Flow Charts
Chart 15
Primary Boom :[XTQK_Y]OZINZU
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6 - 50 Genie Z-30/20N
First Edition • Third Printing
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Part No. 35532
First Edition • Third Printing Section 6 • Troubleshooting Flow Charts

CHART 15

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Part No. 35532 Genie Z-30/20N 6 - 51

Section 6 • Troubleshooting Flow Charts
CHART 15
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6 - 52 Genie Z-30/20N
First Edition • Third Printing
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Part No. 35532
First Edition • Third Printing Section 6 • Troubleshooting Flow Charts

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Part No. 35532 Genie Z-30/20N 6 - 53

Section 6 • Troubleshooting Flow Charts First Edition • Third Printing

Chart 16
Turntable :[XTQK_Y]OZINZU
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Rotate Left HUZN+SKXMKTI_9ZUV
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Part No. 35532 Genie Z-30/20N 6 - 55

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Part No. 35532 Genie Z-30/20N 6 - 59

Section 6 • Troubleshooting Flow Charts First Edition • Third Printing

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6 - 60 Genie Z-30/20N Part No. 35532

First Edition • Third Printing Section 6 • Troubleshooting Flow Charts

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6 - 63
Section 6 • Troubleshooting Flow Charts First Edition • Third Printing

CHART 18

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6 - 64 Genie Z-30/20N Part No. 35532

First Edition • Third Printing Section 6 • Troubleshooting Flow Charts

Turntable
Rotate Right
Function
Inoperative
(after serial
number 3446)
Be sure key switch is in
the appropriate position.
Be sure the Emergency
Stop buttons are pulled
up to the ON position.
Be sure the battery
packs are properly
connected and fully
charged.
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Part No. 35532 Genie Z-30/20N 6 - 65

Section 6 • Troubleshooting Flow Charts First Edition • Third Printing

CHART 19

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6 - 66 Genie Z-30/20N Part No. 35532

First Edition • Third Printing Section 6 • Troubleshooting Flow Charts

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Part No. 35532 Genie Z-30/20N 6 - 67

Section 6 • Troubleshooting Flow Charts First Edition • Third Printing

Chart 20
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6 - 68 Genie Z-30/20N Part No. 35532

First Edition • Third Printing Section 6 • Troubleshooting Flow Charts

CHART 20

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Part No. 35532 Genie Z-30/20N 6 - 69

Section 6 • Troubleshooting Flow Charts First Edition • Third Printing

Chart 21
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6 - 70 Genie Z-30/20N Part No. 35532

First Edition • Third Printing Section 6 • Troubleshooting Flow Charts

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Part No. 35532 Genie Z-30/20N 6 - 71

Section 6 • Troubleshooting Flow Charts
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First Edition • Third Printing Section 6 • Troubleshooting Flow Charts

Platform Level
Down Function
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Section 6 • Troubleshooting Flow Charts First Edition • Third Printing

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Part No. 35532
Section 6 • Troubleshooting Flow Charts
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Section 6 • Troubleshooting Flow Charts First Edition • Third Printing

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Part No. 35532 Genie Z-30/20N 6 - 83

Section 6 • Troubleshooting Flow Charts First Edition • Third Printing

Chart 24
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Left Function
Inoperative
(after serial
number 4082)
Be sure key switch is in
the appropriate position.
Be sure the Emergency
Stop buttons are pulled
up to the ON position.
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packs are properly
connected and fully
charged.
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Section 6 • Troubleshooting Flow Charts First Edition • Third Printing

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6 - 86 Genie Z-30/20N Part No. 35532

First Edition • Third Printing Section 6 • Troubleshooting Flow Charts

Platform Rotate
Right Function
Inoperative
(before serial
number 4083)
Be sure key switch is in
the appropriate position.
Be sure the Emergency
Stop buttons are pulled
out to the ON position.
Be sure the battery
packs are properly
connected and fully
charged.
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Part No. 35532 Genie Z-30/20N 6 - 87

Section 6 • Troubleshooting Flow Charts First Edition • Third Printing

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Section 6 • Troubleshooting Flow Charts First Edition • Third Printing

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6 - 90 Genie Z-30/20N Part No. 35532

First Edition • Third Printing Section 6 • Troubleshooting Flow Charts

Platform Rotate
Right Function
Inoperative
(after serial
number 4082)
Be sure key switch is in
the appropriate position.
Be sure the Emergency
Stop buttons are pulled
out to the ON position.
Be sure the battery
packs are properly
connected and fully
charged.
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Part No. 35532 Genie Z-30/20N 6 - 91

Section 6 • Troubleshooting Flow Charts
CHART 26
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Part No. 35532
First Edition • Third Printing
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Part No. 35532
Section 6 • Troubleshooting Flow Charts
CHART 26
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Genie Z-30/20N 6 - 93
Section 6 • Troubleshooting Flow Charts
Chart 27
Jib Boom Up :[XTQK_Y]OZINZU
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Function HUZN+SKXMKTI_9ZUV
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number 4083) ZUMMRKY]OZIN:9OT
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out to the ON position. L[TIZOUTKTGHRKZUMMRK
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packs are properly ZUMMRKY]OZIN:9OT
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Part No. 35532
First Edition • Third Printing Section 6 • Troubleshooting Flow Charts

CHART 27

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Part No. 35532 Genie Z-30/20N 6 - 95

Section 6 • Troubleshooting Flow Charts
CHART 27
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Part No. 35532
First Edition • Third Printing Section 6 • Troubleshooting Flow Charts

CHART 27

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9KX\OIK*KVGXZSKTZ

Part No. 35532 Genie Z-30/20N 6 - 97

Section 6 • Troubleshooting Flow Charts First Edition • Third Printing

Chart 28
Jib Boom Up :[XTQK_Y]OZINZU
MXU[TJIUTZXURYGTJV[RR
Function HUZN+SKXMKTI_9ZUV
<
Inoperative H[ZZUTYU[ZZUZNKUT
VUYOZOUT.URJZNK
(after serial L[TIZOUTKTGHRKZUMMRK
Y]OZINZUKOZNKXYOJKGTJ
number 4082) SU\KZNKPOHHUUS
ZUMMRKY]OZIN:9OT
Be sure key switch is in ZNK;6JOXKIZOUTGTJ
INKIQZNK\URZGMKUTZNK
the appropriate position. ]NZXKJ ]OXKGZZNK
HUUSL[TIZOUT
Be sure the Emergency VXUVUXZOUTGR\GR\KIUOR
Stop buttons are pulled OZKS55
out to the ON position.
Be sure the battery
packs are properly
connected and fully
charged.
.URJZNKL[TIZOUTKTGHRK 8KVGOXUVKTOT]NZXKJ
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6 - 98 Genie Z-30/20N Part No. 35532

First Edition • Third Printing
)UTZOT[KJLXUSZNK
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Part No. 35532
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Genie Z-30/20N
Section 6 • Troubleshooting Flow Charts
CHART 28
.URJZNKL[TIZOUTKTGHRK 8KVGOXUVKTOTMXT]OXK
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6 - 99
Section 6 • Troubleshooting Flow Charts First Edition • Third Printing

CHART 28

UX
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6 - 100 Genie Z-30/20N Part No. 35532

First Edition • Third Printing Section 6 • Troubleshooting Flow Charts

Jib Boom Down
Function
Inoperative
(before serial
number 4083)
Be sure key switch is in
the appropriate position.
Be sure the Emergency
Stop buttons are pulled
out to the ON position.
Be sure the battery
packs are properly
connected and fully
charged.
:[XTQK_Y]OZINZU
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Chart 29
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:( MXU[TJ]OXKIOXI[OZZU
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:(
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6 - 104 Genie Z-30/20N Part No. 35532

First Edition • Third Printing Section 6 • Troubleshooting Flow Charts

Jib Boom Down
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number 4082)
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Be sure the Emergency
Stop buttons are pulled
out to the ON position.
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Part No. 35532 Genie Z-30/20N 6 - 105

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Genie Z-30/20N 6 - 107
Section 6 • Troubleshooting Flow Charts First Edition • Third Printing

Chart 31
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number 4082)
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the appropriate position.
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packs are properly
connected and fully
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Section 6 • Troubleshooting Flow Charts First Edition • Third Printing

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6 - 110 Genie Z-30/20N Part No. 35532

First Edition • Third Printing Section 6 • Troubleshooting Flow Charts

Jib Boom
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Inoperative
(after serial
number 4082)
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the appropriate position.
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Stop buttons are pulled
out to the ON position.
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packs are properly
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IUTZXURRKXZ[XTKJZU
VXKYYJU]TZNKLUUZ
Y]OZINGTJSU\KZNKPOH
HUUSXUZGZKZUMMRK
Y]OZIN:9OTZNK8/-.:
JOXKIZOUT)NKIQ\URZGMK
GZ:(

<

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Y]OZINGTJSU\KZNKPOH
HUUSXUZGZKZUMMRK <
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JOXKIZOUT)NKIQZNK
\URZGMKGZZNKXKJ]OXK
UTZNKHUUSL[TIZOUT
< YVKKJIUTZXURRKX
8KVGOXUVKTOTXKJ]OXK
IOXI[OZZNXU[MNHUUS
L[TIZOUTZUMMRKY]OZINKY
ZUZNKXKJ]OXKUTZNK
HUUSL[TIZOUTYVKKJ
IUTZXURRKX

<

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Y]OZINGTJSU\KZNKPOH
HUUSXUZGZKZUMMRK <
Y]OZINOTZNK8/-.:
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HUUSL[TIZOUTYVKKJ
IUTZXURRKX
8KVGOXUVKTOTMXU[TJ
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HUUSL[TIZOUTYVKKJ
IUTZXURRKXZUMXU[TJ58
XKVRGIKZNKHUUS
L[TIZOUTYVKKJ
IUTZXURRKX

<

8KVGOXUVKTOTHRQXKJ
]OXKLXUSZNKHUUS
L[TIZOUTYVKKJIUTZXURRKX
ZU:(

)UTZOT[KJUTZNKTK^Z
VGMK

Part No. 35532 Genie Z-30/20N 6 - 111

Section 6 • Troubleshooting Flow Charts
CHART 32
:[XTQK_Y]OZINZU
)UTZOT[KJLXUSZNK MXU[TJIUTZXURYGTJV[RR
VXK\OU[YVGMK HUZN+SKXMKTI_9ZUV
<
H[ZZUTYU[ZZUZNK54
VUYOZOUT.URJZNK
L[TIZOUTKTGHRKZUMMRK
Y]OZINZUKOZNKXYOJKGTJ
SU\KPOHHUUSXUZGZK
ZUMMRKY]OZINOTZNK
8/-.:JOXKIZOUTGTJ
INKIQ\URZGMKUTZNKXKJ
]OXKUTZNKPOHHUUS
XUZGZKJOXKIZOUTGR\GR\K
IUOROZKS('
<
)UTZOT[KJUTZNKTK^Z
VGMK
6 - 112 Genie Z-30/20N
First Edition • Third Printing
.URJZNKL[TIZOUTKTGHRK 8KVGOXUVKTOTUXMHRQ
ZUMMRKY]OZINZUKOZNKX ]OXKIOXI[OZLXUS:(ZU
YOJKGTJSU\KZNKPOH :9GTJLXUSXKJ]OXK
<
HUUSXUZGZKZUMMRK UT:9ZUZNKPOHHUUS
Y]OZINOTZNK8/-.: XUZGZKXOMNZJOXKIZOUTGR
JOXKIZOUTGTJINKIQ \GR\KIUOR58XKVGOX
\URZGMKGZ:( UVKTOTHXTMXU[TJ]OXK
IOXI[OZZUZNKSGTOLURJ
<
:[XTQK_Y]OZINZU < 8KVGOXUVKTOTHXT
VRGZLUXSIUTZXURYGTJ MXU[TJ]OXKIOXI[OZUX
V[RRHUZN+SKXMKTI_ XKVRGIK\GR\KIUOR
9ZUVH[ZZUTYU[ZZUZNK
54VUYOZOUT=OZNZNK
HUUSL[TIZOUTYVKKJ
IUTZXURRKXZ[XTKJZU
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JOXKIZOUT)NKIQ\URZGMK
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<
8KVGOXUVKTXKJ]OXK
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Part No. 35532
First Edition • Third Printing
)UTZOT[KJLXUSZNK
VXK\OU[YVGMK
Part No. 35532
Section 6 • Troubleshooting Flow Charts
CHART 32
UX
*OYIUTTKIZZNKXKJ]OXK OTLOTOZK
LXUSZNKPOHHUUSXUZGZK UNSY 8KVRGIKPOHHUUSXUZGZK
XOMNZJOXKIZOUTGR\GR\K XOMNZJOXKIZOUTGR\GR\K
IUOR:KYZZNKXKYOYZGTIK IUOR
ULZNK\GR\KIUOR9KK
8KVGOX9KIZOUT
ZU
UNSY
L[TIZOUT
+^INGTMKZNKPOHHUUS UVKXGZKY 8KVRGIKJKLKIZO\K
XUZGZKGTJPOHHUUS JOXKIZOUTGR\GR\K
JOXKIZOUTGR\GR\KYOZKSY
('GTJ()'IZO\GZK
ZNKPOHHUUSXUZGZK
8/-.:L[TIZOUT
L[TIZOUTOTUVKXGZO\K
/TYZGRRGZUVYO )NKIQLUXSKINGTOGR
ZUHGXVXKYY[XK XKYZXOIZOUTYQKKVOTMPOH
MG[MKGZZNKW[OIQ HUUSXUZGZKXOMNZ
JOYIUTTKIZIU[VROTMUT VYO L[TIZOUTLXUSSU\OTM
ZNKHUUSL[TIZOUT 58ZNKUXOLOIK
SGTOLURJGTJGIZO\GZK OZKS(*IU[RJHK
ZNKPOHHUUSXUZGZKXOMNZ VR[MMKJ58XKVGOX
L[TIZOUT N_JXG[ROIXUZGZOUTSUZUX
58IUTY[RZ-KTOK
/TJ[YZXOKJ9KX\OIK
*KVGXZSKTZ
RKYYZNGTVYO
8KVGOXN_JXG[ROIXUZGZOUT
SUZUX58POHL[TIZOUT
SGTOLURJIU[RJNG\KGT
OTZKXTGRLG[RZ)UTY[RZ
-KTOK/TJ[YZXOKY9KX\OIK
*KVGXZSKTZ
Genie Z-30/20N 6 - 113
Section 6 • Troubleshooting Flow Charts First Edition • Third Printing

Chart 33
Steer Left :[XTQK_Y]OZINZU 6XKYYJU]TZNKLUUZ <UX
SUXK 8KVGOXUVKTOTHR[
VRGZLUXSIUTZXURYGTJ Y]OZINGTJVXKYYZNK
Function V[RRHUZN+SKXMKTI_ YZKKXXUIQKXY]OZINOT
]OXKIOXI[OZLXUSJXO\K
< IUTZXURRKXZU:(
Inoperative 9ZUVH[ZZUTYU[ZZUZNK ZNK2+,:JOXKIZOUTGTJ
54VUYOZOUT6XKYYJU]T INKIQ\URZGMKGZZNK
(before serial ZNKLUUZY]OZINGTJ JXO\KIUTZURRKXZKXSOTGR
VXKYYZNKYZKKXXUIQKX ]OZNZNKHR[]OXK
number 3447) Y]OZINOTZNK2+,: GZZGINKJ
JOXKIZOUTGTJINKIQ
Be sure key switch is in \URZGMKUT:( <
the appropriate position.
8KVGOXUXXKVRGIKZNK
Be sure the Emergency YZKKXSOIXUY]OZIN58
IUTY[RZ-KTOK/TJ[YZXOKY
Stop buttons are pulled <UXSUXK 9KX\OIK*KVGXZSKTZ
out to the ON position.
Be sure the battery
packs are properly
6XKYYJU]TZNKLUUZ < 8KVGOXUVKTOTZNK]OXK
connected and fully Y]OZINGTJVXKYYZNK IOXI[OZ]OZNJOUJKLXUS
charged. YZKKXXUIQKXY]OZINOT :(ZU:(
ZNK2+,:JOXKIZOUTGTJ
Be sure all other INKIQ\URZGMKUT:(
functions operate
normally. <UXSUXK

6XKYYJU]TZNKLUUZ 8KVGOXUVKTOTHR[ 
Y]OZINGTJVXKYYZNK < ]OXKIOXI[OZLXUS:(ZU
YZKKXXUIQKXY]OZINUT ZNKYZKKXRKLZJOXKIZOUTGR
ZNKJXO\KIUTZXURRKXOTZNK \GR\KIUOR
2+,:JOXKIZOUTGTJINKIQ
\URZGMKUTHR[ ]OXK
GZZNKYZKKXRKLZ
JOXKIZOUTGR\GR\KIUOR
OZKS((UTYZKKXHXGQK
SGTOLURJ

<UXSUXK
UX
OTLOTOZK
*OYIUTTKIZZNK]OXKY UNSY 8KVRGIKYZKKXRKLZ
LXUSZNKYZKKXRKLZ JOXKIZOUTGR\GR\KIUOR
JOXKIZOUTGR\GR\KIUOR
:KYZZNKXKYOYZGTIKUL
ZNK\GR\KIUOR9KK
8KVGOX9KIZOUT

ZUUNSY

)UTZOT[KJUTZNKTK^Z
VGMK

6 - 114 Genie Z-30/20N Part No. 35532

First Edition • Third Printing Section 6 • Troubleshooting Flow Charts

CHART 33

)UTZOT[KJLXUSZNK
VXK\OU[YVGMK
/TYZGRRGZU69/
ZUHGXVXKYY[XK
MG[MKGZZNKW[OIQ 
JOYIUTTKIZIU[VROTMUT 69/
ZNKHUUSL[TIZOUT
SGTOLURJ6XKYYJU]T
ZNKLUUZY]OZINGTJ
VXKYYZNKYZKKXXUIQKX
Y]OZINOTZNK 2+,:
JOXKIZOUTGTJINKIQZNK
VXKYY[XK
)NKIQLUXSKINGTOIGR
XKYZXOIZOUTYQKKVOTM
YZKKXRKLZL[TIZOUTLXUS
SU\OTM58XKVGOXUX
XKVRGIKYZKKXI_ROTJKX
58IUTY[RZ-KTOK
/TJ[YZXOKY9KX\OIK
*KVGXZSKTZ

RKYYZNGT69/

8KVGOXUXXKVRGIKYZKKX
I_ROTJKX58ZNKYZKKX
HXGQKL[TIZOUTSGTOLURJ
IU[RJNG\KGTOTZKXTGR
LG[RZ)UTY[RZ-KTOK
/TJ[YZXOKY9KX\OIK
*KVGXZSKTZ

Part No. 35532 Genie Z-30/20N 6 - 115

Section 6 • Troubleshooting Flow Charts First Edition • Third Printing

Chart 34
Steer Left :[XTQK_Y]OZINZU 6XKYYJU]TZNKLUUZ <UX
SUXK 8KVGOXUVKTOTHR[
VRGZLUXSIUTZXURYGTJ Y]OZINGTJVXKYYZNK
Function V[RRHUZN+SKXMKTI_ YZKKXXUIQKXY]OZINOT
]OXKIOXI[OZLXUSJXO\K
< IUTZXURRKXZU:(
Inoperative 9ZUVH[ZZUTYU[ZZUZNK ZNK2+,:JOXKIZOUTGTJ
54VUYOZOUT6XKYYJU]T INKIQ\URZGMKGZZNK
(after serial ZNKLUUZY]OZINGTJ JXO\KIUTZURRKXZKXSOTGR
VXKYYZNKYZKKXXUIQKX ]OZNZNKHR[]OXK
number 3446) Y]OZINOTZNK2+,: GZZGINKJ
JOXKIZOUTGTJINKIQ
Be sure key switch is in \URZGMKUT:( <
the appropriate position.
8KVGOXUXXKVRGIKZNK
Be sure the Emergency YZKKXSOIXUY]OZIN58
IUTY[RZ-KTOK/TJ[YZXOKY
Stop buttons are pulled <UXSUXK 9KX\OIK*KVGXZSKTZ
out to the ON position.
Be sure the battery
packs are properly
6XKYYJU]TZNKLUUZ < 8KVGOXUVKTOTZNK]OXK
connected and fully Y]OZINGTJVXKYYZNK IOXI[OZ]OZNJOUJKLXUS
charged. YZKKXXUIQKXY]OZINOT :(ZU:(
ZNK2+,:JOXKIZOUTGTJ
Be sure all other INKIQ\URZGMKUT:(
functions operate
normally. <UXSUXK

6XKYYJU]TZNKLUUZ 8KVGOXUVKTOTHR[ 
Y]OZINGTJVXKYYZNK < ]OXKIOXI[OZLXUS:(ZU
YZKKXXUIQKXY]OZINUT ZNKYZKKXRKLZJOXKIZOUTGR
ZNKJXO\KIUTZXURRKXOTZNK \GR\KIUOR
2+,:JOXKIZOUTGTJINKIQ
\URZGMKUTHR[ ]OXK
GZZNKYZKKXRKLZ
JOXKIZOUTGR\GR\KIUOR
OZKS77UTL[TIZOUT
SGTOLURJ

<UXSUXK
UX
OTLOTOZK
*OYIUTTKIZZNK]OXKY UNSY 8KVRGIKYZKKXRKLZ
LXUSZNKYZKKXRKLZ JOXKIZOUTGR\GR\KIUOR
JOXKIZOUTGR\GR\KIUOR
:KYZZNKXKYOYZGTIKUL
ZNK\GR\KIUOR9KK
8KVGOX9KIZOUT

ZUUNSY

)UTZOT[KJUTZNKTK^Z
VGMK

6 - 116 Genie Z-30/20N Part No. 35532

First Edition • Third Printing
)UTZOT[KJLXUSZNK
VXK\OU[YVGMK
Part No. 35532
/TYZGRRGZU69/
ZUHGXVXKYY[XK
MG[MKGZZNKW[OIQ
JOYIUTTKIZIU[VROTMUT 
ZNKHUUSL[TIZOUT 69/
SGTOLURJ6XKYYJU]T
ZNKLUUZY]OZINGTJ
VXKYYZNKYZKKXXUIQKX
Y]OZINOTZNK 2+,:
JOXKIZOUTGTJINKIQZNK
VXKYY[XK
RKYYZNGT69/
8KVGOXUXXKVRGIKYZKKX
I_ROTJKX58ZNKYZKKX
HXGQKL[TIZOUTSGTOLURJ
IU[RJNG\KGTOTZKXTGR
LG[RZ)UTY[RZ-KTOK
/TJ[YZXOKY9KX\OIK
*KVGXZSKTZ
Genie Z-30/20N
Section 6 • Troubleshooting Flow Charts
CHART 34
)NKIQLUXSKINGTOIGR
XKYZXOIZOUTYQKKVOTM
YZKKXRKLZL[TIZOUTLXUS
SU\OTM58
,XUSYKXOGRT[SHKX
ZU ZNK
OTINUXOLOIK
'LZKXYKXOGRT[SHKX
 ZNKOTIN
UXOLOIKIU[RJHKVR[MMKJ
58XKVGOXUXXKVRGIK
YZKKXI_ROTJKX58
IUTY[RZ-KTOK/TJ[YZXOKY
9KX\OIK*KVGXZSKTZ
6 - 117
Section 6 • Troubleshooting Flow Charts First Edition • Third Printing

Chart 35
Steer Right :[XTQK_Y]OZINZU 6XKYYJU]TZNKLUUZ <UX
SUXK 8KVGOXUVKTOTHR[HRQ
VRGZLUXSIUTZXURYGTJ Y]OZINGTJVXKYYZNK
Function V[RRHUZN+SKXMKTI_ YZKKXXUIQKXY]OZINOT
]OXKIOXI[OZLXUSJXO\K
< IUTZXURRKXZU:(
Inoperative 9ZUVH[ZZUTYU[ZZUZNK ZNK8/-.: JOXKIZOUTGTJ
54VUYOZOUT6XKYYJU]T INKIQ\URZGMKGZZNK
(before serial ZNKLUUZY]OZINGTJ JXO\KIUTZURRKXZKXSOTGR
VXKYYZNKYZKKXXUIQKX ]OZNZNKHR[HRQ]OXK
number 3447) Y]OZINOTZNK8/-.: GZZGINKJ
JOXKIZOUTGTJINKIQ
Be sure key switch is in \URZGMKUT:( <
the appropriate position.
8KVGOXUXXKVRGIKZNK
Be sure the Emergency YZKKXSOIXUY]OZIN58
IUTY[RZ-KTOK/TJ[YZXOKY
Stop buttons are pulled <UXSUXK 9KX\OIK*KVGXZSKTZ
up to the ON position.
Be sure the battery
packs are properly
6XKYYJU]TZNKLUUZ < 8KVGOXUVKTOTZNK]OXK
connected and fully Y]OZINGTJVXKYYZNK IOXI[OZ]OZNJOUJKLXUS
charged. YZKKXXUIQKXY]OZINOT :(ZU:(
ZNK8/-.:JOXKIZOUTGTJ
Be sure all other INKIQ\URZGMKUT:(
functions operate
normally. <UXSUXK

6XKYYJU]TZNKLUUZ 8KVGOXUVKTOTHR[HRQ
Y]OZINGTJVXKYYZNK < ]OXKIOXI[OZLXUS
YZKKXXUIQKXY]OZINUT :(ZUZNKYZKKXXOMNZ
ZNKJXO\KIUTZXURRKXOTZNK JOXKIZOUTGR\GR\KIUOR
8/-.:JOXKIZOUTGTJ
INKIQ\URZGMKUTHR[HRQ
]OXKGZZNKYZKKX
XOMNZJOXKIZOUTGR\GR\K
IUOROZKS((UTYZKKX
HXGQKSGTOLURJ

<UXSUXK
UX
OTLOTOZK
*OYIUTTKIZZNK]OXKY UNSY 8KVRGIKYZKKXXOMNZ
LXUSZNKYZKKXXOMNZ JOXKIZOUTGR\GR\KIUOR
JOXKIZOUTGR\GR\KIUOR
:KYZZNKXKYOYZGTIKUL
ZNK\GR\KIUOR9KK
8KVGOX9KIZOUT

ZUUNSY

)UTZOT[KJUTZNKTK^Z
VGMK

6 - 118 Genie Z-30/20N Part No. 35532

First Edition • Third Printing Section 6 • Troubleshooting Flow Charts

CHART 35

)UTZOT[KJLXUSZNK
VXK\OU[YVGMK
/TYZGRRGZU69/
ZUHGXVXKYY[XK
MG[MKGZZNKW[OIQ 
JOYIUTTKIZIU[VROTMUT 69/
ZNKHUUSL[TIZOUT
SGTOLURJ6XKYYJU]T
ZNKLUUZY]OZINGTJ
VXKYYZNKYZKKXXUIQKX
Y]OZINOTZNK 8/-.:
JOXKIZOUTGTJINKIQZNK
VXKYY[XK
)NKIQLUXSKINGTOIGR
XKYZXOIZOUTYQKKVOTM
YZKKXXOMNZL[TIZOUTLXUS
SU\OTM58XKVGOXUX
XKVRGIKYZKKXI_ROTJKX
58IUTY[RZ-KTOK
/TJ[YZXOKY9KX\OIK
*KVGXZSKTZ

RKYYZNGT69/

8KVGOXUXXKVRGIKYZKKX
I_ROTJKX58ZNKYZKKX
HXGQKL[TIZOUTSGTOLURJ
IU[RJNG\KGTOTZKXTGR
LG[RZ)UTY[RZ-KTOK
/TJ[YZXOKY9KX\OIK
*KVGXZSKTZ

Part No. 35532 Genie Z-30/20N 6 - 119

Section 6 • Troubleshooting Flow Charts First Edition • Third Printing

Chart 36
Steer :[XTQK_Y]OZINZU 6XKYYJU]TZNKLUUZ <UX
SUXK 8KVGOXUVKTOTHR[HRQ
VRGZLUXSIUTZXURYGTJ Y]OZINGTJVXKYYZNK
RightFunction V[RRHUZN+SKXMKTI_ YZKKXXUIQKXY]OZINOT
]OXKIOXI[OZLXUSJXO\K
< IUTZXURRKXZU:(
Inoperative 9ZUVH[ZZUTYU[ZZUZNK ZNK8/-.: JOXKIZOUTGTJ
54VUYOZOUT6XKYYJU]T INKIQ\URZGMKGZZNK
(after serial ZNKLUUZY]OZINGTJ JXO\KIUTZURRKXZKXSOTGR
VXKYYZNKYZKKXXUIQKX ]OZNZNKHR[HRQ]OXK
number 3446) Y]OZINOTZNK8/-.: GZZGINKJ
JOXKIZOUTGTJINKIQ
\URZGMKUT:(
Be sure key switch is in <
the appropriate position.
8KVGOXUXXKVRGIKZNK
Be sure the Emergency YZKKXSOIXUY]OZIN58
Stop buttons are pulled <UXSUXK IUTY[RZ-KTOK/TJ[YZXOKY
9KX\OIK*KVGXZSKTZ
out to the ON position.
Be sure the battery
packs are properly
6XKYYJU]TZNKLUUZ < 8KVGOXUVKTOTZNK]OXK
connected and fully Y]OZINGTJVXKYYZNK IOXI[OZ]OZNJOUJKLXUS
charged. YZKKXXUIQKXY]OZINOT :(ZU:(
ZNK8/-.:JOXKIZOUTGTJ
Be sure all other INKIQ\URZGMKUT:(
functions operate
normally. <UXSUXK

6XKYYJU]TZNKLUUZ 8KVGOXUVKTOTHR[HRQ
Y]OZINGTJVXKYYZNK < ]OXKIOXI[OZLXUS
YZKKXXUIQKXY]OZINUT :(ZUZNKYZKKXXOMNZ
ZNKJXO\KIUTZXURRKXOTZNK JOXKIZOUTGR\GR\KIUOR
8/-.:JOXKIZOUTGTJ
INKIQ\URZGMKUTHR[HRQ
]OXKGZZNKYZKKXRKLZ
JOXKIZOUTGR\GR\KIUOR
OZKS77UTL[TIZOUT
SGTOLURJ

<UXSUXK
UX
OTLOTOZK
*OYIUTTKIZZNK]OXKY UNSY 8KVRGIKYZKKXXOMNZ
LXUSZNKYZKKXXOMNZ JOXKIZOUTGR\GR\KIUOR
JOXKIZOUTGR\GR\KIUOR
:KYZZNKXKYOYZGTIKUL
ZNK\GR\KIUOR9KK
8KVGOX9KIZOUT

ZUUNSY

)UTZOT[KJUTZNKTK^Z
VGMK

6 - 120 Genie Z-30/20N Part No. 35532

First Edition • Third Printing
)UTZOT[KJLXUSZNK
VXK\OU[YVGMK
Part No. 35532
/TYZGRRGZU69/
ZUHGXVXKYY[XK
MG[MKGZZNKW[OIQ
JOYIUTTKIZIU[VROTMUT 
ZNKHUUSL[TIZOUT 69/
SGTOLURJ6XKYYJU]T
ZNKLUUZY]OZINGTJ
VXKYYZNKYZKKXXUIQKX
Y]OZINOTZNK 8/-.:
JOXKIZOUTGTJINKIQZNK
VXKYY[XK
RKYYZNGT69/
8KVGOXUXXKVRGIKYZKKX
I_ROTJKX58ZNKYZKKX
HXGQKL[TIZOUTSGTOLURJ
IU[RJNG\KGTOTZKXTGR
LG[RZ)UTY[RZ-KTOK
/TJ[YZXOKY9KX\OIK
*KVGXZSKTZ
Genie Z-30/20N
Section 6 • Troubleshooting Flow Charts
CHART 36
)NKIQLUXSKINGTOIGR
XKYZXOIZOUTYQKKVOTM
YZKKXXOMNZL[TIZOUTLXUS
SU\OTM58
,XUSYKXOGRT[SHKX
ZU ZNK
OTINUXOLOIK
'LZKXYKXOGRT[SHKX
 ZNKOTIN
UXOLOIKIU[RJHKVR[MMKJ
58XKVGOXUXXKVRGIK
YZKKXI_ROTJKX58
IUTY[RZ-KTOK/TJ[YZXOKY
9KX\OIK*KVGXZSKTZ
6 - 121
Section 6 • Troubleshooting Flow Charts
Chart 37
All Drive L[TIZOUT
:[XTQK_Y]OZINZU UVKXGZKY
VRGZLUXSIUTZXURYGTJ
Functions V[RRHUZN+SKXMKTI_
Inoperative, all 9ZUVH[ZZUTYU[ZZUZNK
54VUYOZOUT6XKYYJU]T
Other ZNKLUUZY]OZINGTJNURJ
ZNKJXO\KKTGHRKZUMMRK
Functions Y]OZIN:9ZUKOZNKXYOJK
GTJSU\KZNKJXO\K
Operate IUTZXURRKXOTZNK
,58='8* JOXKIZOUT
Normally
(before serial
number 3447)
Be sure the unit is in the
fully stowed position
with the boom located
between the drive tires.
Be sure the battery
packs are properly
L[TIZOUTOTUVKXGZO\K
connected and fully
charged.
)NKIQ\URZGMKLXUS(
ZKXSOTGRUTZNKSUZUX
IUTZXURRKXZUOTV[ZYOJKUL
'L[YK,
<UXSUXK
)NKIQ\URZGMKUTU[ZV[Z
YOJKUL'L[YK,
<UXSUXK
)UTZOT[KJUTZNKTK^Z
VGMK
6 - 122 Genie Z-30/20N
First Edition • Third Printing
<UX
6XKYYJU]TZNKLUUZ SUXK (KLUXKYKXOGRT[SHKX
Y]OZINGTJINKIQ  8KVGOXUVKTOTUXM
\URZGMKGZ:( XKJ]OXKIOXI[OZLXUS
:(ZUZKXSOTGRUT
ZNKJXO\KIUTZXURRKX
'LZKXYKXOGRT[SHKX
 8KVGOXUVKTOTUXM
XKJ]OXKIOXI[OZLXUS
:(ZU)858XKVGOX
UVKTOTMXU[TJ]OXK
IOXI[OZLXUS)8ZU
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Part No. 35532
Section 6 • Troubleshooting Flow Charts
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Part No. 35532 Genie Z-30/20N 6 - 127

Section 6 • Troubleshooting Flow Charts First Edition • Third Printing

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Genie Z-30/20N 6 - 131
Section 6 • Troubleshooting Flow Charts First Edition • Third Printing

Chart 39
All Drive ZOXKY
(RUIQZNKYZKKX]NKKRY JUT Z -UZU)NGXZ(XGQK
GTJXGOYKZNKSGINOTK
Functions YUZNKJXO\KZOXKYGXKULL
SU\K 8KRKGYK,[TIZOUT
/TUVKXGZO\KGLZKXYKXOGR
Inoperative, all ZNKMXU[TJ=OZNQK_ T[SHKX
Y]OZINZ[XTKJZUVRGZLUXS
Other IUTZXURYGTJHUZN
+SKXMKTI_9ZUVH[ZZUTY
Functions V[RRKJU[ZZUZNK54
VUYOZOUTVXKYYJU]TZNK
Operate LUUZY]OZINGTJSU\K
ZNKJXO\KIUTZXURRKXOT
Normally KOZNKXJOXKIZOUT.G\K
YUSKUTKZX_ZUXUZGZK
(after serial ZNKJXO\KZOXKYH_NGTJ
4UZK ZNOY]ORRXKW[OXK
number 3446) VKUVRK
Troubleshooting drive
ZOXKYSU\K
function faults may also
be accomplished by 6XKYYJU]TZNKLUUZ <UX 6XKYYJU]TZNKLUUZ < 8KVRGIKZNKJXO\K
using the hand-held Y]OZINGTJSU\KZNK SUXK Y]OZINGTJINKIQ IUTZXURRKX
pendant motor controller JXO\KIUTZURRKXOTZNK \URZGMKUTZKXSOTGR 
,58='8* JOXKIZOUT UTZNKJXO\KIUTZXURRKX
programmer (Genie part )NKIQ\URZGMKGZ
number 56303). ZKXSOTGR UTZNKJXO\K <UXSUXK
IUTZXURRKX
Be sure to check the
motor controller status 6XKYYJU]TZNKLUUZ 8KVGOXUVKTOTZNK]NZ
Y]OZINGTJSU\KZNK ]OXKIOXI[OZLXUSZKXSOTGR
indicator light on the JXO\KIUTZXURRKXOTZNK UTZNKJXO\K
<
ground control box or on ,58='8* JOXKIZOUT IUTZXURRKXZU:(ZUVOT
the motor controller. If )NKIQ\URZGMKGZVOT UTZNKSUZUX
UTZNKSUZUXIUTZXURRKX IUTZXURRKXNGXTKYY
the motor controller NGXTKYYIUTTKIZUX IUTTKIZUX
status indicator light is
flashing a fault code, <UXSUXK
refer to the fault code
chart at the beginning of 6XKYYJU]TZNKLUUZ < 8KVRGIKZNKJXO\K
this section. Y]OZINGTJSU\KZNK IUTZXURRKX
JXO\KIUTZXURRKXOTZNK
< 8+<+89+ JOXKIZOUT
Be sure the circuit )NKIQ\URZGMKUT
breakers and fuses are ZKXSOTGR UTZNKJXO\K
not tripped or blown. IUTZXURRKX

Be sure the batteries <UXSUXK

are properly connected
and fully charged.
Be sure the machine is
not in the free wheel
configuration.
Be sure the unit is in the
fully stowed position
with the boom located
between the non-steer
end tires.
6XKYYJU]TZNKLUUZ 8KVGOXUVKTOTZNK]NZ
Y]OZINGTJSU\KZNK HRQ]OXKLXUSZKXSOTGR
JXO\KIUTZXURRKXOTZNK UTZNKJXO\K
8+<+89+ JOXKIZOUT
<
IUTZXURRKXZU:(ZUVOT
)NKIQ\URZGMKGZVOT UTZNKSUZUX
UTZNKSUZUXIUTZXURRKX IUTZXURRKXNGXTKYY
NGXTKYYIUTTKIZUX IUTTKIZUX
<UXSUXK
)UTZOT[KJUTZNKTK^Z
VGMK
9KK)NGXZ'3UZUX
)UTZXURRKX,G[RZ)UJK
 :NXUZZRK,G[RZ

6 - 132 Genie Z-30/20N Part No. 35532

First Edition • Third Printing
)UTZOT[KJLXUSZNK
VXK\OU[YVGMK
Part No. 35532
Section 6 • Troubleshooting Flow Charts
CHART 39
6XKYYJU]TZNKLUUZ <UX 8KVGOXUVKTOTUXMXKJ
Y]OZINGTJSU\KZNK SUXK ]OXKIOXI[OZLXUS:(ZU
JXO\KIUTZXURRKXOTKOZNKX ZKXSOTGR UTZNKJXO\K
JOXKIZOUT)NKIQ\URZGMK IUTZXURRKX
GZ:(
<
<UX
6XKYYJU]TZNKLUUZ SUXK 8KVGOXUVKTOTXKJ
Y]OZINGTJSU\KZNK ]OXKIOXI[OZLXUSZKXSOTGR
JXO\KIUTZXURRKXOTKOZNKX UT29ZU:(
JOXKIZOUT)NKIQ\URZGMK
GZZKXSOTGR UT29
<
<UX
6XKYYJU]TZNKLUUZ SUXK
Y]OZINGTJSU\KZNK 8KVRGIK29
JXO\KIUTZXURRKXOTKOZNKX
JOXKIZOUT)NKIQ\URZGMK
GZZKXSOTGR UT29
<
<UX
6XKYYJU]TZNKLUUZ SUXK 8KVGOXUVKTOTHRQ
Y]OZINGTJSU\KZNK ]OXKIOXI[OZLXUS:(ZU
JXO\KIUTZXURRKXOTKOZNKX ZKXSOTGR UT29
JOXKIZOUT)NKIQ\URZGMK
GZ:(
<
6XKYYJU]TZNKLUUZ <UX 8KVGOXUVKTOTHR[]NZ
Y]OZINGTJSU\KZNK SUXK ]OXKIOXI[OZLXUSZNK
JXO\KIUTZXURRKXOTKOZNKX IKTZKXZKXSOTGRGZ:9
JOXKIZOUT)NKIQ\URZGMK ZU:(
GZZNKIKTZKXZKXSOTGRGZ
:9
<UX
6XKYYJU]TZNKLUUZ SUXK 8KVGOXUVKTOTHR[]NZ
Y]OZINGTJSU\KZNK ]OXKIOXI[OZLXUS
JXO\KIUTZXURRKXOTKOZNKX ZKXSOTGR GZZNKSUZUX
JOXKIZOUT)NKIQ\URZGMK IUTZXURRKXZU:(
GZZKXSOTGR GZZNK
SUZUXIUTZXURRKX
<
8KVRGIKZNKSUZUX
IUTZXURRKX58IUTZGIZ
-KTOK/TJ[YZXOKY9KX\OIK
*KVGXZSKTZ
Genie Z-30/20N 6 - 133
Section 6 • Troubleshooting Flow Charts First Edition • Third Printing

Chart 39A
Motor :[XTQK_Y]OZINZUZNK RKYY 8KVGOXUVKTOTZNK]OXK
5,,VUYOZOUTGTJ
ZNGT IOXI[OZLXUSZNK
Controller Fault JOYIUTTKIZSUZUX  VUZKTZOUSKZKXZU
IUTZXURRKXNGXTKYY UNSY ZKXSOTGRYGTJUTZNK
Code 21: IUTTKIZUXLXUSZNK JXO\KIUTZXURRKX58
Throttle Fault SUZUXIUTZXURRKX XKVRGIKZNKJXO\K
)UTTKIZZNKRKGJYLXUS IUTZXURRKX
(after serial GTUNSSKZKXZUVOTY
GTJUTZNKIUTTKIZUX
number 3446) VOTYGTJGXKZNK MXKGZKX
]NZXKJGTJXKJ]NZ ZNGT 8KVGOXUVKTOTZNK
Troubleshooting drive ]OXKY)NKIQZNK  MXU[TJ]OXKIOXI[OZOTZNK
XKYOYZGTIK UNSY XKJ]NZUX]NZXKJ]OXKY
function faults may also LXUSVOTYGTJZU
be accomplished by ZKXSOTGRY GTJ UT
using the hand-held ZNKJXO\KIUTZXURRKX58
XKVRGIKZNKJXO\K
pendant motor controller ZU IUTZXURRKX
programmer (Genie part UNSY
number 56303).

Be sure to check the (RUIQZNKYZKKX]NKKRY TU 8KVRGIKZNKJXO\K

motor controller status GTJXGOYKZNKSGINOTK IUTZXURRKX
indicator light on the YUJXO\KZOXKYGXKULLZNK
ground control box or on MXU[TJ
=OZNZNKRKGJYLXUSGT
the motor controller. If UNSSKZKXIUTTKIZKJZU
the motor controller VOTYGTJUTZNK
status indicator light is IUTTKIZUXSU\KZNK
JXO\KIUTZXURRKXYRU]R_ZU
flashing a fault code, L[RRYZXUQKOTHUZNZNK
refer to the fault code ,58='8* GTJ8+<+89+
chart at the beginning of JOXKIZOUTY]NORK
]GZINOTMZNKUNSSKZKX
this section. *UKYZNKXKYOYZGTIK
XGSVYSUUZNR_JU]TZU
Be sure the circuit UNSYUXRKYYOTHUZN
breakers and fuses are JOXKIZOUTY%
4UZK :NOY]ORRXKW[OXK
not tripped or blown. VKUVRK
Be sure the battery
_KY
packs are properly
connected and fully (KMOTZXU[HRKYNUUZOTM
charged. LXUSZNKHKMOTTOTMUL
ZNKINGXZ58IUTY[RZ
Be sure the machine is -KTOK/TJ[YZXOKY9KX\OIK
not in the free wheel *KVGXZSKTZ
configuration.

Be sure the unit is in the

fully stowed position
with the boom located
between the non-steer
end tires.

6 - 134 Genie Z-30/20N Part No. 35532

First Edition • Third Printing
Motor
Controller Fault
Code 32:
Main Contactor
Welded
(after serial
number 3446)
Troubleshooting drive
function faults may also
be accomplished by
using the hand-held
pendant motor controller
programmer (Genie part
number 56303).
Be sure to check the
motor controller status
indicator light on the
ground control box or on
the motor controller. If
the motor controller
status indicator light is
flashing a fault code,
refer to the fault code
chart at the beginning of
this section.
Be sure the circuit
breakers and fuses are
not tripped or blown.
Be sure the battery
packs are properly
connected and fully
charged.
Be sure the machine is
not in the free wheel
configuration.
Be sure the unit is in the
fully stowed position
with the boom located
between the non-steer
end tires.
Part No. 35532
Section 6 • Troubleshooting Flow Charts
Chart 39B
*OYIUTTKIZZNKHGZZKX_ 8KVRGIKJXO\KIUTZGIZUX
VGIQYLXUSZNKSGINOTK _KY 68IUTZGIZY58
<OY[GRR_OTYVKIZZNK XKVRGIKZNKJXO\K
IUTZGIZYUT68'XK IUTZGIZUX68
ZNKIUTZGIZYYZ[IQ
IRUYKJ%
TU
:KYZZNKXKYOYZGTIK :KYZZNKXKYOYZGTIK TU 8KVRGIKZNKJXO\KSUZUX
HKZ]KKTZKXSOTGRY3 SUXKZNGT HKZ]KKTZKXSOTGRY' ZNGZNGYGXKYOYZGTIKUL
GTJ(UTZNKSUZUX UNS GTJ'UTKGINJXO\K SUXKZNGTUNS
IUTZXURRKX SUZUX/YZNKXKYOYZGTIK
4UZK 'TUNSSKZKX UNSUXRKYYUTKGIN
IGVGHRKULXKGJOTM JXO\KSUZUX%
UNSUXRKYYOYTKKJKJ
LUXZNOYZKYZ
_KY
8KVGOXUVKTOTSUZUX
GXSGZ[XKIGHRKYLXUS
ZKXSOTGRY3GTJ(UT
UNSUX ZNKSUZUXIUTZXURRKXZU
RKYY KGINJXO\KSUZUX
RKYYZNGT
8KSU\KZNKMXT]OXK RKYYZNGT 8KSU\KZNKSUZUX  8KVGOXUVKTOTZNK
LXUS68)NKIQ  IUTZXURRKXNGXTKYY QORUNSY MXU[TJ]OXKIOXI[OZLXUS
IUTZOT[OZ_LXUSZNKMXT QORUNSY IUTTKIZUXLXUSZNK VOTUTZNKSUZUX
]OXKZNGZ]GYP[YZ SUZUXIUTZXURRKX)NKIQ IUTZXURRKXNGXTKYY
XKSU\KJLXUS68ZU IUTZOT[OZ_LXUSZNKMXT IUTTKIZUXZU68
ZNK(ZKXSOTGRUTZNK ]OXKZNGZ]GYP[YZ
SUZUXIUTZXURRKX XKSU\KJLXUS68ZU
ZNK(ZKXSOTGRUTZNK
SUZUXIUTZXURRKX
SUXK
ZNGT
QORUNSY
RKYYZNGT
SUXK )NKIQIUTZOT[OZ_LXUS 
ZNGT VOTMXT]OXKUTZNK QORUNSY 8KVRGIKZNKSUZUX
QORUNSY SUZUXIUTZXURRKXZUZNK
(ZKXSOTGRUTZNKSUZUX IUTZXURRKX
IUTZXURRKX
SUXK
ZNGT
QORUNSY
6RKGYKHKMOT 6RKGYKHKMOT
ZXU[HRKYNUUZOTMLXUS ZXU[HRKYNUUZOTMLXUS
HKMOTTOTMULINGXZ HKMOTTOTMULINGXZ
Genie Z-30/20N 6 - 135
Section 6 • Troubleshooting Flow Charts First Edition • Third Printing

Chart 39C
Motor Controller (RUIQZNKYZKKX]NKKRY < 6XKYYJU]TZNKLUUZ < 8KVGOXUVKTOTUXMXKJ
GTJXGOYKZNKSGINOTK Y]OZINGTJINKIQZNK ]OXKIOXI[OZ]OZNJOUJK
Fault Code 34: YUJXO\KZOXKYGXKULLZNK \URZGMKGZ:( LXUS:(ZUVOTUT
Missing Main MXU[TJ=OZNQK_Y]OZIN ZNKSUZUXIUTZXURRKX
Z[XTKJZUVRGZLUXS NGXTKYYIUTTKIZUX58
Contactor OR IUTZXURYGTJHUZN XKVRGIKZNKJOUJK
+SKXMKTI_9ZUVH[ZZUTY <
Main Contactor V[RRKJU[ZZUZNK54
VUYOZOUTVXKYYJU]TZNK
Did Not Close LUUZY]OZINGTJINKIQ <
ZNK\URZGMKGZVOTUT )NKIQ\URZGMKGZ:( 8KVGOXUVKTOTXKJ]NZ
(after serial ZNKSUZUXIUTZXURRKX ]OXKIOXI[OZLXUS:(ZU
NGXTKYYIUTTKIZUX VRGZLUXS+SKXMKTI_
number 3446) 9ZUVH[ZZUT6
<
Troubleshooting drive
function faults may also
be accomplished by )NKIQ\URZGMKGZ < 8KVGOXUVKTOTXKJ]NZ
using the hand-held ZKXSOTGR UT)8 ]OXKLXUS:(ZU
pendant motor controller ZKXSOTGR UT)8
programmer (Genie part <
number 56303).

Be sure to check the )NKIQZNK\URZGMKGZ < 8KVGOXUVKTOTHXT

ZKXSOTGR UT)8 MXU[TJ]OXKIOXI[OZLXUS
motor controller status ZKXSOTGR UT)8ZU
indicator light on the MXU[TJ58XKVGOXUVKT
ground control box or on OT]OXKLXUSZKXSOTGR 
UT)8ZUZKXSOTGR 
the motor controller. If UT)858XKVGOXUVKT
the motor controller OTUXMXKJ )8LXUS
status indicator light is < ZNK'L[YK,ZU
ZKXSOTGR UT)858
flashing a fault code, < XKVRGIK)8
refer to the fault code
chart at the beginning of
this section.
)NKIQZNK\URZGMKGZ < 8KVGOXUVKTOTHXT
Be sure the circuit ZKXSOTGR UT)8 MXU[TJ]OXKLXUS
breakers and fuses are ZKXSOTGR UT)8ZU
not tripped or blown. MXU[TJ58XKVGOXUVKT
OTXKJ]NZ]OXKLXUS:(
ZUZKXSOTGR UT)8
Be sure the battery < 58XKVRGIK)8
packs are properly
connected and fully
charged.
8KVGOXUVKTOTUXMXKJ
Be sure the machine is ]OXKLXUSZKXSOTGR 
not in the free wheel UT)8ZU:(
configuration.

Be sure the unit is in the

fully stowed position with )UTZOT[KJUTZNKTK^Z
the boom located VGMK
between the non-steer
end tires.

6 - 136 Genie Z-30/20N Part No. 35532

First Edition • Third Printing Section 6 • Troubleshooting Flow Charts

CHART 39C

)NKIQ\URZGMKUTZNK < 8KVGOXUVKTOTIGHRK

)UTZOT[KJLXUSZNK
VXK\OU[YVGMK
HGZZKX_IGHRKUTZNK
OTV[ZYOJKUL68
<
IOXI[OZLXUSHGZZKX_
VGIQYZU'L[YK,
58XKVRGIKZNK'
L[YK,

6XKYYJU]TZNKLUUZ < 8KVGOXUVKTOTHR[]NZ

Y]OZINGTJINKIQ ]OXKLXUS:(ZU
\URZGMKGZ:( ZKXSOTGR'UTZNK
PU_YZOIQIUTZXURRKX

<UXSUXK

6XKYYJU]TZNKLUUZ
Y]OZINGTJINKIQ <
\URZGMKGZVOTUTZNK
SUZUXIUTZXURRKXNGXTKYY
IUTTKIZUX
8KVGOXUVKTOTHR[]NZ
]OXKLXUS:(ZUVOT
UTZNKSUZUXIUTZXURRKX
NGXTKYYIUTTKIZUX

<UXSUXK

< <
:[XTQK_Y]OZINZUZNK )NKIQ\URZGMKUTZNK 8KVRGIK68
5,,VUYOZOUT=GOZLUX UXMXKJ]OXKGZ68
YKIUTJYGTJZ[XTZNK
QK_Y]OZINZUVRGZLUXS
IUTZXURY*UTUZVXKYY <
JU]TZNKLUUZY]OZIN
)NKIQ\URZGMKGZZNKMXT 8KVGOXUVKTOTUXMXKJ
]OXKUT68 ]OXKIOXI[OZLXUS:(ZU
68
<

8KSU\KZNKJOUJKLXUS /TYZGRRGTK]JOUJKUTZU
68GTJOTYZGRROZUTZU _KY 68]OZNZNKHGTJUT
68]OZNZNKHGTJUT ZNKJOUJKGROMTKJ]OZN
ZNKJOUJKGROMTKJ]OZN ZNKXKJ]OXK
ZNKUXMXKJ]OXK
6[YNOTZNK+SKXMKTI_
9ZUVH[ZZUTZUZNK5,,
VUYOZOUTGTJ]GOZLUX
YKIUTJYZNKTV[RRU[Z
ZNK+SKXMKTI_9ZUV
H[ZZUTZUZNK54
VUYOZOUT6XKYYJU]TZNK
LUUZY]OZINGTJZKYZZNK
JXO\KL[TIZOUT*UKYZNK
SGINOTKJXO\K%

TU

)UTZOT[KJUTZNKTK^Z
VGMK

Part No. 35532 Genie Z-30/20N 6 - 137

Section 6 • Troubleshooting Flow Charts
CHART 39C
)NKIQ\URZGMKHKZ]KKT
)UTZOT[KJLXUSZNK ZNKZKXSOTGRY(GTJ(
VXK\OU[YVGMK
UTZNKSUZUXIUTZXURRKX
4UZKZNK\URZGMK6XKYY
JU]TZNKLUUZY]OZINGTJ TU
INKIQ\URZGMKHKZ]KKT
VOTUTZNKSUZUX
IUTZXURRKXNGXTKYY
IUTTKIZUXGTJZKXSOTGR
(/YZNK\URZGMK]OZNOT
<ULZNKLOXYZXKGJOTM%
_KY
8KVGOXUVKTOTMXT]OXK
LXUS68ZUVOT58
XKVRGIK6858ZKYZZNK
SUZUXIUTZXURRKX9KK
8KVGOX9KIZOUT
6 - 138 Genie Z-30/20N
First Edition • Third Printing
*OYIUTTKIZZNKHGZZKXOKY *XO\KL[TIZOUTYNU[RJHK
LXUSZNKSGINOTK UVKXGZOTMTUXSGRR_/LOZ
_KY
8KSU\KZNK68 JUKYTUZHKMOT
SU[TZOTMLGYZKTKXY ZXU[HRKYNUUZOTMLXUS
)RKGTGRRIUTZGIZZOVY HKMOTTOTMULINGXZ
[TZORZNK_GXKIRKGTGTJ
YSUUZN/TYZGRRZNK
IUTZGIZUXUTZUZNK
VU]KXVGTKRGTJ
IUTTKIZZNKHGZZKXOKY
=OZNQK_Y]OZINZ[XTKJ
ZUVRGZLUXSIUTZXURYGTJ
HUZN+SKXMKTI_9ZUV
H[ZZUTYV[RRKJU[ZZUZNK
54VUYOZOUTVXKYYJU]T
ZNKLUUZY]OZINGTJZKYZ
ZNKJXO\KL[TIZOUT*UKY
ZNKSGINOTKJXO\K%
TU
8KVRGIKZNKSUZUX
IUTZXURRKX
Part No. 35532
First Edition • Third Printing
Brake Release
Function
Inoperative
(after serial
number 3446)
Be sure all other
functions operate
normally.
Troubleshooting brake
release faults may also
be accomplished by
using the hand-held
pendant motor controller
programmer (Genie part
number 56303).
Be sure to check the
motor controller status
indicator light on the
ground control box or on
the motor controller. If
the motor controller
status indicator light is
flashing a fault code,
refer to the fault code
chart at the beginning of
this section.
Be sure the battery
packs are properly
connected and fully
charged.
Be sure the circuit
breakers and fuses are
not tripped or blown.
Be sure the unit is in the
fully stowed position
with the boom located
between the non-steer
end tires.
Part No. 35532
:[XTQK_Y]OZINZU
VRGZLUXSIUTZXURYGTJ _KY
V[RRHUZN+SKXMKTI_
9ZUVH[ZZUTYU[ZZUZNK
54VUYOZOUT6XKYYJU]T
ZNKLUUZY]OZINGTJ
INKIQZNKYZGZ[Y
OTJOIGZUXROMNZUTZNK
SUZUXIUTZXURRKXZUYKKOL
ZNKXKOYGLG[RZ/YZNKXK
GLG[RZ%
TU
(RUIQZNKYZKKX]NKKRY
GTJXGOYKZNKSGINOTK
<
YUJXO\KZOXKYGXKULLZNK
MXU[TJ=OZNQK_Y]OZIN
Z[XTKJZUVRGZLUXS
IUTZXURYGTJHUZN
+SKXMKTI_9ZUVH[ZZUTY
V[RRKJU[ZZUZNK54
VUYOZOUTVXKYYJU]TZNK
LUUZY]OZINGTJSU\K
ZNKJXO\KIUTZXURRKXOT
KOZNKXJOXKIZOUTGTJ
INKIQ\URZGMKGZ:(
<
6XKYYJU]TZNKLUUZ <
Y]OZINGTJSU\KZNK
JXO\KIUTZXURRKXOTKOZNKX
JOXKIZOUTGTJINKIQ
\URZGMKGZZKXSOTGR 
UT)8
<
6XKYYJU]TZNKLUUZ
Y]OZINGTJSU\KZNK
JXO\KIUTZXURRKXOTKOZNKX <
JOXKIZOUTGTJINKIQ
\URZGMKGZZKXSOTGR  SUZUXIUTZXURRKXNGXTKYY
UT)8
<
)UTZOT[KJUTZNKTK^Z
VGMK
Genie Z-30/20N
Section 6 • Troubleshooting Flow Charts
Chart 40
8KLKXZUZNKLG[RZIUJK
INGXZGZZNKHKMOTTOTMUL
ZNOYYKIZOUTZUJKZKXSOTK
ZNKIG[YKULZNKLG[RZ
6XKYYJU]TZNKLUUZ 9KK)NGXZ*XO\K
Y]OZINGTJSU\KZNK < +TGHRK9_YZKS
JXO\KIUTZXURRKXOTKOZNKX /TUVKXGZO\KGLZKXYKXOGR
JOXKIZOUTGTJINKIQZNK T[SHKX
\URZGMKGZ:6
<
8KVGOXUVKTOTUXMHRQ
]OXKLXUS:(ZU:6
8KVGOXUVKTOTUXMHRQ
]OXKLXUS:(ZU
ZKXSOTGR UT)8
*UTUZVXKYYJU]TZNK 8KVGOXUVKTOTUXMXKJ
LUUZY]OZIN)NKIQ ]OXKIOXI[OZLXUS:(ZU
\URZGMKGZZNKXKJHRQ < ZKXSOTGR UT)858
]OXKUTVOTULZNK XKVGOXUVKTOTXKJHRQ
]OXKLXUSVOTZU
IUTTKIZUX ZKXSOTGR UT)858
XKVRGIK)8
<
6XKYYJU]TZNKLUUZ < 8KVRGIKZNKSUZUX
Y]OZINGTJINKIQ IUTZXURRKX
\URZGMKGZZNKXKJHRQ
]OXKUTVOTULZNK
SUZUXIUTZXURRKXNGXTKYY
IUTTKIZUX
<
8KVRGIK)8
6 - 139
Section 6 • Troubleshooting Flow Charts
CHART 40
6XKYYJU]TZNKLUUZ
)UTZOT[KJLXUSZNK Y]OZINGTJSU\KZNK <
VXK\OU[YVGMK JXO\KIUTZXURRKXOTKOZNKX
JOXKIZOUTGTJINKIQ
\URZGMKGZ:(
<
/TYKXZGP[SVKX]OXK
HKZ]KKT:(GTJ
:(6XKYYJU]TZNK
LUUZY]OZINGTJSU\K _KY
ZNKJXO\KIUTZXURRKXOT
KOZNKXJOXKIZOUT*UKY
ZNKVU]KX[TOZZ[XTUT%
TU
6XKYYJU]TZNKLUUZ
Y]OZINGTJSU\KZNK <
JXO\KIUTZXURRKXOTKOZNKX
JOXKIZOUT)NKIQ\URZGMK
UTZNKXKJ]NZ]OXKYUT
ZNKHXGQKXKRKGYK\GR\K
IUORYOZKSY==GTJ
::
<
8KSU\KZNKHXGQK
XKRKGYK\GR\KIUORGTJ
IRKGTZNKIUORIUTZGIZ _KY
XOTMYUTHUZNKTJYUL
ZNKIUOR:NKTOTYZGRRZNK
IUORUTZUZNK\GR\K
IGXZXOJMK*XO\KZNK
SGINOTK*UZNKHXGQKY
XKRKGYK%
TU
)UTZOT[KJUTZNKTK^Z
VGMK
6 - 140 Genie Z-30/20N
First Edition • Third Printing
8KVGOXUVKTOTXKJ]NZ
]OXKLXUSZKXSOTGR
UT)8ZU:(58
XKVRGIKJOUJK
8KSU\KZNKVXKYY[XK _KY 8KVRGIKZNKVXKYY[XK
Y]OZINVR[MGTJVRGIKG Y]OZIN
P[SVKXHKZ]KKT
ZKXSOTGRYGTJUTZNK
VR[M6XKYYJU]TZNK
LUUZY]OZINGTJSU\K
ZNKJXO\KIUTZXURRKXOT
KOZNKXJOXKIZOUT*UKY
ZNKVU]KX[TOZZ[XTUT%
TU
8KVGOXUVKTOTXKJ]NZ
]OXKLXUS:(
ZNXU[MNXKJ]NZ]OXK
IOXI[OZZUVXKYY[XK
Y]OZINZNKTMXT]NZ 
]OXK]OZNJOUJKZU:(
58XKVRGIKZNKJOUJK
8KVGOXUVKTOTXKJ]NZ
]OXKYLXUS:(ZUZNK
HXGQKXKRKGYK\GR\K
IUORYOZKSY==GTJ
::
*XO\KGTJHXGQKXKRKGYK
L[TIZOUTYYNU[RJHK
UVKXGZOTMTUXSGRR_/L
ZNK_JUTUZHKMOT
ZXU[HRKYNUUZOTMLXUS
HKMOTTOTMULINGXZ
Part No. 35532
First Edition • Third Printing Section 6 • Troubleshooting Flow Charts

CHART 40

)UTZOT[KJLXUSZNK
VXK\OU[YVGMK
)NKIQIUTZOT[OZ_LXUS
ZNKHXGQKXKRKGYK\GR\K TU
IGXZXOJMKZUZNKMXU[TJ IUTZOT[OZ_
HURZOTYOJKZNKMXU[TJ
IUTZXURHU^
8KVGOXUVKTOTHXT
MXU[TJ]OXKIOXI[OZLXUS
ZNKL[TIZOUTSGTOLURJZU
ZNKMXU[TJHURZOTYOJK
ZNKMXU[TJIUTZXURHU^

IUTZOT[OZ_
UX
*OYIUTTKIZZNK]OXKY OTLOTOZK
LXUSKGINULZNK\GR\K UNSY
IUORYGTJINKIQZNK 8KVRGIKJKLKIZO\K\GR\K
XKYOYZGTIKULZNK\GR\K IUOR
IUORY9KK8KVGOX
9KIZOUT
ZU
UNSY
)UTY[RZ-KTOK/TJ[YZXOKY
9KX\OIK*KVGXZSKTZ

Part No. 35532 Genie Z-30/20N 6 - 141

Section 6 • Troubleshooting Flow Charts First Edition • Third Printing

Chart 41
Drive Forward =OZNQK_Y]OZINZ[XTKJ 8KSU\K]NZHRQ GTJ
UX

<UX OTLOTOZK

Function ZUVRGZLUXSIUTZXURYGTJ

HUZN+SKXMKTI_9ZUV
SUXK
MXU[TJ]OXKYLXUS68

IUORGTJINKIQ
UNSY
8KVGOXUXXKVRGIK68

Inoperative H[ZZUTYV[RRKJU[ZZUZNK

54VUYOZOUTVXKYYJU]T
XKYOYZGTIKULLUX]GXJ

IUOR

ZNKLUUZY]OZINGTJSU\K
Be sure key switch is in ZNKJXO\KIUTZXURRKXOTZNK
UNSY
the appropriate position. ,58='8*JOXKIZOUTGTJ
INKIQ\URZGMKUT]NZHRQ

Be sure the Emergency ]OXKUTLUX]GXJ 8KVGOXUXXKVRGIK68

IUTZGIZUX68 IUTZGIZY58XKVGOXUVKT
Stop buttons are pulled OTMXU[TJ]OXKIOXI[OZ58
out to the ON position. IUTY[RZ-KTOK/TJ[YZXOKY

9KX\OIK*KVGXZSKTZ

Be sure the battery <

packs are properly

connected and fully
charged. 6XKYYJU]TZNKLUUZ <UX 8KVGOXUVKTOT]NOZKHRQ

Y]OZINGTJSU\KZNK SUXK ]OXKIOXI[OZLXUS

JXO\KIUTZXURRKXOTZNK :(ZUZNKLUX]GXJ

,58='8*JOXKIZOUTGTJ IUTZGIZUX

INKIQ\URZGMKUT:(

<

6XKYYJU]TZNKLUUZ <UX 8KVGOXUVKTOT]OXK

Y]OZINGTJSU\KZNK SUXK IOXI[OZLXUS]NZHRQ

JXO\KIUTZXURRKXOTZNK ]OXKUTSOIXUY]OZINUT

,58='8*JOXKIZOUTGTJ JXO\KIUTZXURRKXZU:(

INKIQ\URZGMKUT]NZ

HRQ]OXKUTSOIXU

Y]OZINUTZNKJXO\K

IUTZXURRKX

<

8KVGOXUXXKVRGIKSOIXU

Y]OZINUTZNKJXO\K

IUTZXURRKX58JXO\K

IUTZXURRKXIGSYGXKU[Z

ULGJP[YZSKTZ)UTY[RZ

-KTOK/TJ[YZXOKY9KX\OIK

*KVGXZSKTZ

6 - 142 Genie Z-30/20N Part No. 35532

First Edition • Third Printing
Drive Reverse
Function
Inoperative
Be sure key switch is in
the appropriate position.
Be sure the Emergency
Stop buttons are pulled
out to the ON position.
Be sure the battery
packs are properly
connected and fully
charged.
Part No. 35532
Section 6 • Troubleshooting Flow Charts
Chart 42
=OZNQK_Y]OZINZ[XTKJ 8KSU\K]NZ GTJ
UX
<UX OTLOTOZK
ZUVRGZLUXSIUTZXURYGTJ
HUZN+SKXMKTI_9ZUV
SUXK
MXU[TJ]OXKYLXUS68
IUORGTJINKIQ
UNSY
8KVGOXUXXKVRGIK68
H[ZZUTYV[RRKJU[ZZUZNK
54VUYOZOUTVXKYYJU]T
XKYOYZGTIKULXK\KXYK
IUOR
ZNKLUUZY]OZINGTJ
SU\KZNKJXO\KIUTZXURRKX
UNSY
8+<+89+ JOXKIZOUT
OTZNK
GTJINKIQ\URZGMKUT
]NZ ]OXKUTLUX]GXJ 8KVGOXUXXKVRGIK68
XK\KXYKIUTZGIZUX68 IUTZGIZY58XKVGOXUVKT
OTMXU[TJ]OXKIOXI[OZ58
IUTY[RZ-KTOK/TJ[YZXOKY
9KX\OIK*KVGXZSKTZ
<
6XKYYJU]TZNKLUUZ
<UX
8KVGOXUVKTOT]NZ 
SUXK
Y]OZINGTJSU\KZNK ]OXKIOXI[OZLXUS:(ZU
JXO\KIUTZXURRKXOTZNK LUX]GXJXK\KXYK
8+<+89+ JOXKIZOUTGTJ IUTZGIZUX
INKIQ\URZGMKUT:(
<
6XKYYJU]TZNKLUUZ <UX 8KVGOXUVKTOT]OXK
Y]OZINGTJSU\KZNK SUXK IOXI[OZLXUS]NZ]OXK
JXO\KIUTZXURRKXOTZNK UTSOIXUY]OZINUTZNK
8+<+89+ JOXKIZOUTGTJ JXO\KIUTZXURRKXZU:(
INKIQ\URZGMKUT]NZ
]OXKUTSOIXUY]OZINUT
ZNKJXO\KIUTZXURRKX
<
8KVGOXUXXKVRGIKSOIXU
Y]OZINUTZNKJXO\K
IUTZXURRKX58JXO\K
IUTZXURRKXIGSYGXKU[Z
ULGJP[YZSKTZ)UTY[RZ
-KTOK/TJ[YZXOKY9KX\OIK
*KVGXZSKTZ
Genie Z-30/20N 6 - 143
Section 6 • Troubleshooting Flow Charts First Edition • Third Printing

Chart 43
Machine Will :[XTQK_Y]OZINZU 'JP[YZZNKJXO\K
VRGZLUXSIUTZXURYGTJ IUTZXURRKX9KK8KVGOX
Not Drive At V[RRHUZN+SKXMKTI_
<UX
9KIZOUT58XKVGOXUX
SUXK
Full Speed 9ZUVH[ZZUTYU[ZZUZNK XKVRGIKJXO\KIUTZXURRKX
54VUYOZOUT)NKIQ 58IUTY[RZ-KTOK
(before serial \URZGMKUT8ZKXSOTGR /TJ[YZXOKY9KX\OIK
UTZNKJXO\KIUTZXURRKX *KVGXZSKTZ
number 3447)
<
Be sure the unit is in the <UX
fully stowed position SUXK
)NKIQ\URZGMKUT:( 8KVGOXUVKTOTUXM
with the boom located ]OXKIOXI[OZLXUS:(ZU
between the non-steer 8ZKXSOTGRUTZNKJXO\K
IUTZXURRKX
end tires. <
Be sure the battery <UX
packs are properly SUXK
)NKIQ\URZGMKUT:( 8KVGOXUVKTOT]OXK
connected and fully IOXI[OZLXUS
charged. (KLUXKYKXOGRT[SHKX
 :(ZU29ZU
:(ZU29ZU:(
'LZKXYKXOGRT[SHKX
 :(ZU29ZU
< :(ZU29ZU:(ZU
29ZU:(

8KVGOXUVKTOTZNK]NZ
]OXKIOXI[OZ]OZNJOUJK
LXUSZNKVRGZLUXS
+SKXMKTI_9ZUVH[ZZUT
ZU:(58XKVRGIKZNK
JOUJK

6 - 144 Genie Z-30/20N Part No. 35532

First Edition • Third Printing
Machine Will
Not Drive At
Full Speed
(after serial
number 3446)
Be sure all other
functions operate
normally.
Be sure the boom is in
the stowed position with
the primary boom fully
retracted.
Be sure that the primary
boom extension limit
switch (LS1) is being
activated when the
primary boom is
retracted.
Be sure that the primary
boom and secondary
boom limit switches
(LS2 and LS3) are not
being activated when
the primary and
secondary booms are in
the stowed position.
Be sure the battery
packs are properly
connected and fully
charged.
Part No. 35532
:[XTQK_Y]OZINZU
MXU[TJIUTZXURYGTJV[RR
HUZN+SKXMKTI_9ZUV
H[ZZUTYU[ZZUZNK54
VUYOZOUT)NKIQZNK
YZGZ[YOTJOIGZUXROMNZUT
ZNKSUZUXIUTZXURRKXZU
YKKOLZNKXKOYGLG[RZ/Y
ZNKXKGLG[RZ%
TU
)NKIQ\URZGMKGZ:(
<
)NKIQ\URZGMKGZZNK
]NZ]OXKUTZNKOTV[Z
YOJKUL29
<
)NKIQ\URZGMKGZ:(
<
)NKIQ\URZGMKGZZNK
HRQ]OXKUTZNKOTV[Z
YOJKUL29
<
)NKIQ\URZGMKGZ:(
<
)UTZOT[KJUTZNKTK^Z
VGMK
Genie Z-30/20N
Section 6 • Troubleshooting Flow Charts
Chart 44
8KLKXZUZNKLG[RZIUJK
_KY INGXZGZZNKHKMOTTOTMUL
ZNOYYKIZOUTZUJKZKXSOTK
ZNKIG[YKULZNKLG[RZ
<
8KVGOXUVKTOTHRQ 
]OXKLXUSQK_Y]OZINZU
:(
< 8KVGOXUVKTOT]NZ
]OXKLXUS:(ZUZNK
OTV[ZYOJKUL29
<
)NKIQZUSGQKY[XK29
OYHKOTMGIZO\GZKJ]NKT
ZNKVXOSGX_HUUSOY
XKZXGIZKJ58XKVGOX
UVKTOTHRQ]OXKLXUS
ZNKU[ZV[ZYOJKUL29ZU
:(58XKVRGIK29
IUTZGIZY58XKVRGIK
29
< 8KVGOXUVKTOTHRQ
]OXKLXUS:(ZUZNK
OTV[ZYOJKUL29
<
)NKIQZUSGQKY[XK29
OYTUZHKOTMGIZO\GZKJ
]NKTZNKVXOSGX_HUUS
OYOTZNKYZU]KJVUYOZOUT
58XKVGOXUVKTOT]NZ
]OXKLXUSZNKU[ZV[ZYOJK
UL29ZU:(58
XKVRGIK29IUTZGIZY
58XKVRGIK29
6 - 145
Section 6 • Troubleshooting Flow Charts
CHART 44
)NKIQ\URZGMKGZZNK <
)UTZOT[KJLXUSZNK ]NZ]OXKUTZNKOTV[Z
VXK\OU[YVGMK YOJKUL29
<
<
)NKIQ\URZGMKGZ:(
<
)NKIQ\URZGMKGZVOT <
UTZNKSUZUXIUTZXURRKX
NGXTKYYIUTTKIZUX
<
:KYZZNKSUZUXIUTZXURRKX
YKK8KVGOX9KIZOUT58
IUTY[RZ-KTOK/TJ[YZXOKY
9KX\OIK*KVGXZSKTZ
6 - 146 Genie Z-30/20N
First Edition • Third Printing
8KVGOXUVKTOT]NZ
]OXKLXUS:(ZUZNK
OTV[ZYOJKUL29
)NKIQZUSGQKY[XK29
OYTUZHKOTMGIZO\GZKJ
]NKTZNKYKIUTJGX_
HUUSOYOTZNKRU]KXKJ
VUYOZOUT58XKVGOXUVKT
OTHRQ]OXKIOXI[OZLXUS
ZNKU[ZV[ZYOJKUL29ZU
:(58XKVRGIK29
IUTZGIZY58XKVRGIK
29
8KVGOXUVKTOTUXM 
]OXKIOXI[OZLXUS:(ZU
VOTUTZNKSUZUX
IUTZXURRKXNGXTKYY
IUTTKIZUX
Part No. 35532
First Edition • Third Printing
Machine Drives
At Full Speed
With Platform
Raised Or
Extended
(before serial
number 3447)
Remove the machine
from service
immediately.
Be sure the wiring to the
limit switches is intact
and shows no signs of
damage or corrosion.
Be sure the primary
boom drive limit switch
is being activated by the
cam on the boom when
the primary boom is
raised.
Be sure the secondary
boom drive limit switch
is being activated by the
secondary boom
compression arm when
the secondary boom is
raised.
Part No. 35532
Section 6 • Troubleshooting Flow Charts
Chart 45
:[XTQK_Y]OZINZU <UX 8KVGOXUXXKVRGIK29 'JP[YZJXO\KIUTZXURRKX
VRGZLUXSIUTZXURYGTJ SUXK 58INKIQLUX < 58XKVGOXUXXKVRGIK
V[RRHUZN+SKXMKTI_ SKINGTOIGRXKYZXOIZOUT JXO\KIUTZXURRKX58
9ZUVH[ZZUTYU[ZZUZNK QKKVOTM29GIZO\GZKJ IUTY[RZ-KTOK/TJ[YZXOKY
54VUYOZOUT=OZNZNK 9KX\OIK*KVGXZSKTZ
VXOSGX_HUUSXGOYKJ
GHU\KZNKROSOZY]OZIN
29INKIQ\URZGMKUT
:(
<
+^ZKTJZNKVXOSGX_ <UX 8KVGOXUXXKVRGIK29 'JP[YZJXO\KIUTZXURRKX
HUUSVGYZZNKROSOZ SUXK 58INKIQLUX < 58XKVGOXUXXKVRGIK
Y]OZIN29GTJINKIQ SKINGTOIGRXKYZXOIZOUT JXO\KIUTZXURRKX58
\URZGMKUT QKKVOTM29GIZO\GZKJ IUTY[RZ-KTOK/TJ[YZXOKY
(KLUXKYKXOGRT[SHKX 9KX\OIK*KVGXZSKTZ
 :(
'LZKXYKXOGRT[SHKX
 :(
<
'LZKXYKXOGRT[SHKX <UX 8KVGOXUXXKVRGIK29
 8GOYKZNK SUXK 58INKIQLUX
YKIUTJGX_HUUSGHU\K SKINGTOIGRXKYZXOIZOUT
ZNKROSOZY]OZIN29GTJ QKKVOTM29GIZO\GZKJ
INKIQ\URZGMKUT:(
<
'JP[YZJXO\KIUTZXURRKX
58XKVGOXUXXKVRGIK
JXO\KIUTZXURRKX58
IUTY[RZ-KTOK/TJ[YZXOKY
9KX\OIK*KVGXZSKTZ
Genie Z-30/20N 6 - 147
Section 6 • Troubleshooting Flow Charts First Edition • Third Printing

Chart 46
Machine Drives :[XTQK_Y]OZINZU 8KLKXZUZNKLG[RZIUJK
MXU[TJIUTZXURYGTJV[RR _KY INGXZGZZNKHKMOTTOTMUL
At The Incorrect HUZN+SKXMKTI_9ZUV ZNOYYKIZOUTZUJKZKXSOTK
Speed With H[ZZUTYU[ZZUZNK54 ZNKIG[YKULZNKLG[RZ
VUYOZOUT)NKIQZNK
Platform Raised YZGZ[YOTJOIGZUXROMNZUT
ZNKSUZUXIUTZXURRKXZU
Or Extended YKKOLZNKXKOYGLG[RZ
/YZNKXKGLG[RZ%
(after serial
number 3446) TU
<
Troubleshooting the =OZNZNKHUUSOTZNK 8KLKXZU)NGXZ
raised drive speed faults RU]KXKJVUYOZOUTINKIQ
\URZGMKGZVOTUTZNK
may be accomplished by SUZUXIUTZXURRKXNGXTKYY
using the hand-held IUTTKIZUX
pendant motor controller
programmer (Genie part <
number 56303).
8GOYKZNKVXOSGX_HUUS )NKIQLUXVXUVKX
Be sure the M1 MAX GVVXU^OSGZKR_LKKZ < GIZO\GZOUTULVXOSGX_
SGTJINKIQ\URZGMK HUUSROSOZY]OZIN29
SPEED is set to 33. If GZVOTUTZNKSUZUX 58XKVRGIK29IUTZGIZ
needed, adjust the M1 IUTZXURRKXNGXTKYY 58XKVRGIK29
MAX SPEED higher or IUTTKIZUX
lower to achieve the
<
maximum raised drive
speed of 0.6 mph
2U]KXZNKVXOSGX_HUUS )NKIQLUXVXUVKX
/ 1Km/h or 40 feet / ZUZNKRU]KXKJVUYOZOUT GIZO\GZOUTULYKIUTJGX_
<
45 seconds / 12.2 meters GTJXGOYKZNKYKIUTJGX_ HUUSROSOZY]OZIN29
/ 45 seconds. HUUSGVVXU^OSGZKR_ 58XKVRGIK29IUTZGIZ
LKKZS)NKIQ\URZGMK 58XKVRGIK29
GZVOTUTZNKSUZUX
Be sure wiring to limit IUTZXURRKXNGXTKYY
switches is intact and IUTTKIZUX
shows no signs of
damage or corrosion. <

Be sure the primary 2U]KXZNKYKIUTJGX_ )NKIQLUXVXUVKX

boom drive limit switch is HUUSZUZNKRU]KXKJ GIZO\GZOUTULVXOSGX_
being activated by the VUYOZOUTGTJK^ZKTJZNK < HUUSK^ZKTJROSOZY]OZIN
VXOSGX_HUUS 2958XKVRGIK29
cam on the boom when GVVXU^OSGZKR_OTINKY IUTZGIZ58XKVRGIK29
the primary boom is IS)NKIQ\URZGMK
raised. GZVOTUTZNKSUZUX
IUTZXURRKXNGXTKYY
IUTTKIZUX
Be sure the secondary
boom drive limit switch is <
being activated by the
secondary boom 8KVRGIKZNKSUZUX
compression arm when IUTZXURRKX58IUTY[RZ
the secondary boom is -KTOK/TJ[YZXOKY9KX\OIK
*KVGXZSKTZ
raised.

6 - 148 Genie Z-30/20N Part No. 35532

First Edition • Third Printing
Drive Enable :[XTQK_Y]OZINZU <
VRGZLUXSIUTZXURYGTJ
System Is V[RRHUZN+SKXMKTI_
Malfunctioning 9ZUVH[ZZUTYU[ZZUZNK
54VUYOZOUT6XKYYJU]T
(before serial ZNKLUUZY]OZINGTJ
INKIQ\URZGMKGZ:(
number 3447)
<
Be sure the machine is
in the stowed position 6XKYYJU]TZNKLUUZ <
Y]OZINGTJINKIQ
with the turntable \URZGMKGZ:(
rotated so the boom is
in between the non- <
steer wheels.
6XKYYJU]TZNKLUUZ
Be sure all other Y]OZINGTJINKIQ <
functions operate \URZGMKGZZKXSOTGR
normally. UTJXO\KIUTZXURRKX
<
<
8UZGZKZNKHUUSVGYZ
KOZNKXTUTYZKKX]NKKR
GTJINKIQ\URZGMKUT
:(
<
6XKYYJU]TZNKLUUZ
Y]OZINGTJNURJZNK
JXO\KKTGHRKZUMMRK <
Y]OZIN:9ZUKOZNKXYOJK
GTJINKIQ\URZGMKUT
ZKXSOTGRUTJXO\K
IUTZXURRKX
<
'JP[YZJXO\KIUTZXURRKX
58XKVRGIKJXO\K
IUTZXURRKX58IUTY[RZ
-KTOK/TJ[YZXOKY9KX\OIK
*KVGXZSKTZ
Part No. 35532 Genie Z-30/20N
Section 6 • Troubleshooting Flow Charts
Chart 47
8KVGOXUVKTOTHR[]NZ
]OXKIOXI[OZLXUS:(ZU
IKTZKXVURKUL:9
8KVGOXUVKTOTHRQ 
]OXKIOXI[OZLXUS:(
ZNXU[MNTUXSGRR_IRUYKJ
IUTZGIZUL29ZU:(
(KLUXKYKXOGRT[SHKX
 8KVGOXUVKTOTUXM
XKJ]OXKIOXI[OZLXUS
:(ZUZKXSOTGRUT
ZNKJXO\KIUTZXURRKX
'LZKXYKXOGRT[SHKX
 8KVGOXUVKTOT
UXMXKJ]OXKIOXI[OZLXUS
:(ZU)858XKVGOX
UVKTOTMXU[TJ]OXK
IOXI[OZLXUS)8ZU
MXU[TJ58XKVGOXUVKT
OTHR[]NZ]OXKIOXI[OZ
LXUSIKTZKXVURKGZ:9
ZU)858XKVGOXUVKT
OT]OXKIOXI[OZLXUS)8
ZUZKXSOTGRUTZNK
JXO\KIUTZXURRKX58
XKVRGIK)8
8KVGOXUXXKVRGIK29
8KVGOXUVKTOT]OXK
IOXI[OZLXUSJXO\KKTGHRK
ZUMMRKY]OZIN:9ZU
ZKXSOTGRUTJXO\K
IUTZXURRKX58XKVRGIK
:958IUTY[RZ-KTOK
/TJ[YZXOKY9KX\OIK
*KVGXZSKTZ
6 - 149
Section 6 • Troubleshooting Flow Charts First Edition • Third Printing

Chart 48
Drive Enable :[XTQK_Y]OZINZU 8KVGOXUVKTOTHR[]NZ
VRGZLUXSIUTZXURYGTJ < ]OXKIOXI[OZLXUS:(ZU
System Is V[RRHUZN+SKXMKTI_ ZNK]NZ]OXKUTZNK
Malfunctioning 9ZUVH[ZZUTYU[ZZUZNK IKTZKXZKXSOTGRUL:9
54VUYOZOUT6XKYYJU]T
(after serial ZNKLUUZY]OZINGTJ
INKIQ\URZGMKGZ:(
number 3446)
<
Be sure the machine is
in the stowed position 6XKYYJU]TZNKLUUZ 8KVGOXUVKTOTZNKHRQ
Y]OZINGTJINKIQ < ]OXKLXUS:(ZU
with the turntable \URZGMKGZZKXSOTGR  ZKXSOTGR UTZNK
rotated so the boom is UTZNKJXO\KKTGHRKROSOZ JXO\KKTGHRKROSOZY]OZIN
in between the non- Y]OZIN29
steer wheels.
<
Be sure all other
8UZGZKZNKHUUSVGYZ )NKIQLUXVXUVKX
functions operate KOZNKXTUTYZKKX]NKKR GIZO\GZOUTULJXO\K
normally. GTJINKIQ\URZGMKUT < KTGHRKROSOZY]OZIN29
ZNKXKJ]OXKGZ ]NKTZNKHUUSOY
ZKXSOTGR ULZNKJXO\K XUZGZKJVGYZKOZNKXTUT
KTGHRKROSOZY]OZIN29 YZKKX]NKKR58XKVRGIK
29IUTZGIZ58XKVRGIK
29
<

<
6XKYYJU]TZNKLUUZ 8KVRGIKJXO\KIUTZXURRKX
Y]OZINGTJINKIQ
\URZGMKUTUXMHRQ]OXK
GZZKXSOTGR UTJXO\K
IUTZXURRKX

<

6XKYYJU]TZNKLUUZ
Y]OZINGTJINKIQ <
\URZGMKGZZNK]NZ]OXK
UTZNKIKTZKXZKXSOTGR
UT:9
8KVGOXUVKTOT]NZ]OXK
LXUSZKXSOTGR UTZNK
JXO\KIUTZXURRKXZUZNK
IKTZKXZKXSOTGRUT:9

<

6XKYYJU]TZNKLUUZ
Y]OZINGTJNURJZNK <
JXO\KKTGHRKZUMMRK
Y]OZIN:9ZUKOZNKX
YOJKGTJINKIQ\URZGMK
GZZKXSOTGR UTZNK
JXO\KIUTZXURRKX
8KVRGIKZNKJXO\K
KTGHRKZUMMRKY]OZIN58
XKVGOXUVKTOTZNK]NZ
]OXKLXUS:9ZUIKTZKX
ZKXSOTGRUT:9

<

(KMOTZXU[HRKYNUUZOTM
LXUSZNKHKMOTTOTMUL
ZNKINGXZ58IUTY[RZ
-KTOK/TJ[YZXOKY9KX\OIK
*KVGXZSKTZ

6 - 150 Genie Z-30/20N Part No. 35532

First Edition • Third Printing Section 6 • Troubleshooting Flow Charts

Chart 49
Remote Brake 6[RRZNK+SKXMKTI_ 8KVGOXUVKTOTXKJ]OXK
9ZUVH[ZZUTGZMXU[TJ IOXI[OZLXUSOTV[ZYOJKUL
Release IUTZXURYU[ZZUZNK54
<
ZNKQK_Y]OZINZUZNK
Inoperative VUYOZOUT)NKIQ\URZGMK OTV[ZYOJKULZNKXKSUZK
GZZNKOTV[ZYOJKULZNK HXGQKXKRKGYKPGIQ
XKSUZKHXGQKXKRKGYK
Be sure all other PGIQ0UTZNKMXU[TJ
functions operate IUTZXURVGTKR
normally.
<UXSUXK
Be sure the battery
packs are properly =OZNZNKXKSUZKHXGQK < 8KVRGIKXKSUZKHXGQK
connected and fully XKRKGYKY]OZINVR[MMKJ XKRKGYKH[ZZUT58
OTZUZNKXKSUZKHXGQK XKVRGIKZNKXKSUZK
charged. XKRKGYKPGIQUTZNK HXGQKXKRKGYKPGIQ
MXU[TJIUTZXURVGTKR
VXKYYJU]TZNKXKSUZK
HXGQKXKRKGYKH[ZZUT
GTJINKIQ\URZGMKGZZNK
U[ZV[ZYOJKULZNKVR[M

<UXSUXK

(KLUXKYKXOGRT[SHKX
 'IZO\GZKXKSUZK
HXGQKXKRKGYKGTJINKIQ
\URZGMKGZ:( <
'LZKXYKXOGRT[SHKX
 'IZO\GZKXKSUZK
HXGQKXKRKGYKGTJINKIQ
\URZGMKGZ:(  8KVGOXUVKTOT
<UXSUXK
(KLUXKYKXOGRT[SHKX
 8KVGOXUVKTOT
XKJ]NZ]OXKIOXI[OZLXUS
ZNKU[ZV[ZYOJKULZNK
XKSUZKHXGQKXKRKGYK
PGIQZU:(
'LZKXYKXOGRT[SHKX
XKJ]NZ]OXKIOXI[OZLXUS
ZNKU[ZV[ZYOJKULZNK
XKSUZKHXGQKXKRKGYK
PGIQZU:(

(KLUXKYKXOGRT[SHKX
 'IZO\GZKXKSUZK <
HXGQKXKRKGYKGTJINKIQ
\URZGMKGZ:(
<UXSUXK
(KLUXKYKXOGRT[SHKX
 8KVGOXUVKTOT
XKJ]NZ]OXKIOXI[OZ]OZN
JOUJKLXUS:(ZU
:(58XKVRGIKZNK
JOUJK

8KSUZKHXGQKXKRKGYK
L[TIZOUTYNU[RJHK
UVKXGZOTM(KMOT
ZXU[HRKYNUUZOTMLXUSZNK
HKMOTTOTMULZNOYINGXZ

Part No. 35532 Genie Z-30/20N 6 - 151

Section 6 • Troubleshooting Flow Charts First Edition • Third Printing

This page intentionally left blank.

6 - 152 Genie Z-30/20N Part No. 35532

First Edition • Third Printing Section 7 • Schematics

Schematics
About This Section
There are two groups of schematics in this section.
An illustration legend precedes each group of
drawings.

Electrical Schematics

Observe and Obey: Electrocution hazard. Contact with

Troubleshooting and 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 Troubleshooting:
Read, understand and obey the safety rules
and operating instructions printed in the
Genie Z-30/20N Operator's Manual.
Be sure that all necessary tools and test
equipment are available and ready for use.
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 slowly to allow
the oil pressure to dissipate
gradually. Do not allow oil to squirt
or spray.
General Repair Process
Malfunction Identify Troubleshoot
discovered symptoms

problem
still exists

Return to Inspect Perform

service problem and test repair
solved

Part No. 35532 Genie Z-30/20N 7-1

Section 7 • Schematics First Edition • Third Printing

Electrical Components

Item Description Genie Part Manufacturer Manufacturer Qty

Number Part Number
AP1, AP2 ....... Anderson connector ............ 19436 ............. Anderson ............................. 63325-G1 ....................... 2

BAT1 .............. Battery, 6V DC, 350 AH ....... 56461 ............ Trojan .................................. L-16GH .......................... 8

BCI ................. Battery charge indicator ...... 23868 ............ Curtis Instruments ............... 900R48BN .................... 1

BP1 ................ Rotational Controller ........... 56886 ............ OEM Controls ...................... RS10T6585 ................... 1

CB1 ................ Circuit breaker .................... 375785 ........... ETA ...................................... 45-700-IG1-P10 ............. 1

CR .................. Relay, DPDT, 24V DC ......... 42616 ............ Potter and Brumfield ............ K10P 11D15-24 ............. 3

CR .................. Relay, SPST, 24V DC ......... 56302 ............ Potter and Brumfield ............ VF4-15H11-CO5 ........... 9

Diode ............. Diode, 6 amp, 200 PIV ........ 45782 ............ Motorola .............................. MOTMR752 ................. 36

DP1 ................ Joystick controller ................ 56773 ............ OEM Controls ...................... MS4M11750 ................. 1

FB ................... Flashing beacon .................. 20189 ............ ECCO Electronic Controls ... 6400X ............................ 1

F1 ................... Fuse, 500A .......................... 43179 ............ Buss ..................................... ANN-500 ........................ 1

F2, F3 ............. Fuse, 100A .......................... 36355 ............ Buss ..................................... ANN-100 ........................ 2

FS1 ................ Footswitch ........................... 13482 ............ Linemaster Switch Corp. ..... 632-S ............................. 1

H1 .................. Alarm, Warble tone .............. 45383 ............ Floyd Bell Inc. ...................... MW-09-530-Q ................ 1

H2 .................. Horn, 24V DC, 108 dB ......... 81579 ............ Hella .................................... 95348 ............................. 1

H3 .................. Alarm, intermittent ............... 18963 ............ Floyd Bell Inc. ...................... XB-09-630-Q ................. 1

H4 .................. Alarm, chime tone ............... 45462 ............ Floyd Bell Inc. ...................... CH-09-525-Q ................. 1

HM ................. Hourmeter ........................... 19506 ............ ENM Corporation ................ T40A4508 ...................... 1

This list continues on the next page.

7-2 Genie Z-30/20N Part No. 35532

First Edition • Third Printing Section 7 • Schematics

ELECTRICAL COMPONENTS

Item Description Genie Part Manufacturer Manufacturer Qty

Number Part Number
KS1 ................ Contact - Key switch, N.O. ... 45081 ............ Telemecanique ................... ZB2-BE101 .................... 2

LS1-LS4 ......... Contact - Limit switch .......... 19491 ............ Telemecanique ................... XESP2051 ..................... 1

Level sensor .. Level sensor,

4.5° (ANSI & CSA) ............... 44586 ............ Power Comp. of Midwest .... LS60-00733 ................... 1

MC1 ............... Motor controller, Curtis ........ 23314 ............ Curtis Instruments ............... 1205-205 ....................... 1

MC1 ............... Motor controller, Sepex,

48V DC, 500A ................... 56774-03 .......... Curtis Instruments ............... 1244-5508 ..................... 1

P1, P2 ............ Contact, N.C. ....................... 29732 ............ Telemecanique ................... ZB2-BE102 .................... 4

P3 ................... Contact, N.O. ....................... 45081 ............ Telemecanique ................... ZB2-BE101 .................... 1

PR1 ................ Relay, 180A ......................... 74267 ............ Curtis Instruments ............... 13221947 ...................... 1

PR2 ................ Relay, 180A ......................... 74266 ............ Curtis Instruments ............... 13221946 ...................... 1

PR3 ................ Relay, 80A ........................... 74268 ............ Curtis Instruments ............... 13221948 ...................... 1

TS ................... Toggle switch, DPST

2 position momentary .......... 13480 ............ Microswitch Control Inc. ...... 2NT1-8 ........................... 2

TS ................... Toggle switch, DPDT

3 position momentary .......... 16397 ............ Microswitch Control Inc. ...... 2NT1-7 ......................... 16

TS ................... Toggle switch, SPDT

3 position momentary .......... 13037 ............ Microswitch Control Inc. ...... 1NT1-7 ........................... 6

TS ................... Toggle switch, SPDT

2 position momentary .......... 42730 ............ Microswitch Control Inc. ...... 1NT1-8 ........................... 2

Part No. 35532 Genie Z-30/20N 7-3

Section 7 • Schematics First Edition • Third Printing

Load Sensor Option Diagram

(before serial number 4083)

LABEL DESCRIPTION

WH
RE

BLK

YE
P2 EMERGENCY STOP BUTTON

L
T
2 1 P3 HORN BUTTON
4 3 DP1 DRIVE CONTROLLER
BP1 BOOM SPEED CONTROLLER
TS1 TURNTABLE ROTATE SWITCH
CR5 2 1
4 3 TS2 SECONDARY BOOM SWITCH
6 5 TS3 PRIMARY BOOM SWITCH
8 7 TS4 EXTEND/RETRACT SWITCH
TS5 PLATFORM LEVEL SWITCH
RED/BLK 6 5 TS6 PLATFORM ROTATE SWITCH
TS7 JIB SWITCH
8 7
TS8 AUXILIARY SWITCH
TS9 DRIVE ENABLE SWITCH

BRN
L1 DRIVE ENABLE LIGHT
BCI BATTERY CHARGE INDICATOR
TS18 LIFT/DRIVE SELECT (OPTION)
L2 OVERLOAD LIGHT (OPTION)
FUSE

FOOT
110 SWITCH JIB
RED/BLK
BLK - FOOT SWITCH
BRN

CR6
BRN
CABLE CABLE CABLE 8 6 8
6 4 2 4
#3 #2 #1 WHT
7 2
5 3 1
7
5 3 1

TILT
ALARM

RED/BLK

RED/WHT

TS9 TS1 TS2 TS7

BP1

TS3 TS5
GRN
L2
RED
BLK/RED

TS4 TS6 TS18

L1 (OPTION)

DP1
BLK

B
+
-
X
TS8 P3 P2 D
L R
NO NC NC
+
R

BRN

7-4 Genie Z-30/20N Part No. 35532

First Edition • Third Printing Section 7 • Schematics

Load Sensor Option Diagram

(from serial number 4083 to 4255)

T
N

BLK
WH
GR

RE
1 2 3 4

LOAD SENSE
OPTION

123456789

- + NO NC C

F.S. JIB
RED/WHT
RED/BLK

WHT-FS
WHT
BRN

BRN

BRN
CABLE CABLE CABLE
#3 #2 #1
LOAD CELL
WHT-FS

TS15 TS12 TS10

BP1

BLK/RED
TS7 TS11 TS8
RED
GRN

LABEL DESCRIPTION
P2 EMERGENCY STOP BUTTON
P3 HORN BUTTON TS9 TS13 TS16
DP1 DRIVE CONTROLLER
BP1 BOOM FUNCTION SPEED CONTROLLER BRN
+ R
1 2 3 4 5 6 7 8 9 10

TS1 AUXILIARY SWITCH

TS7 PLATFORM ROTATE SWITCH L1 L2 L
TS8 JIB UP/DOWN SWITCH
TS9 PLATFORM LEVEL SWITCH
TS10 SECONDARY BOOM SWITCH
TS11 PRIMARY BOOM SWITCH
TS12 TURNTABLE ROTATE SWITCH
TS13 PRIMARY BOOM EXTEND SWITCH
TS15 DRIVE ENABLE SWITCH
TS16 JIB ROTATE SWITCH (OPTION)
L1 DRIVE ENABLE LIGHT NO NC NC
L2 OVERLOAD LIGHT (OPTION)
TS1
P3 P2 DP1

Part No. 35532 Genie Z-30/20N 7-5

Section 7 • Schematics First Edition • Third Printing

Load Sensor Option Diagram

(after serial number 4255)

T
N

BLK
WH
GR

RE
1 2 3 4

LOAD SENSE
OPTION

123456789

- + NO NC C

F.S. JIB
RED/WHT
RED/BLK

WHT-FS
WHT
BRN

BRN

BRN
CABLE CABLE CABLE
#3 #2 #1
LOAD CELL
WHT-FS

TS15 TS12 TS10

BP1

BLK/RED
TS7 TS11 TS8 RED
GRN

LABEL DESCRIPTION
P2 EMERGENCY STOP BUTTON
BRN

P3 HORN BUTTON TS9 TS13 TS16

DP1 DRIVE CONTROLLER
BP1 BOOM FUNCTION SPEED CONTROLLER
1 2 3 4 5 6 7 8 9 10

R
TS1 AUXILIARY SWITCH +
TS7 PLATFORM ROTATE SWITCH
L1 L2 L
TS8 JIB UP/DOWN SWITCH
TS9 PLATFORM LEVEL SWITCH
TS10 SECONDARY BOOM SWITCH
TS11 PRIMARY BOOM SWITCH
TS12 TURNTABLE ROTATE SWITCH
TS13 PRIMARY BOOM EXTEND SWITCH
TS15 DRIVE ENABLE SWITCH
TS16 JIB ROTATE SWITCH (OPTION)
L1 DRIVE ENABLE LIGHT NO NC NC
L2 OVERLOAD LIGHT (OPTION)
TS1
P3 P2 DP1

7-6 Genie Z-30/20N Part No. 35532

First Edition • Third Printing Section 7 • Schematics

Power Cable Diagram

(before serial number 3447)
Section 7 • Schematics First Edition • Third Printing

Power Cable Diagram

(before serial number 3447)
A B C D E F G H I J K L M N

1 TANK SIDE GROUND CONTROLS SIDE

+ BATTERY PACK BATTERY PACK +
6V DC AMMETER 6V DC
- BLK + -

WHT-
_ -
2
6V DC 6V DC
+ +
RED

BLK
AC
+ BATTERY +
3 6V DC PRIMARY CHARGER 6V DC
- LIFT AUXILIARY -
PUMP LIFT
+ - PUMP
- BLK -
-
6V DC 6V DC

WHT (10 Ga)

BLK (10 Ga)

4 + + +
RED

BLK

RED
RED
BLK

AP2 RED BLK AP1

5 + + - -

- -
RED + +
BLK
24V DC
(PR4)
1
F3 AUXILIARY
(PR3) F1 (PR1) B- B+
100A
6
PRIMARY F2 3 LIFT PUMP
100A 400A DRIVE M- A2
LIFT CONTACTOR CONTACTOR
PUMP 48V DC
CONTACTOR

7 FWD REV
PR2

8
A1 A2
LEFT SIDE RIGHT SIDE
S2 S1 S1 S2
DRIVE MOTOR DRIVE MOTOR
A2 A1

7-7 Genie Z-30/20N Part No. 35532

 First Edition • Third Printing Section 7 • Schematics

Power Cable Diagram

(after serial number 3446)
N M L K J I H G F E D C B A

1
GROUND CONTROLS SIDE TANK SIDE
+ +
BATTERY PACK BATTERY PACK
6V DC AMMETER 6V DC
- BLK (10 Ga) + -

WHT (10 Ga) -

_ - 2
6V DC 6V DC
+ +

RED (2 Gauge)

BLK (2 Ga)
AC
+ BATTERY +
6V DC CHARGER 6V DC 3
- PRIMARY -
LIFT PUMP
-
A1 D1 BLK (4 Ga) -
D1
6V DC 6V DC

WHT (10 Ga)

BLK (10 Ga)

AUXILIARY 4
+ A2 +
LIFT PUMP

RED (4 Ga)

BLK (4 Ga)

(2 Ga)
(4 Ga)

RED
(2 Ga)

RED
BLK

RED
AP2 (2 Ga) BLK (2 Ga) AP1
+ + - - 5
24V DC RED (2 Ga)
- - + +
BLK BATTERY DRIVE
(2 Ga) CONTACTOR
AUXILIARY
(PR1)
CONTROLLER

F3
F1 LIFT PUMP
F2 100A
500A CONTACTOR 6
100A (PR3)
PRIMARY 3 DIODES

LIFT PUMP 48V DC

CONTACTOR (PR2)

BLK (2 Ga)
MOTOR
CONTROLLER 7
RED (10 Ga) F1 F2
B- M- B+

(10 Ga)
RED
BLK (2 Ga) 8
F1
F2 A2 A1
LEFT SIDE BLK (2 Ga) BLK (2 Ga) RIGHT SIDE
F1 F2
DRIVE MOTOR A1 A2 DRIVE MOTOR

RED (10 Ga)

Part No. 35532 Genie Z-30/20N 7-8

First Edition • Third Printing Section 7 • Schematics

Power Cable Diagram

(after serial number 3446)
First Edition • Third Printing Section 7 • Schematics

This page intentionally left blank.

Part No. 35532 Genie Z-30/20N 7-9

Section 7 • Schematics First Edition • Third Printing

Electrical Symbols Legend

P1

+ P4
TS6
Emergency
ORG/BLK-1

HORN
Stop button

LEFT
RIGHT
normally closed -

Horn button
Wire color Toggle switch DPDT normally open
with cable TB17 6V DC
number Battery
BLK

FS1
GRN/BLK

BLK
TB20

DE Foot switch

Terminal Tilt sensor PSI

Light
Ground DP1 Pressure
supression BRAKE DRIVE switch
AP1 BOARD BOARD
circuit
A
FB X -
Quick disconnect - X
+ L
A R
terminal +
Circuit breaker R
Flashing
beacon Drive controller Horn
TB21 FORWARD REVERSE
Joystick
BLK #21
PR2

T-circuits connect RED

GRN
at terminal Dual pole
HM
BLK/RED

relay
WHT

Hour BP1 Solenoid or

meter relay coil
3 1 Boom function
B-
T-circuits M- speed controller
connect B+
CR4

A2
J1
NC NO

Motor Brake release LS3 Relay contact

controller jack normally open
Connection
no terminal A2 S2 Limit switch

TS3

S1
START

A1
ENGINE

PR4
Relay contact
Drive motor normally closed
Circuits crossing Toggle switch SPDT
no connection
Relay panel
contactor
PUMP PLATFORM Fuse
KS1

GROUND LS1
Auxiliary lift pump NOHC
Diode Key switch

Limit switch
normally open
held closed

7 - 10 Genie Z-30/20N Part No. 35532

Section 7 • Schematics First Edition • Third Printing

Electrical Schematic
(before serial number 747)
A B C D E F G H I J K L M N
WHT - FS
RED/WHT-3
1 ORG-1
FS1 BLU/WHT-1
P2 GRN OR BRN GROUND
TS18
EMERGENCY WHT - FS
STOP

ORG-1
RED/WHT-3
ORG/RED-1
BCI
BLK LIFT/DRIVE 4 5 3
SELECT

O/R

ORG
O/B
OPTION

BLK-2
TS1 TS2 TS3

2 A1

TURNTABLE ROTATE

SECONDARY BOOM

PRIMARY BOOM
TB42
TILT
ALARM P3 8 7 6 5 4 3 2 1
HORN

DOWN

DOWN
RIGHT
LEFT
P1 KS1 RESET DISCHARGE

UP
UP
F4 EMERGENCY KEY SWITCH
10A LVI
AP2 ( + ) CB1 STOP PLATFORM TB22 SET TO "N"
TB20 SET TO "A"
15 A GROUND RED
F2 F1 CIRCUIT LVI / BCI
100A 400A CR3 CR3 OPTION
BREAKER CR3

RED/BLK-1

BLK/RED-3

WHT-2

WHT-3

WHT/BLK-3

BLU/BLK-3

BLU-3

RED/BLK-3

RED-3
TB3
TB40

WHT#40
48V
ORG/BLK
LS2 RED
+

N.O.H.C. WHT

BLK#49 BLK#49
RED/WHT#3
ORG/BLK#41
RED#20

TB49
TS10 TS11 TS12
4

TURNTABLE ROTATE

SECONDARY BOOM
+
-

PRIMARY BOOM
LS1
N.O.H.C.
+

DOWN
-

DOWN
RIGHT
LEFT

UP

UP
PR3 WHT#23
GRN/WHT
3 1
M-
B- TB5 TB10 TB1
+
-

TB28 TB9
TB4 TB11 TB2
5 AP2 ( - )
F3 B+ TB23

50A A2
PR1
AP1 ( + )
24V

WHT#23

RED/BLK#28

WHT#4

WHT/BLK#5

BLU/BLK#11

BLU#10

RED/BLK#2

RED#1
BLK/RED#9
ORG/BLK#41

RED#R1
+

PR4
-

FWD REV
PR2

6 FB GRN/BLK
+
-

6
7
CR1 CR1
+

A1 A2 4 8

MOTOR PR1
A3
S2 S2
PUMP PUMP MOTOR
+

A1 S1
-

S1 A2
7 (GND)

AP1 ( - )

TURNTABLE ROTATE RIGHT

DECENT ALARM

PRIMARY BOOM DOWN

TURNTABLE ROTATE LEFT

OPTION

SECONDARY BOOM DOWN

SECONDARY BOOM UP

PRIMARY BOOM UP
AUXILIARY PUMP MOTOR

PRIMARY PUMP MOTOR

DRIVE MASTER RELAY

DRIVE MOTOR SYSTEM

HORN

OPTION
FLASHING BEACON

TILT LEVEL SENSOR

HORN COIL

7 - 11 Genie Z-30/20N Part No. 35532

 1

8
(before serial number 747)

7 - 12
Section 7 • Schematics

Electrical Schematic

BOOM PROPORTIONAL CONTROLLER

DRIVE PROPORTIONAL CONTROLLER

A

BRAKE RELEASE RECEPTACLE

BATTERY CHARGE INDICATOR

TERMINAL BASE LOCATION

LOW VOLTAGE INTERRUPT

DESCRIPTION

PRESSURE SWITCH
FLASHING BEACON
CIRCUIT BREAKER
ANDERSON PLUG

TOGGLE SWITCH
CONTROL RELAY

POWER SWITCH
DRIVE ENABLE

POWER RELAY
FOOT SWITCH

LIMIT SWITCH
HOUR METER
B

Genie Z-30/20N
ALARM

LIGHT
LABEL

B.C.I.
L.V.I.
C

HM
CR

TS
CB

DE
DP

PR
AP
BP

PS
FB
FS

TB
LS
P
A

L
J
First Edition • Third Printing

LS3
TB13
L1

BLU/RED-3 WHT#13 GRN - GROUND DRIVE ENABLE

DE
D

BLU/WHT-3 BLK#12 RED#16

TB16
TB12

ORG/RED-3
HOUR METER
TB41

HM

ORG/BLK-1 ORG/BLK
RELEASE

RED/WHT RED#47 BRAKE RELEASE N.C.

Part No. 35532
BRAKE
J1

TB46

A2

RED BRAKE RELEASE/TRAVEL ALARM

TB47

GRN-2
TB31 TB29

RED/WHT-1 RED/WHT#29 BRAKE RELEASE HALF STROKE

E

DRIVE
BOARD

R
A

WHT/BLK-1 WHT/BLK#31 DRIVE FORWARD RELAY COIL

TB30

WHT-1 WHT#30 DRIVE REVERSE RELAY COIL

JOYSTICK

TB37
DP1

BLU/BLK-1 BLU/BLK#37 STEER RIGHT

BLU-1
+
R
L

BLU#36 STEER LEFT

TB36

WHT/RED#32 BRAKE RELEASE PROPORTIONAL

F

BOARD
BRAKE

TB32

GRN/WHT RED
+
A
X
-

WHT/RED-1
PS1

PRESSURE SWITCH
CR2
TB19
TS9

AUXILIARY CONTROL RELAY COIL

DRIVE
ENABLE
PUMP
AUX.

RED#27
PR4
G

RED-1 RED#R2 AUXILIARY PUMP RELAY COIL

TB27
TS17
TS8
AUXILIARY
PUMP

TB19

PR3

GRN/WHT-3 GRN/WHT GRN/WHT#R2 LIFT PUMP RELAY COIL

WHT/RED-3 WHT/RED#6
TB6

BLU/WHT-1
TB48

BLU/WHT#48 PROPORTIONAL FLOW

BLK/RED

CONTROL COIL
H

TB43
WHT
GRN
RED

UP
TB44
CONTROLLER

JIB BOOM
FUNCTION

TS16

JIB BOOM
BP1

SPEED

DOWN
BOOM

UP GRN-1
JIB BOOM
GRN/BLK-1
TS7
I

DOWN
WHT-JIB

TB18

RIGHT
BLK-JIB

GRN-JIB
TB17

PLATFORM ROTATE
TS15

PLATFORM ROTATE
LEFT
RIGHT GRN/BLK-3
J

PLATFORM ROTATE
GRN-3
TS6

LEFT
ORG-JIB
YEL-JIB

TB14
UP ORG#14 PLATFORM LEVEL UP
K

TB15
PLATFORM LEVEL
ORG/BLK#15 PLATFORM LEVEL DOWN
TS14 DOWN
UP ORG-3
PLATFORM LEVEL
ORG/BLK-3
TS5

DOWN
L

TB7
EXTEND BLK#7 PRIMARY BOOM EXTEND

TB8
PRIMARY BOOM
BLK/WHT#8 PRIMARY BOOM RETRACT

TS13
RETRACT
GRN OR BRN (GROUND)
M

EXTEND BLK-3
PRIMARY BOOM
BLK/WHT-3
TS4
RETRACT
RED/WHT-3

BLU/WHT-1

GRN/WHT
ORG/BLK

GRN/BLK
ORG - 1

(GND)
WHT

WHT

WHT
RED

RED
N
First Edition • Third Printing Section 7 • Schematics

Electrical Schematic
(before serial number 747)
Section 7 • Schematics First Edition • Third Printing

Electrical Schematic
(from serial number 747 to 3446)
A B C D E F G H I J K L M N

WHT - FS
1

RED/WHT
RED/WHT-3
1 2 3 4 P2 OL ORG-1
LOAD SENSE PCB
EMERGENCY
FS1 BLU/WHT-1
STOP FS1 BRN
RED/BLK BLK TS18
1 2 3 4 5 6 7 8 9 10 11 12 -2 WHT P2 WHT
B LK
WHT CR6 EMERGENCY STOP
BLK BCI
LIFT/DRIVE

RED/WHT-3
ORG/RED-1

ORG-1
CR6 4 5 3
BLK/RED-3
3A SELECT
BRN LOAD SENSE

O/R

ORG
O/B
WHT-2
OPTION
LOAD SENSE OPTION TS3
TS1 TS2
OPTION DETAIL (SEE DETAIL AT LEFT)
2 RED/BLK

BOOM

BOOM
SECONDARY

PRIMARY
BLK-2

ROTATE
TURNTABLE
KS1 A1
8 7 6 5 4 3 2 1
TB42 P3

DOWN

DOWN
KEY

RIGHT
LEFT
RESET DISCHARGE
F4 TILT HORN

UP
UP
P1 SWITCH BLK-22 LVI
AP2 ( + ) 10A ALARM
CB1 EMERGENCY STOP PLATFORM
TB22 SET TO "A” SET TO "N”
RED
48V 10 A GROUND
F2 F1 LVI / BCI
100A 400A CR3 OPTION
3 TB3
BLK#40
TB40

WHT/BLK-3
WHT-3

RED/BLK-3
BLU/BLK-3

BLU-3

RED-3
RED/BLK-1

BLK/RED-3

WHT-2

WHT#23
WHT#23
RED/WHT#3
ORG/BLK#41
LS4

RED
WHT#52
TB20
N.O.H.C.
WHT#23
ORG/BLK
TB52 RED
+

RED#20 RED
WHT

WHT#52
4 TS19 TS10 TS11 TS12
LS2
N.O.H.C. FUNCTION
+
-

BOOM
SECONDARY

BOOM
PRIMARY
ENABLE

ROTATE
BLK#49

TURNTABLE
+

DOWN

DOWN
RIGHT
LEFT

UP

UP
TB49
PR3
CB2 BLK#49
3 1 ORG/BLK
M-
B-
10 A
5
+

LS1
-

F3 B+ N.O.H.C. TB5 TB10 TB1

WHT#23

AP2 ( - ) TB9
100A A2
TB4 TB11 TB2
PR1 TB28
AP1 ( + ) TB23
24V
+

PR4

RED#23
RED#R1

RED/BLK#28

WHT#4

WHT/BLK#5

BLU/BLK#11

BLU#10

RED/BLK#2

RED#1
BLK/RED#9
ORG/BLK#41

FWD REV

PR2
6
FB
+
-

GRN/BLK
CR1
+

A1 A2

PR1
BLK/RED#R1

MOTOR
S2 S2
PUMP PUMP MOTOR
+

S1 A2 A1 S1
7
-

A3
AP1 ( - ) TB50
BRN
SYSTEM
DRIVE MOTOR
LIFT PUMP MOTOR

LIFT PUMP MOTOR

MASTER RELAY

ROTATE LEFT

ROTATE RIGHT

OPTION

BOOM DOWN

BOOM DOWN

BOOM UP
AUXILIARY

PRIMARY

DRIVE

HORN

TILT LEVEL SENSOR

HORN COIL

TURNTABLE

TURNTABLE

DECENT ALARM

SECONDARY

PRIMARY

PRIMARY
BOOM UP
SECONDARY
FLASHING BEACON (OPTION)

7 - 13 Genie Z-30/20N Part No. 35532

 First Edition • Third Printing Section 7 • Schematics

Electrical Schematic
(from serial number 747 to 3446)
N M L K J I H G F E D C B A

WHT - FS 1
RED/WHT-3
ORG-1
BLU/WHT-1
BRN
WHT

TS8 TS9 RED

LCR
WHT NC RED
CR5

ENABLE
AUXILIARY WHT/RED

DRIVE
FWD/REV
WHT/BLK NO
TS4 TS5 TS6 TS7 PUMP
2

WHT/GRN
WHT/YEL
POWER NC
R
BP1 RED NC 2
BRN NO
D

LEVEL
BOOM

PLATFORM
PRIMARY

PLATFORM

JIB BOOM
1
X

ROTATE
RED/WHT NO
BOOM
FUNCTION
BLK/RED RED NC -
SPEED NC STEER +

UP

UP
EXTEND

DOWN

BRN-JIB
RETRACT

DOWN
RIGHT
LEFT
NO
CONTROLLER B
NO BLK L1
BLK DP1
DRIVE/BRAKE CONTROL DE
RED

RED/WHT-3 3

GRN-1
BLK/WHT-3

BLK-3

ORG/BLK-3

ORG-3

GRN/BLK-1

RED-1

BLU/RED-3
GRN/BLK-3

ORG/RED-3

BLU/WHT-3
GRN-3

GRN/WHT-3

ORG/BLK-1
WHT/RED-3
WHT/BLK-1
WHT-1
ORG-JIB WHT-JIB BLU/BLK-1
YEL-JIB BLK-JIB WHT/RED-1
BLU-1 BRN-2
WHT#23
ORG/BLK
RED

ORG/BLK
RED#20
WHT#23 J1
BRAKE
RELEASE
4
TS13 TS14 TS15 TS16 TS17 TB32

RED/WHT
TB30

AUXILARY
BOOM

ROTATE
PRIMARY

LEVEL

PLATFORM
PLATFORM

TB36

JIB BOOM
TB31
TB41
TB37 TB29
EXTEND
RETRACT

RIGHT
UP
DOWN

LEFT

UP
DOWN
TB46
TB27
TB19
ORG/BLK TB19
5

GRN/WHT
RED#27
GRN/WHT
LS2
N.O. TB18

BLU/BLK#37
WHT/RED#32

WHT#30

RED/WHT#29

RED/WHT
BLU#36

WHT/BLK#31
TB7 TB14 ORG TB43 TB6
TB12 TB13
TB8 TB15 TB17 TB44
CR2
ORG/BLK#15

ORG#14

RED

RED#12

BLK#12
WHT#13
PS1
BLK/WHT#8

BLK#7

GRN/BLK#44

WHT/RED#6

GRN/WHT#R8

RED#R2
RED#20
CR4 PLATFORM LEVEL

RED
N.C. N.C. CUT-OUT OPTION
TB47 LS3 LABEL DESCRIPTION
6
ORG/BLK

ORG

BRN

A ALARM

RED#16
ORG/BLK#47

BRN
AP ANDERSON PLUG

RED#47
GRN/BLK#44 CR8
BP BOOM PROPORTIONAL CONTROLLER
TB16 CB CIRCUIT BREAKER

GRN/WHT
CR CONTROL RELAY
DE DRIVE ENABLE

PR3 PR4 A2
DP DRIVE PROPORTIONAL CONTROLLER 7
HM FB FLASHING BEACON
FS FOOT SWITCH
HM HOUR METER
BRN J BRAKE RELEASE
CONTACTOR RELAY

RELAY COIL
CONTROL COIL

PROPORTIONAL

RELAY COIL

RELAY COIL

TRAVEL ALARM
LS LIMIT SWITCH

HALF STROKE
STEER LEFT
STEER RIGHT
LIFT PUMP

LIFT PUMP RELAY COIL

AUXILIARY PUMP
PRIMARY BOOM RETRACT

PRIMARY BOOM EXTEND

PLATFORM LEVEL DOWN

PLATFORM LEVEL UP

PROPORTIONAL FLOW

BRAKE RELEASE

DRIVE REVERSE

DRIVE FORWARD

BRAKE RELEASE/

HOUR METER

DRIVE ENABLE
BRAKE RELEASE

BRAKE RELEASE N.C.

RELAY COIL
AUXILIARY CONTROL
P POWER SWITCH
PLATFORM JIB
PLATFORM ROTATE

PRESSURE SWITCH
PR POWER RELAY
PS PRESSURE SWITCH 8
TB TERMINAL BASE LOCATION
TS TOGGLE SWITCH
B.C.I. BATTERY CHARGE INDICATOR (OPTION)
L.V.I. LOW VOLTAGE INTERRUPT (OPTION)
OL OVERLOAD LIGHT (OPTION)

Part No. 35532 Genie Z-30/20N 7 - 14

First Edition • Third Printing Section 7 • Schematics

Electrical Schematic
(from serial number 747 to 3446)
Section 7 • Schematics First Edition • Third Printing

Electrical Schematic
(from serial number 3447 to 4082)
A B C D E F G H I J K L M N

1
LOAD SENSE OPTION

RED/WHT
L4
1 2 3 4 OL
LOAD SENSE OPTION
LOAD SENSE PCB P2 FS1 RED-FS
(DETAIL AT LEFT)
WHT
RED/BLK BLK-FS P2
1 2 3 4 5 6 7 8 9 10 1112
CR17
WHT-FS EMERGENCY STOP FS1
WHT BLK-FS ORG/RED-1
3A WHT-FS

BRN CR17 RED/WHT-3

2 RED/BLK

RED
BLK-2
P1 KS1 P3
HORN + A1
KEY PLATFORM
CB1 EMERGENCY
SWITCH
BLK #22
TILT
STOP TB22
- ALARM
10 A GROUND

3
TB30 RED
TB31 WHT-1
WHT/BLK-1

TB29
RED/WHT-1
TB32
TB40 WHT/RED-1
TB3
4 F4
10A TB42
AP2 (+)

BLK-8
85 CR5
48V
86 22
LS4
RED/BLK
RED/WHT #29
BLU/WHT #12

BLK #22

RED/BLK-1
RED #CB1

RED/WHT

RED/WHT
ORG #40

BLK/RED-3
WHT #30

WHT-23A

WHT-2
WHT/BLK #31

WHT/RED #32
ORG/RED

ORG/RED #42

ORG/RED #CR2

ORG/RED
ORG/RED

BLU/WHT #12
+

21
F1 RED
500A
WHT-8
RED
PR1 TB23
RED
5
+
-

TS55
TB50
TB28

WHT-6
+

F2 30 CR2 86
OFF-LIMIT SPEED INPUT

100A
L3 21 87 FUNCTION
85
ENABLE
LS2
22
+

DIODE RETURN
-

TB9
86 CR1 30
BLK-6
2-WIRE POT.
INTERLOCK
+48V INPUT

BRAKE/REL

AP2
FORWARD

POT. LOW
REVERSE

BLK BLK F3 85 87

RED/WHT #23

RED/BLK #28
100A

BLK/RED #CR4
6 RED RED
TB49
GRN

AP1 24V
BLK-7
1 9 10 11 2 16 14 3 20
17
BLK

5 14
+

BLK

CURTIS 1244
SEPEX MOTOR CONTROLLER B- LS1*
BLK

13
F1 M- B+ F2
*Shown
WHT-7

PR3 PR2
+
-

with
boom
+

RED

WHT
extended CR4
7 F2 A2 A2 F1
30 86
RED

RED

WHT

MOTOR 87 85
+
-

FB
BLK/RED

MOTOR
F1 A1 A1 F2

BLK
PUMP PUMP

8 BRN
BLK

BLK

BRN
BLK

AP1 ( - ) CB2 TB52

BLK BLK BRN
LIMIT SWITCH LS1
EXTEND/RETRACT
LIMIT SWITCH LS2
PRIMARY BOOM
SECONDARY
LIMIT SWITCH LS4
BOOM
CONTROLLER
COIL
CONTACTOR
DRIVE

LIGHT
FAULT INDICATOR

10 A
SENSOR
TILT

48V POWER
RELAY CR1

RELAY CR2
48V POWER

ENABLE
FUNCTION
HORN

RELAY
HORN

(OPTION)
BEACON
LIFT PUMP

48V BATTERY
PRIMARY

CHARGER
AUXILIARY
LIFT PUMP

FLASHING
DRIVE CONTACTOR

BRN

7 - 15 Genie Z-30/20N Part No. 35532

 1

7 - 16
Section 7 • Schematics

(from serial number 3447 to 4082)

Electrical Schematic

ENABLE

BRN-2
DRIVE
(remove for CE version)

TB52
TB13
LED

21

22

BLU/RED-3 WHT-5 BRN-5

LS3*
Jumper

*Shown with the boom

A

rotated past either

non-steer wheel

BLU/WHT-3 BLK-5 RED-5 DRIVE ENABLE

LIMIT SWITCH
14

13
TB12

TB16

ORG/RED-3
A2

ORG/RED BRAKE RELEASE

TRAVEL ALARM
+

A2
CR5
30

RED/WHT
87

RED/WHT
B

RELEASE

BRAKE RELEASE
BRAKE
ENABLE

N.C. COIL
DRIVE

J1

Genie Z-30/20N
TB48

WHT BRAKE RELEASE

RED RED/WHT #48 RED/WHT #48
N.O. COIL
TS15

RED/WHT BRAKE RELEASE

PRESSURE
RED PS1 SWITCH PS1
TB36

BLU-1 BLU #36 STEER LEFT

COIL
TB37
C

BLU/BLK-1 BLU/BLK #37 STEER RIGHT

COIL
10
6
7
8
9
DRIVE CONTROLLER

WHT/BLK
HM

HOUR METER
DRIVE
LIFT

+
CONTROL BOX
STEER
L

GRN/WHT #19
PLATFORM
DP1

GROUND
R

WHT/BLK
First Edition • Third Printing

FUNCTION
MANIFOLD
GROUND
REV

FWD
D

ORG/RED
1
2
3
4
5

TS51

TB27

Part No. 35532

AUXILIARY
85
86

RED #27
CONTROL
RELAY COIL
RED-1
LIFT PUMP
85

GRN/WHT
86
TS1
E

(OPTION)

CONTACTOR
BCI

RELAY CR20
CR20
CR3

PR2
F

LIFT PUMP
+

RED GRN/WHT CONTACTOR

COIL PR2
30
87A

87

ORG/RED
TB19
LVI / BCI OPTION

DISCHARGE

SET TO "N”

30

GRN/WHT-3 GRN/WHT RED AUXILIARY

8 7 6 5 4 3 2 1

ORG
LIFT PUMP
5 3

87
BCI

PR3

O/R CONTACTOR
TB6
BRN

WHT/RED-3 COIL PR3

O/B
F

LVI

GRN/WHT #19
WHT/RED #6
BLK/RED
SET TO "A”

PROPORTIONAL
RESET

WHT WHT/RED #6
GRN
RED

FLOW CONTROL
TB43

COIL
CONTROLLER

UP
BRN-JIB
FUNCTION
SPEED
BOOM
BP1

JIB BOOM
CE VERSION ONLY
PLATFORM LEVEL
TS58
BLK

DOWN
TB44

BRN
G

GRN-1
CUTOUT

UP
JIB BOOM PLATFROM
GRN/BLK-1
86
85

LEVEL
TS8

DOWN
WHT-JIB

TB18

CUTOUT
RED-6
MANIFOLD GROUND

LS2

RIGHT RELAY COIL

BLK-JIB

86
85
13

PLATFORM ROTATE
TS57

LEFT
CR10A/B
TB17

14
JIB
H

ORG-6

RIGHT GRN/BLK-3
PLATFROM ROTATE
GRN-3

(A)
TB14

LEFT
TS7

ORG-JIB

87A
PLATFORM

30
UP ORG #14
LEVEL UP COIL
BLU-JIB

PLATFORM LEVEL
ORG/BLK #15 PLATFORM
TS59

87A
DOWN

30
LEVEL DOWN
TB15

(B)
COIL
I

UP ORG-3
PLATFORM LEVEL ORG/BLK-3
DOWN
TS9

TB7
PRIMARY BOOM
EXTEND BLK #7
EXTEND COIL
PRIMARY BOOM
BLK/WHT # 8
PRIMARY BOOM
TS63

RETRACT
RETRACT COIL

TB8
J

EXTEND BLK-3
PRIMARY BOOM
BLK/WHT-3
TS13

RETRACT

TB1
UP RED #1 PRIMARY
BOOM UP COIL
PRIMARY BOOM
RED/BLK #2 PRIMARY

TS61
DOWN BOOM DOWN

TB2
COIL
CR19
K

UP RED-3
5

3
PRIMARY BOOM RED/BLK-3
TS11

DOWN

TB10
SECONDARY
UP BLU #10 BOOM UP COIL
SECONDARY BOOM SECONDARY
BLU/BLK #11 BOOM DOWN

TS60
DOWN
COIL

TB11
CR19

A3
DESCENT
ALARM
L

UP BLU-3

+
OPTION

4
SECONDARY BOOM
BLU/BLK-3
TS10

DOWN

TB5
RIGHT WHT/BLK #5 TURN ROTATOR
RIGHT COIL
TURNTABLE ROTATE
WHT #4 TURN ROTATOR

TS62
LEFT LEFT COIL

TB4
M

RIGHT WHT/BLK-3
TURNTABLE ROTATE
WHT-3

TS12
LEFT

RED

BLU/WHT #12
WHT/RED-1
ORG/RED-1

RED/WHT-1
WHT/BLK-1
WHT-FS

WHT-1
N

BRN

BRN
RED

RED
RED
RED
First Edition • Third Printing Section 7 • Schematics

Electrical Schematic
(from serial number 3447 to 4082)
Section 7 • Schematics First Edition • Third Printing

Electrical Schematic
(after serial number 4082)
A B C D E F G H I J K L M N
P2 FS1
BLK-FS
WHT-FS
1 NC
LOAD SENSE OPTION (SEE DETAIL )
WHT
C
RED/BLK NO P2 FS1

RED
+ RED/WHT
BLK-2 BLK-FS
- 8
OL WHT-FS WHT

LOAD SENSE PCB ORG/RED-1

RED/WHT-3
LOAD SENSE OPTION

ORG/RED-1
P3 RED
HORN
PLT
+ A1
2 10 A P1 KS1 BLK #22

WHT-2
TILT
TB22
ALARM
CB1 GND

RED RED
ORG/RED #CR20 ORG/RED
WHT #30 TB30 WHT-1 WHT-1
WHT/BLK #31 TB31 WHT/BLK-1 WHT/BLK-1

3
RED/WHT #29 TB29 RED/WHT-1 RED/WHT-1
WHT/RED #32 TB32 WHT/RED-1 WHT/RED-1

ORG #40 TB40 BLK-8 TB3

ORG/RED #CR2
TB42
BLU/WHT #12
22
LS4
21 RED
BLU/WHT #12

ORG/RED #42
4
ORG/RED

RED/BLK-1
ORG/RED
F4

RED/WHT
RED/WHT
WHT-8
85 CR5
AP2 F1

BLK/RED-3
10A
RED RED 48V DC 500A
86
PR1 TB23
+48V DC TB50
TS55

WHT-6
FUNCTION
OFF-LIMIT SPEED INPUT

TB28 30 86
+

F2 + ENABLE RED
RED/BLK

PR1

ORG/RED
100A
PR1
CR2
L3 21 87 85
LS2
+
-

DIODE RETURN

22
RED #CB1

86 30
5
2-WIRE POT.
+48V INPUT

TB9
BLK-6
BRAKE/REL

CR1
+

INTERLOCK
-

POT. LOW
FORWARD

REVERSE

BLK
GRN
BLK

85 87

RED/WHT #23

RED/BLK #28
BLK/RED #CR4
TB49
BLK-7
+
-

2
9

10

11

14
16

20
1

AP2 BLK 17
14
BLK BLK
F3 CURTIS 1244 5 STATUS LED
RED RED 100A LS1*
SEPEX CONTROLLER B- 13
* Shown
WHT-7

AP1 24V DC
F1 M- B+ F2
BLK #22

6 +24V DC PR3 PR2

with
boom

RED

WHT
extended
+

30
CR4 86
F2 A2 A2 F1
RED

RED

WHT

87 85
MOTOR
+

BLK/RED
-

MOTOR FB
+

BLK
F1 A1 A1 F2
BLK

PUMP PUMP

7 BRN
BRN
+
-

BRN (GND)
GROUND
CB2
BLK

BLK

BLK

10A
BLK BLK BRN BRN (GND)
HORN

RELAY
HORN
LIFT PUMP
AUXILIARY

CHARGER
48V DC BATTERY
LIFT PUMP
PRIMARY

OPTION
BEACON
FLASHING
CONTACTOR
DRIVE

COIL
CONTACTOR
DRIVE

SENSOR
TILT
FAULT LIGHT
CONTROLLER

RELAY
POWER
48V DC
TB52

RELAY
POWER
48V DC
AP1

BRN
8 BLK (24V DC)

7 - 17 Genie Z-30/20N Part No. 35532

 First Edition • Third Printing Section 7 • Schematics

Electrical Schematic
(after serial number 4082)
N M L K J I H G F E D C B A

LVI/BCI OPTION JP1 (REMOVE FOR CE MODELS)

WHT
ORG/RED-1 DP1
RED

WHT
WHT
BCI

ORG/RED
4 5 3 1 6
TURNTABLE SECONDARY PRIMARY PRIMARY JIB JIB BOOM LIFT

ORG
TS11 BOOM TS9 PLATFORM TS7 PLATFORM TS8

O/B
TS12 ROTATE TS10 BOOM

O/R
TS13 BOOM TS16 ROTATE BLK 2 7
LEVEL ROTATE BOOM
3 REV 8
2
DRIVE
LEFT

RETRACT
DOWN

DOWN
RIGHT

DOWN

LEFT
EXTEND

DOWN
UP

UP

UP

RIGHT
RIGHT

UP
LEFT
4 9
8 7 6 5 4 3 2 1 TS1 FWD R L
5
STEER
10 TS15 DRIVE
RESET DISCHARGE ENABLE
7
CR19 L.V.I.
6 CR19 5 CR19 SET TO "B" SET TO "N" AUX
ON ORG/RED +
RED BRN
4 3 8 L1
ORG/RED
DRIVE
ENABLE
WHT-1 LED
WHT/BLK-1
3

RED/WHT-1 RED
BLU-JIB BLK-JIB RED-JIB BCI OPTION
BP1
WHT/RED-1

GRN/BLK-3
ORG-JIB YEL-JIB ROTARY RED

BLU/BLK-1

BLU-1

RED

BLU/WHT-3
WHT/BLK-3

BLU/BLK-3

BLU-3

RED/BLK-3

RED-3

BLK/WHT-3

BLK-3

ORG/BLK-3

ORG-3

RED-1

ORG/RED-3
WHT-JIB

BLU/RED-3
WHT-3

OEM
+
GRN BRN

ORG-1

ORG/BLK-1
F

GRN/BLK-1

GRN-1
GRN-3
FLOW
CONTROL BLK/RED E J1
BCI BRAKE
JIB
RELEASE
MANIFOLD
GROUND BRN-JIB
JACK 4
BLU/WHT #12 TB12
RED TS51

PRESSURE SWITCH
BRAKE RELEASE
AUX PLATFORM
POWER CONTROL BOX 87
GROUND TB13

RED/WHT #48
TB36

GRN/WHT-3
WHT/RED-3
CR5

RED
30
TURN SEC PRI PRI PLAT PLAT JIB JIB BOOM
TS62 ROT TS60 BOOM TS61 BOOM
TS63 TS59 TS57 TS58 BOOM TS66 ROTATE TB37
BOOM LVL ROT

BRN-2
BLK-5
RED/WHT

WHT-5
ORG/RED
RED L R DN UP DN UP RET EXT DN UP L R DN UP

RIGHT
LEFT

PS1
RED GRN/WHT #19
TB19
GRN/WHT #19 5
TB5
TB27
TB7 TB18 TB43 TB47 RED/WHT

GRN/WHT

ORG/RED (48V)
TB4 TB11 TB10 TB2 TB1 TB8 TB17 TB44 TB46
TB48
JIB BOOM ROTATE OPTION

WHT/BLK
RED #27

BLU/BLK #37

RED/WHT
RED/WHT #48
BLU #36
BLU/BLK #11

BLK/WHT #8
BLU #10

RED/BLK #2

RED #1

BLK #7

TB14 14 LS3 21
WHT #4

WHT/BLK #5

TB15 DRIVE
ENABLE
LS2 TB6 LIMIT
ORG-6 WHT/RED #6 30
86 13 22 SWITCH*
14 13 CR3

RED-6
87

WHT/RED #6
85
87A * Shown

BRN-5
RED-5
PLATFORM LEVEL 6

+
5 6 CR10 with boom

GRN/WHT
7 CUTOUT
HM rotated past
CE VERSION

RED
8 either
1 2 ONLY non-steer
+ TB16 wheel
ORG/BLK #15

ORG #14

30 CR20 85

87 86
A3 +
A2
(GND)
FUNCTION
7
MANIFOLD
(GND) GROUND

N.O. COIL
BRAKE RELEASE
COIL
ROTATE LEFT
TURNTABLE
RIGHT COIL
ROTATE
TURNTABLE

COIL
BOOM DOWN
SECONDARY
COIL
BOOM UP
SECONDARY

PR2
CONTACTOR COIL
LIFT PUMP

CR20
CONTACTOR RELAY
LIFT PUMP

COIL
STEER LEFT
COIL
BOOM DOWN
PRIMARY
COIL
BOOM UP
PRIMARY

COIL
LEVEL DOWN
PLATFORM

COIL
LEVEL UP
PLATFORM

(A2)
TRAVEL ALARM
BRAKE RELEASE
N.C. COIL
BRAKE RELEASE
COIL
STEER RIGHT
COIL
RETRACT
BOOM
PRIMARY

EXTEND COIL
BOOM
PRIMARY

COIL
CONTROL
FLOW
PROP.

RELAY COIL
AUXILIARY CONTROL

HOUR METER
TB52
OPTION
ALARM
DESCENT

RELAY COIL
CUTOUT
LEVEL
PLATFORM

BRN
BLK (24V DC)

CONTACTOR COIL
PUMP
AUXILIARY LIFT
PR3
Part No. 35532 Genie Z-30/20N 7 - 18
First Edition • Third Printing Section 7 • Schematics

Electrical Schematic
(after serial number 4082)
 First Edition • Third Printing Section 7 • Schematics

Ground Control Panel Legend

(before serial number 747)
N M L K J I H G F E D C B A

CR2 AUXILIARY PUMP

1
+
1 3 7 5
AL 1 3 5 RED-TB27D
2 7
2 4 6 8 GRN/YEL-GROUND
4 6 8
GRN/WHT-TB19D
BLK-TILT AL. GRN/YEL-2 51 GRN/YEL-CR2 GRN/YEL-TB50 GROUND
RED-PR4
GRN/YEL-TB51 GR/YL-PUMP 50 GRN/YEL-S.P. GRN/YEL-LS3 GROUND
GRN/WHT-PR3
BLK-LS1 BLK-LS2 49 LIMIT SWITCH 2
CR1 HORN
BLU/WHT-4 BLU/WHT-1 48 HOUR METER
1 3 7 5
2
1 3 5
7
BLK/RED-TB9D RED-B.R.V. RED-S.P. AL. 47 RD/WT-TB46 OR/BLK-TB41 BRAKE RELEASE N.C.
8 RD/WT-TB29 46 RD/WT-TB47 RD/WT S.P. EMERGENCY BRAKE RELEASE N.C.
P1 + 4 2 4 6 6 8
GRN/YEL-GROUND
44 GR/BK-S.P. JIB BOOM DOWN
BLK-HORN GRN/BLK-1 GR/BK-D.A.
NC RED-SP
GRN-1 43 GRN S.P. JIB BOOM UP
HM WHT-HORN
OG/RD-POW. ORG/RED-1 42 48V DC SUPPLY 3
NC
ORG/BLK-PR1 ORG/BLK-1 41 ORG/BLK-TB47 DRIVE COIL PR1
WHT-LS2 ORG-1 40 LIMIT SWITCH
BLU/BLK-S.V. BLU/BLK-1 37 BL/BK-TB19 STEER LEFT
LS1 LS2 BLU-STEER V. BLU-1 36 BU-TB19 STEER RIGHT
TS17 EXTEND/RETRACT LIFT
WT/RD-BK.F.C. WHT/RED-1 32 BRAKE FLOW CONTROL
LIMIT SWITCH LIMIT SWITCH
BRAKE WT/BK-PR2 WHT/BLK-1 31
KS1 REVERSE PR2 4
WHT-PR2 WHT-1 30 FORWARD PR2
WHT#40-TB40D
N.O. BLK#49-TB49D N.O.
RD/WT-B.V. R/W-1 29 R/W-TB46 BRAKE H.S.
RELEASE NO NO N.C. N.C.
WHT-T. AL. RED/BLK-1 28 TILT ALARM
WHT#23-TB23D
BLK#49-TB49C RED-CR2 RED-1 27 RED-S.P. AUXILIARY POWER PR4
LS3 WHT-LS1 RED-TILT AL. 23 WT-S.P. WHT-2 KEY SWITCH POWER
DRIVE ENABLE 22 BLK S.P.
LIMIT SWITCH BLK-2 POWER TO PLATFORM 5
RED-POWER 20 RED S.P. 24V DC BATTERY SUPPLY
TS15 TS13 GN/WT-P.S. 19 GR/WT-TB36&37
N.O. BLK#12-TB12A
N.C. GRN/WHT-CR2 GRN/WHT-3 19 GR/WT S.P. LIFT PUMP PR3
GRN-GROUND
WHT#13-TB13A GRN/BLK-3 18 GR/BK S.P. PLATFORM ROTATE RIGHT
RED#16-TB16D GRN-3 17 GRN S.P. PLATFORM ROTATE LEFT
ORG/RED-3 16 RED-LS3 DRIVE ENABLE
6
TS14 TS12 ORG/BLK-4 ORG/BLK-3 15 OG/BK S.P. PLATFORM LEVEL DOWN
ORG-4 ORG-3 14 ORG S.P. PLATFORM LEVEL UP
CB1
LABEL DESCRIPTION BLU/RED-3 13 WHT-LS3 DRIVE ENABLE LIGHT
P1 EMERGENCY STOP BUTTON BLU/WHT-3 12 RED S.P.-H.M. BLK-LS3 DRIVE ENABLE
KS1 KEY SWITCH
TS10 TURNTABLE ROTATE SWITCH BLU/BLK-4 BLU/BLK-3 11 BU/BK S.P. BU/BK-D.A. SECONDARY BOOM DOWN
TS11 SECONDARY BOOM SWITCH BLU-4 BLU-3 10 BLU S.P. SECONDARY BOOM UP
TS16 TS11 TS12 PRIMARY BOOM SWITCH 7
TS10 BLK/RED-3 9 BK/RD-CR1 HORN
TS13 EXTEND/RETRACT SWITCH
TS14 PLATFORM LEVEL SWITCH BLK/WHT-4 BLK/WHT-3 8 BK/WT S.P. BOOM RETRACT
TS15 PLATFORM ROTATE SWITCH
BLK-4 BLK-3 7 BLK S.P. BOOM EXTEND
TS16 JIB SWITCH
TS17 AUXILIARY SWITCH W/R-4 WHT/RED-3 6 WT/RD S.P. LIFT FLOW CONTROL
CB1 15amp. CIRCUIT BREAKER 5
WHT/BLK-4 WHT/BLK-3 WT/BK S.P. TURNTABLE ROTATE LEFT
HM HOUR METER
CR1 CONTROL RELAY, HORN WHT-4 WHT-3 4 WHT S.P. TURNTABLE ROTATE RIGHT
CR2 CONTROL RELAY, AUXILIARY PUMP 3
8
R/W-CURTIS RED/WHT-3 0-5V DC TO MOTOR CONTROLLER
RED/BLK-4 RED/BLK-3 2 RD/BK S.P. RD/BK-D.A. PRIMARY BOOM DOWN
RED-4 RED-3 1 RED S.P. PRIMARY BOOM UP
D C B A

Part No. 35532 Genie Z-30/20N 7 - 19

First Edition • Third Printing Section 7 • Schematics

Ground Control Panel Legend

(before serial number 747)
 First Edition • Third Printing Section 7 • Schematics

Ground Control Panel Wiring Diagram

(from serial number 747 to 3446)
N M L K J I H G F E D C B A

1
CR2 AUXILIARY PUMP
1 3 7 5
1 3 5 RED-TB27D
+ 2 7
ALARM 4 2 4 6 8
6 8
BRN-CR4 (BRN-TB51A w/o CR4)

GRN/WHT-TB19D
RED-CH
GRN/WHT-CH

WHT-LS2 52 WHT-LS4 LIMIT SWITCH 2

CR1 HORN
BLK-TILT ALARM 51 BRN-2 BRN-CR4 (BRN-CR2 w/o CR4) GROUND
1 3 7 5
1 3 5 BLK/RED-TB9A BRN-CH 50 BRN-LS3 BRN-SP GROUND
2 7
8 BLK-LS1 BLK-LS2 49 LIMIT SWITCH
4 2 4 6 6 8
BRN-MH BLU/WHT-MH BLU/WHT-1 48 HOUR METER
BLK-HORN
RED/WHT-TB46 RED-CH 47 RED-SP ALARM ORG/BLK-TB41 BRAKE RELEASE N.C.
RED-SP
+ WHT-HORN RED/WHT-TB47 RED/WHT-TB29 46 RED/WHT SP BRAKE RELEASE REMOTE
P1 GRN/BLK-1 44 GRN/BLK-D/A GRN/BLK-SP JIB BOOM DOWN 3
NC HOUR GRN-1 43 GRN SP
CR4 (PLATFORM LEVEL CUT-OUT OPTION) JIB BOOM UP
METER ORG/RED-CH ORG/RED-1 42
RED#47 ORG-TB14D 48V DC SUPPLY
NC 1 3 7 5
ORG/BLK-CH ORG/BLK-1 41 ORG/BLK-TB47
1 3 5 RED-LS2 DRIVE COIL PR1
RED#12 2 7
8 BRN-TB51A
ORG-1 40 BLK-LS4 LIMIT SWITCH
RED-CR1 4 2 4 6 6 8
BRN-CR2 BLU/BLK-CH BLU/BLK-1 37 BLU/BLK-TB19 STEER LEFT
BRN-GROUND ORG/BLK-TB15D BLU-CH BLU-1 36 BLU-TB19 STEER RIGHT
BLK#7 ORG/BLK-MH WHT/RED-CH WHT/RED-1 32 BRAKE FLOW CONTROL 4
BLK#22 ORG-MH WHT/BLK-CH WHT/BLK-1 31 REVERSE PR2
J1 KS1 TS17 WHT-CH WHT-1 30 FORWARD PR2
RED/WHT#46 LS1 LS2 RED/WHT-CH RED/WHT-1 29 RED/WHT-TB46 BRAKE HS
EXTEND/RETRACT PRIMARY BOOM WHT-TILT ALARM RED/BLK-1 28 TILT ALARM
WHT#23 BRAKE RELEASE NO NO LIMIT SWITCH LIMIT SWITCH
RED-CR3 RED-1 27 RED-SP AUXILIARY PWR PR4
RED#27 RED-TILT ALARM WHT-LS1 23 WHT-2 WHT-SP KEY SWITCH POWER
ORG-TB14D+TB15D 22 BLK-2 BLK SP POWER TO PLATFORM 5
BLK/WHT#8 N.O. BLK#49-TB49D N.O.

N.C. N.C. BLK-TB49C RED-CH 20 RED SP 24V DC BATT SUPPLY

WHT/RED#6 WHT-TB52D GRN/WHT-PS 19 BLU+BLU/BLK TB36 & 37
WHT#23-TB23C
GRN/BLK#18 RED-CR4 GRN/WHT-CR2,CR3 GRN/WHT-3 19 GRN/WHT-SP LIFT PUMP PR3
TS15 TS13
GRN#17 CB1 LS3 GRN/BLK-3 18 GRN/BLK SP PLATFORM ROTATE RIGHT
DRIVE ENABLE LS4 GRN-3 17 GRN SP PLATFORM ROTATE LEFT
LIMIT SWITCH SECONDARY BOOM
GRN/WHT#19 LIMIT SWITCH ORG/RED-3 16 RED-LS3 DRIVE ENABLE
ORG/BLK-CR4 ORG/BLK-3 15 ORG-LS2 (OPT) ORG/BLK-SP PLATFORM LEVEL DOWN 6
ORG-CR4 ORG-3 14 ORG-LS2 (OPT) ORG-SP PLATFORM LEVEL UP
RED/BLK#2 N.O. BLK#12-TB12B
N.C.
N.O. BLU/RED-3 13 WHT-LS3 DRIVE ENABLE LIGHT
TS14 TS12 BRN-TB50B
ORG/BLK#15 WHT#13-TB13B
N.C. BLK#40-TB40B BLU/WHT-3 12 BLK-LS3 RED SP-HM DRIVE ENABLE
TS19
RED#16-TB16B WHT#52-TB52B BLU/BLK-MH BLU/BLK-3 11 BLU/BLK-D/A BLU/BLK SP SECONDARY BOOM DOWN
BLU-MH BLU-3 10 BLU SP SECONDARY BOOM UP
ORG#14 LABEL DESCRIPTION
BLK/RED-3 9 BLK/RED-CR1 HORN
RED#1 P1 EMERGENCY STOP BUTTON
BLK/WHT-MH BLK/WHT-3 8 BLK/WHT S.P
KS1 KEY SWITCH BOOM RETRACT 7
WHT#4 TS10 TURNTABLE ROTATE SWITCH BLK-MH BLK-3 7 BLK SP BOOM EXTEND
TS16 TS11 TS10 TS11 SECONDARY BOOM UP/DOWN SWITCH
WHT/RED-MH WHT/RED-3 6 WHT/RED SP LIFT FLOW CONTROL
GRN/BLK#44 TS12 PRIMARY BOOM UP/DOWN SWITCH
TS13 BOOM EXTEND/RETRACT SWITCH WHT/BLK-MH WHT/BLK-3 5 WHT/BLK SP TURNTABEL ROTATE LEFT
TS14 PLATFORM LEVEL SWITCH
WHT-MH WHT-3 4 WHT SP TURNTABEL ROTATE RIGHT
GRN#43 TS15 PLATFORM ROTATE SWITCH
TS16 JIB UP/DOWN SWITCH RED/WHT-CH RED/WHT-3 3 0-5V DC TO MOTOR CONT.
TS17 AUXILIARY SWITCH
RED/BLK-MH RED/BLK-3 2 RED/BLK D/A RED/BLK SP PRIMARY BOOM DOWN
BLU#10 TS19 FUNCTION ENABLE SWITCH
CB1 CIRCUIT BREAKER, CONTROLS, 10A RED-MH RED-3 1 RED SP PRIMARY BOOM UP
RED#20 8
HM HOUR METER
D C B A
BLU/BLK#11 CR1 CONTROL RELAY - HORN
CR2 CONTROL RELAY - AUXILIARY PUMP
WHT/BLK#5 CR4 PLATFORM LEVEL CUT-OUT (OPTION)
CH CHASSIS HARNESS
MH MANIFOLD HARNESS
SP SWITCH PANEL
AL TRAVEL ALARM
J1 BRAKE RELEASE JACK

Part No. 35532 Genie Z-30/20N 7 - 20

First Edition • Third Printing Section 7 • Schematics

Ground Control Panel Wiring Diagram

(from serial number 747 to 3446)
 First Edition • Third Printing Section 7 • Schematics

Ground Control Panel Wiring Diagram

(from serial number 3447 to 4082)
N M L K J I H G F E D C B A

BRN
1
A3 A2 A2

BRN RED/WHT BRN

TILT SENSOR RED-23D

ORG

WHT-28D BRN-CB2 BLK [OPTION 2] 52 BRN-CH GROUND

BRN-5 52 BRN-CR4 GROUND
BLK BRN-CB2
BRN-2 52 BRN-MH BRN-SP GROUND 2
WHT-6 WHT-8 50 LS2-LS4 JUNCTION
SWITCH PANEL
BLK-7 BLK-6 49 LS1-LS2 JUNCTION
CB2 L3 WHT/BLK-SP RED/WHT-CR5 48 RED/WHT-MH RED/WHT-SP BRAKE RELEASE
BRN-52D BLK-CH GRN/BLK-1 44 GRN/BLK-SP JIB DOWN
WHT/BLK-19D/48D
HM GRN-1 43 GRN-SP JIB UP HM
BRN-CH ORG/RED-42A ORG/RED-CR1 ORG/RED-1 42 ORG/RED-CH ORG/RED-L3 SWITCHED 48V
BLK-8 40 ORG-CH OFF-LIMIT SPEED
BRN-52A
P1
BLU/BLK-19D BLU/BLK-1 37 BLU/BLK-MH STEER RIGHT
NC BLU-19D BLU-1 36 BLU-MH STEER LEFT NC
WHT/RED-1 32 WHT/RED-CH JOYSTICK POT. LOW
NC WHT/BLK-1 31 WHT/BLK-CH REVERSE NC 3
WHT-1 30 WHT-CH FORWARD
P1
RED/WHT-1 29 RED/WHT-CH 2-WIRE POT.
RED
WHT-TILT RED/BLK-1 28 TILT ALARM
RED-CR3 RED-1 27 RED-SP AUXILIARY PUMP SELECT TS51
TS51
J1 KS1 [OPTION 2] 23 KEYSWITCH POWER J1
RED-TILT WHT-2 23 WHT-SP KEYSWITCH POWER RED/WHT-48A KS1
WHT-7 BLK-2 22 BLK-CR4 BLK-SP +24V TO PLATFORM
NO NO NO NO
TB36/TB37 GRN/WHT-CR3 19 GRN/WHT-MH LIFT PUMP WHT-23A
WHT/BLK-SP GRN/WHT-3 19 GRN/WHT-SP LIFT PUMP
BLK-22A
GRN/BLK-3 18 GRN/BLK-SP PLAT. ROTATE RIGHT RED
GRN-3 17 GRN-SP PLAT. ROTATE LEFT
RED-27A 4
RED-5 ORG/RED-3 16 ORG/RED-CR5 DRIVE ENABLE BLK-7A
* ORG/BLK-3 15 ORG/BLK-MH * ORG/BLK-SP PLAT. LEVEL DOWN BLK/WHT-8A
* ORG-3 14 ORG-MH * ORG-SP PLAT. LEVEL UP
13 DRIVE ENABLE LIGHT
WHT/RED-6A
WHT-5 BLU/RED-3 TS63
TS57 TS63 BLK-5 BLU/WHT-3 12 BLU/WHT-CH FOOTSWITCH GRN/BLK-18A TS57
CB1 BLU/BLK-3 11 BLU/BLK-MH BLU/BLK-SP SEC. BOOM DOWN GRN-17A CB1
BLU-3 10 BLU-MH BLU-SP SEC. BOOM UP L R R E
BLK/RED-CR4 BLK/RED-3 9 HORN
GRN/WHT-19A
BLK/WHT-3 8 BLK/WHT-MH BLK/WHT-SP BOOM RETRACT RED/BLK-2A
ORG 7 BLK-MH
BLK-3 BLK-SP BOOM EXTEND RED-1A RED 5
WHT/RED-3 6 WHT/RED-MH WHT/RED-SP BOOM FUNCTION F.C.
TS59 TS61 TS59 TS61
5 WHT/BLK-MH TURN. ROTATE RIGHT
TS55
WHT/BLK-3 WHT/BLK-SP ORG/BLK-15A D D
TS55
WHT-3 4 WHT-MH WHT-SP TURN. ROTATE LEFT
RED/WHT-CR1 RED/WHT-3 3 48V RELAY COIL PWR.
2 RED/BLK-MH
ORG-14A U U
RED/BLK-3 RED/BLK-SP PRIMARY BOOM DOWN
RED-3 1 RED-MH RED-SP PRIMARY BOOM UP WHT/BLK-5A
ORG
D C B A WHT-4A
TS58 TS60 TS58 TS60 TS62
TS62 * [SEE OPTIONAL WIRING]
ORG GRN/BLK-44A D D
[DENOTES TEST PORT] L R
GRN-43A U U 6
GRN/WHT-19C
ORG/RED-CH RED-27D
GRN/WHT-CH BLK-22B BLU/BLK-11A
1 2 3 4 BLU-10A
BRN-52A
RED/WHT-TB3D RED-CH
BLK/RED-HORN
DESCENT ALARM WIRING (OPTION)
ORG/RED-42D RED-CH BLK/RED-9D

LABEL DESCRIPTION
RED/WHT-48C ORG-MH ORG/BLK-MH 7
P1 EMERGENCY STOP BUTTON
5 10A 10B
KS1 KEY SWITCH
RED/BLK-CH RED-6 CONTROL RELAY I.D. SPARE WIRE LIST OPTION NUMBERS
TS51 AUXILIARY TOGGLE SWITCH
CR1 - SECONDARY 48V DC POWER BLK-1 1 - PLATFORM LEVEL CUTOUT
TS55 FUNCTION ENABLE TOGGLE SWITCH ORG/RED-16A
CR2 - PRIMARY 48V DC POWER BLK/WHT-1 2 - FLASHING BEACON
TS57 PLATFORM ROTATE TOGGLE SWITCH
CR3 - AUXILIARY PUMP BLK/RED-1 3 - DESCENT ALARM
TS58 JIB BOOM UP/DOWN TOGGLE SWITCH
CR4 - HORN BLU/WHT-1
TS59 PLATFORM LEVEL TOGGLE SWITCH ORG-14B ORG/BLK-15B
CR5 - BRAKE RELEASE BLU/RED-1
TS60 SECONDARY BOOM UP/DOWN TOGGLE SWITCH
CR10A - PLATFORM LEVEL CUTOUT (CE ONLY) ORG-1
TS61 PRIMARY BOOM UP/DOWN TOGGLE SWITCH
CR10B - PLATFORM LEVEL CUTOUT (CE ONLY) ORG/BLK-1
TS62 TURNTABLE ROTATE TOGGLE SWITCH ORG-6
GRN/WHT-1
TS63 BOOM EXTEND/RETRACT TOGGLE SWITCH
CIRCUIT BREAKER, CONTROLS, 10A
8
CB1 ORG/BLK-3 15 ORG/BLK-CR10B ORG/BLK-SP PLATFORM LEVEL DOWN
CB2 CIRCUIT BREAKER, CONTROLS RETURN, 10A ORG-3 14 ORG-CR10A ORG-SP PLATFORM LEVEL UP
J1 BRAKE RELEASE JACK
HM HOURMETER
CH CHASSIS HARNESS
PLATFORM LEVEL CUTOUT (CE VERSION ONLY)
MH MANIFOLD HARNESS
SP SWITCH PANEL
CR CONTROL RELAY
A2 BRAKE RELEASE/TRAVEL ALARM
A3 DESCENT ALARM (OPTION)
L3 CONTROLLER STATUS LED

Part No. 35532 Genie Z-30/20N 7 - 21

First Edition • Third Printing Section 7 • Schematics

Ground Control Panel Wiring Diagram

(from serial number 3447 to 4082)
 First Edition • Third Printing Section 7 • Schematics

Ground Control Panel Wiring Diagram

(after serial number 4082)
N M L K J I H G F E D C B A

GRN/WHT-19C
BRN-CB2 BLK [OPTION 2] 52 BRN-CH BRN-CR4 GROUND ORG/RED-CH RED-27D 1
GRN/WHT-CH BLK-22B
BRN-5 BRN-2 52 BRN-MH BRN-SP GROUND
1 2 3 4
WHT-6 WHT-8 50 LS2-LS4 JUNCTION BRN-52A
RED/WHT-TB3D
BLK-7 BLK-6 49 LS1-LS2 JUNCTION RED/WHT BRN
BLK/RED-HORN
WHT/BLK-SP RED/WHT-CR5 48 RED/WHT-MH RED/WHT-SP BRAKE RELEASE
ORG/BLK-1 47 ORG/BLK-SP ** JIB BOOM ROTATE RIGHT ORG/RED-42D RED-CH BLK/RED-9D
A2
ORG-1 46 ORG-SP ** JIB BOOM ROTATE LEFT
GRN/BLK-1 44 GRN/BLK-SP JIB BOOM DOWN RED/WHT-48C ORG-MH ORG/BLK-MH

GRN-1 43 GRN-SP JIB BOOM UP 5 10A 10B

2
RED-6
ORG/RED-CR1 ORG/RED-1 42 ORG/RED-CH ORG/RED-L3 SWITCHED 48V DC
RED/BLK-CH

ORG/RED-16A
SWITCH PANEL
BLK-8 40 ORG-CH OFF-LIMIT SPEED
BLU/BLK-19D BLU/BLK-1 37 BLU/BLK-MH STEER RIGHT
ORG-14B ORG/BLK-15B
BLU-19D BLU-1 36 BLU-MH STEER LEFT
WHT/RED-1 32 WHT/RED-CH JOYSTICK POT. LOW
WHT/BLK-1 31 WHT/BLK-CH DRIVE REVERSE ORG-6 WHT/BLK-19D/48D
BRN-52A HM 3
WHT-1 30 WHT-CH DRIVE FORWARD ORG/BLK-3 15 ORG/BLK-CR10B ORG/BLK-SP PLAT. LEVEL DOWN
RED/WHT-1 29 RED/WHT-CH 2-WIRE POT. ORG-3 14 ORG-CR10A ORG-SP PLAT. LEVEL UP P1
WHT-TILT RED/BLK-1 28 TILT ALARM
NC
RED-CR3 RED-1 27 RED-SP AUXILIARY PUMP SELECT PLATFORM LEVEL CUTOUT (CE VERSION ONLY)
[OPTION 2] 23 KEY SWITCH POWER NC
RED-TILT WHT-2 23 WHT-SP KEY SWITCH POWER
WHT-7 BLK-2 22 BLK-CR4 BLK-SP +24V DC TO PLATFORM
TB36/TB37 GRN/WHT-CR3 19 GRN/WHT-MH LIFT PUMP 4
CB1
WHT/BLK-SP GRN/WHT-3 19 GRN/WHT-SP LIFT PUMP RED-CH KS1
GRN/BLK-3 18 GRN/BLK-SP PLATFORM ROTATE RIGHT TS51
GRN-3 17 GRN-SP PLATFORM ROTATE LEFT
RED-5 ORG/RED-3 16 ORG/RED-CR5 DRIVE ENABLE TILT SENSOR RED-23D
RED
* ORG/BLK-3 15 ORG/BLK-MH * ORG/BLK-SP PLATFORM LEVEL DOWN RED/WHT-48A
WHT-28D J1 NO NO
* ORG-3 14 ORG-MH * ORG-SP PLATFORM LEVEL UP
BLK BRN-CB2
WHT-5 BLU/RED-3 13 DRIVE ENABLE LIGHT
BLU/WHT-3 12 BLU/WHT-CH FOOTSWITCH WHT-23A
5
BLK-5 RED
BLU/BLK-3 11 BLU/BLK-MH BLU/BLK-SP SECONDARY BOOM DOWN CB2 L3 BLK-22A
RED-27A
BLU-3 10 BLU-MH BLU-SP SECONDARY BOOM UP BRN-52D BLK-CH
ORG/BLK-15A
BLK/RED-CR4 BLK/RED-3 9 HORN BLK-7A
BRN-CH ORG/RED-42A BLK/WHT-8A
BLK/WHT-3 8 BLK/WHT-MH BLK/WHT-SP BOOM RETRACT
7 BLK-MH BOOM EXTEND WHT/RED-6A
BLK-3 BLK-SP TS59
TS63
WHT/RED-3 6 WHT/RED-MH WHT/RED-SP BOOM FUNCTION FLOW CONTROL JIB ROTATE ORG/BLK-47A
D
5 WHT/BLK-MH TURNTABLE ROTATE RIGHT ORG-46A 6
WHT/BLK-3 WHT/BLK-SP (OPTION) TS66 L R R E
WHT-3 4 WHT-MH WHT-SP TURNTABLE ROTATE LEFT
RED/WHT-CR1 RED/WHT-3 3 48V DC RELAY COIL POWER U
LABEL DESCRIPTION
RED/BLK-3 2 RED/BLK-MH RED/BLK-SP PRIMARY BOOM DOWN ORG-14A
P1 EMERGENCY STOP BUTTON
1 RED-MH PRIMARY BOOM UP GRN/BLK-18A
RED-3 RED-SP KS1 KEY SWITCH
TS51 AUXILIARY TOGGLE SWITCH
GRN/WHT-19A TS61 TS57
D C B A TS55 FUNCTION ENABLE TOGGLE SWITCH GRN/BLK-44A D D
TS57 PLATFORM ROTATE TOGGLE SWITCH
TS58 L R 7
TS58 JIB BOOM UP/DOWN TOGGLE SWITCH GRN-43A
TS59 PLATFORM LEVEL TOGGLE SWITCH U U
RED/BLK-2A
TS60 SECONDARY BOOM UP/DOWN TOGGLE SWITCH RED-1A
TS61 PRIMARY BOOM UP/DOWN TOGGLE SWITCH GRN-17A
[* SEE OPTIONAL WIRING] TS62
TS63
TURNTABLE ROTATE TOGGLE SWITCH
BOOM EXTEND/RETRACT TOGGLE SWITCH
WHT/BLK-5A TS62
WHT-4A
[** JIB BOOM ROTATE OPTION] TS66 JIB BOOM ROTATE TOGGLE SWITCH (OPTION) D TS60
CB1 CIRCUIT BREAKER, CONTROLS, 10A TS55 L R
CB2 CIRCUIT BREAKER, CONTROLS RETURN, 10A
BLU/BLK-11A
U 8
J1 BRAKE RELEASE JACK
CONTROL RELAY I.D. SPARE WIRE LIST OPTION NUMBERS HM HOURMETER
CR1 - SECONDARY 48V DC POWER BLK-1 1 - PLATFORM LEVEL CUTOUT CH CHASSIS HARNESS
CR2 - PRIMARY 48V DC POWER BLK/WHT-1 2 - FLASHING BEACON MH MANIFOLD HARNESS BLU-10A
CR3 - AUXILIARY PUMP BLK/RED-1 3 - DESCENT ALARM SP SWITCH PANEL
CR4 - HORN BLU/WHT-1 CR_ CONTROL RELAY
CR5 - BRAKE RELEASE BLU/RED-1 A2 BRAKE RELEASE/TRAVEL ALARM
CR10A - PLATFORM LEVEL CUTOUT (CE ONLY) GRN/WHT-1 A3 DESCENT ALARM (OPTION)
CR10B - PLATFORM LEVEL CUTOUT (CE ONLY)
L3 CONTROLLER STATUS LED

Part No. 35532 Genie Z-30/20N 7 - 22

First Edition • Third Printing Section 7 • Schematics

Ground Control Panel Wiring Diagram

(after serial number 4082)
 First Edition • Third Printing Section 7 • Schematics

Platform Control Box Wiring Diagram

(before serial number 3447)
N M L K J I H G F E D C B A

TS9
TS8 L.V.I./B.C.I.
OPTION
8 2

SET TO "A"

RESET
7

- 6 BCI
4
TS1 5
P3 L1
+ 5

LVI
4
3
NO TILT 3

DISCHARGE
SET TO "N"
ALARM 2

P2 TS4 1
3
NC TS3
TS2
NC
CABLE
110
#3
TS6 TS5 RED
TS7 RED 4

B.C.I. CABLE FOOT

SWITCH
OPTION #2 8 6 6 4 2 4
8
+

TS18 7 5 3 1 2
(OPTION)
BCI 5 7 3 1
CABLE
JIB
- #1
- + A CR5 5

MAXOUT
THRESH
RED
GRN

BLK/RED
LABEL DESCRIPTION
P2 EMERGENCY STOP BUTTON
P3 HORN BUTTON
BP1 DP1 DRIVE CONTROLLER
WHT
WHT/BLK

RED/WHT
BP1 BOOM SPEED CONTROLLER
RED
RED TS1 TURNTABLE ROTATE SWITCH
TS2 SECONDARY BOOM SWITCH
6
R + L BLK
TS3 PRIMARY BOOM SWITCH
TS4 EXTEND/RETRACT SWITCH
DP1 TS5 PLATFORM LEVEL SWITCH

R D X - + B
TS6
TS7
PLATFORM ROTATE SWITCH
JIB SWITCH
TS8 AUXILIARY SWITCH
TS9 DRIVE ENABLE SWITCH
L1 DRIVE ENABLE LIGHT
BCI BATTERY CHARGE INDICATOR
7
TS18 LIFT/DRIVE SELECT (OPTION)

8
BLU/BLK-3

CR3 COIL +
WHT-FS

BRN-F.S.
RED-JIB

BLK/RED#35-1

BLU/RED#39-1
ORG/RED-3

BLU/WHT#48-1
BLK#33-1
WHT-FS

GRN/WHT#45-1
RED/BLK-1

BLK/WHT#34-1
BLK/WHT-3

GRN/BLK-3
RED-3

GRN#43-1
BLK-JIB

ORG/BLK#41-1

BLU/RED-3

BLK-3

ORG-3
GRN-3

RED/BLK-3

GRN/BLK#44-1
ORG/BLK-3
WHT/RED-3

WHT-3
WHT/BLK-3

BLU/WHT-3
BLU/BLK#37-1

BRN
BLU-3
GRN/WHT-3
WHT/BLK#31-1
WHT-JIB

BLUE-JIB

WHT#30-1
RED#27-1

RED-TILT A.
ORG/RED#42-1
ORG-JIB

BLK/RED-3

BRN-JIB

RED/WHT#29-1
BLK-FS
WHT-2

BLU#36-1

ORG#40-1
RED/WHT-3
BLK-2

WHT/RED#32-1

BRN-2

ORG/RED-1
SPARE
WIRES

Part No. 35532 Genie Z-30/20N 7 - 23

First Edition • Third Printing Section 7 • Schematics

Platform Wiring Diagram

(before serial number 3447)
 First Edition • Third Printing Section 7 • Schematics

Platform Control Box Wiring Diagram

(from serial number 3447 to 4082)
N M L K J I H G F E D C B A

WHT

ORG/BLK TS15
TS1
2
RED

TS12 A1
P3 L1
NO

RED
TS13 TS11

TS10
NC
P2
CABLE 110
NC
TS7 #3
TS9
4

TS8 #2 F.S.

BCI RED
BRN GRN BLK/RED

BRN-JIB
CABLE JIB
#1 5
BP1

BRN LABEL DESCRIPTION

P2 EMERGENCY STOP BUTTON

P3 HORN BUTTON

BRN-2
L R DP1 DRIVE CONTROLLER

1 2 3 4 5 6 7 8 9 10
BP1
TS1
BOOM FUNCTION SPEED CONTROLLER
AUXILIARY SWITCH
6
TS7 PLATFORM ROTATE SWITCH
TS8 JIB UP/DOWN SWITCH
TS9 PLATFORM LEVEL SWITCH
TS10 SECONDARY BOOM UP/DOWN SWITCH
TS11 PRIMARY BOOM UP/DOWN SWITCH
TS12 TURNTABLE ROTATE SWITCH
TS13 EXTEND/RETRACT SWITCH
TS15 DRIVE ENABLE SWITCH
A1 TILT ALARM
L1 DRIVE ENABLE LIGHT
BCI BATTERY CHARGE INDICATOR 7

BLU/WHT-3

RED/BLK-1
BLK-JIB

WHT-JIB

ORG-JIB

BLUE-JIB

RED-1

BLK/RED-3

BLK-2

BLK-F.S.

WHT-2
RED/WHT-3
RED/WHT-1
WHT/RED-1
WHT/BLK-1
WHT-1

WHT-FS

BLU-1
BLU/BLK-1
BLU/RED-3

BLK-3
ORG/RED-1

BLK/WHT-3

ORG/BLK-3

GRN/WHT-3

GRN-1

GRN/BLK-1

BLU-3

BLU/BLK-3

WHT-3

WHT/BLK-3

ORG/RED
GRN-3
GRN/BLK-3

RED-3

RED/BLK-3

ORG-3

WHT/RED-3
8

REMOVE THIS WIRE WHEN

LOAD SENSE OPTION IS REQUIRED. REMOVE JUMPER JP1 FOR CE VERSION.

Part No. 35532 Genie Z-30/20N 7 - 24

First Edition • Third Printing Section 7 • Schematics

Platform Control Box Wiring Diagram

(from serial number 3447 to 4082)
 First Edition • Third Printing Section 7 • Schematics

Platform Control Box Wiring Diagram

(after serial number 4082)
N M L K J I H G F E D C B A

WHT WHT
2
SPARE WIRES
L1
TS1 DRIVE BLK-1
AUXILIARY ENABLE BLK/WHT-1
POWER LED BLK/RED-1
TS15 BLU/WHT-1
BLU/RED-1
GRN/WHT-1
TS12 3
P3 TS7

WHT
HORN
A1
NO TS9

RED

RED
TS11
CABLE LOAD SENSE
#3 (ACCESSORY)
P2
EMERGENCY NC
STOP BUTTON TS13 TS10 4
NC

ORG/RED
CABLE
#2
F.S.

TS16
TS8
BCI CABLE JIB
(OPTION) #1
BRN
5
LABEL DESCRIPTION
P2 EMERGENCY STOP BUTTON
BP1

GRN
RED
BLK/RED
P3 HORN BUTTON
BOOM DP1 DRIVE CONTROLLER
FUNCTION BP1 BOOM FUNCTION SPEED CONTROLLER
TS1 AUXILIARY POWER TOGGLE SWITCH
SPEED
TS7 PLATFORM ROTATE TOGGLE SWITCH
CONTROL

BRN-JIB
TS8 JIB BOOM UP/DOWN TOGGLE SWITCH
TS9 PLATFORM LEVEL TOGGLE SWITCH
TS10 SECONDARY BOOM UP/DOWN TOGGLE SWITCH
BRN
TS11 PRIMARY BOOM UP/DOWN TOGGLE SWITCH
TS12 TURNTABLE ROTATE TOGGLE SWITCH
TS13 BOOM EXTEND/RETRACT TOGGLE SWITCH
6
TS15 DRIVE ENABLE TOGGLE SWITCH
RED
TS16 JIB BOOM ROTATE TOGGLE SWITCH (OPTION)

BRN-2
DP1 L R
A1
L1
TILT ALARM
DRIVE ENABLE LIGHT
BCI BATTERY CHARGE INDICATOR (OPTION)
1 2 3 4 5 6 7 8 9 10

8
ORG/BLK-3
ORG-1

ORG/BLK-1
ORG-3

RED-3
RED/BLK-3
GRN/BLK-1

GRN/WHT-3

GRN-1

GRN-3

GRN/BLK-3

WHT/RED-3

BLU-3

BLU/BLK-3

WHT-3

WHT/BLK-3

ORG/RED-3
BLU/WHT-3
RED/BLK-1
RED-JIB

YEL-JIB

BLK-JIB

WHT-JIB

ORG-JIB

BLUE-JIB

RED-1

BLK/RED-3

BLK-2

BLK-FS

ORG/RED-1
WHT-2

RED/WHT-1
WHT/RED-1
WHT/BLK-1
WHT-1

WHT-FS

BLU-1
BLU/BLK-1
BLU/RED-3

BLK-3
BLK/WHT-3
RED/WHT-3

REMOVE THIS WIRE WHEN LOAD REMOVE JUMPER JIB BOOM ROTATE
SENSE OPTION IS REQUIRED. FOR CE MODELS OPTION

Part No. 35532 Genie Z-30/20N 7 - 25

First Edition • Third Printing Section 7 • Schematics

Platform Control Box Wiring Diagram

(after serial number 4082)
First Edition • Third Printing Section 7 • Schematics

This page intentionally left blank.

Part No. 35532 Genie Z-30/20N 7 - 26

Section 7 • Schematics First Edition • Third Printing

Hydraulic Symbols Legend

Normally open
poppet valve
Hydraulic filter Fixed displacement
pump

3000 psi /
207 bar
3:1
1.5 gpm /
Check valve Counterbalance valve 5.7 L/min

Flow regulator valve

Solenoid operated
dump valve

0.045 /
1.14 mm

Orifice with size

2800 psi /
193 bar

Relief valve
with pressure
Differential
sensing valve
Brake

1100 psi /
75.8 bar
Dual relief valve
with pressure
Solenoid operated
Double acting proportional valve
cylinder

25 psi /
1.7 bar
M
Pump prime mover Filter with by-pass
(motor) Solenoid operated
2 position, 3 way
directional valve

N.O.
COM
N.C.

Normally closed
Pressure switch Solenoid operated 3 position, poppet valve
4 way, directional valve

7 - 27 Genie Z-30/20N Part No. 35532

 First Edition • Third Printing Section 7 • Schematics

Hydraulic Schematic
(before serial number 3447)
N M L K J I H G F E D C B A

N.O. 1
COM DD BRAKES
STEERING N.C. M M
CYLINDER
BB
EE
S2 Z CC FF
HH
S1 0.040 inch / 0.052 inch / BRAKE
1 mm GG 1.32 mm 2
0.085 inch /
2.15 mm

STEER/BRAKE
FUNCTION
AA
MANIFOLD

PLATFORM LEVEL P T
SLAVE CYLINDER 3
JIB BOOM
CYLINDER

0.025 inch /
0.63 mm
ORIFICE DELETED
PRIMARY EXTENSION AFTER SERIAL NUMBER 2207
4
SECONDARY
CYLINDER CYLINDER CYLINDER
0.032 inch
0.81 mm
3000 psi / TURNTABLE PLATFORM
207 bar
ROTATE ROTATE
8:1
AUXILIARY PRIMARY
M PUMP M PUMP 5
0.5 gpm / 1.7 gpm /
1.9 L/min 6.4 L/min MASTER 5.9 CU. IN.
CYLINDER /REV

100
MICRON
MESH

3000 psi / 3000 psi / 2500 psi / 2500 psi / 2500 psi /
207 bar 207 bar 172 bar 172 bar 172 bar 6
HYDRAULIC TANK 1.5:1 3:1 3:1 3:1 3:1
P1 G1 C1 C2 M1 M2 C3 C4 C5 C6 C7 C8
BOOM FUNCTION
MANIFOLD O N
P R S T
2800 psi / 1750 psi / 1600 psi / 1400 psi / 1800 psi /
193 bar 121 bar 110 bar 96 bar 124 bar 7
B
25 psi / 3000 psi / JIB/PLATFORM
5
1.7 bar MICRON 207 bar ROTATE
A 3:1 Q MANIFOLD
1750 psi / T1 T2 PR1 PR2
121 bar

U G L K F E J D I H C U Y 0.030 inch / X V
0.76 mm
8
P2 P
W
0.050 inch /
1.27 mm T2 T
T1

Part No. 35532 Genie Z-30/20N 7 - 28

First Edition • Third Printing Section 7 • Schematics

Hydraulic Schematic
(before serial number 3447)
 First Edition • Third Printing Section 7 • Schematics

Hydraulic Schematic
(from serial number 3447 to 4082)
N M L K J I H G F E D C B A

1
JIB BOOM PLATFORM ROTATE

UP DOWN V1 V2
3000 psi / 2500 psi /
207 bar (172 bar
PLATFORM 3:1 3:1
J1 J2 PR1 PR2
LEVEL 3
W
0.025 inch / JIB/PLATFORM ROTATE
SLAVE 0.64 mm
CYLINDER
MANIFOLD

U Y X V
P
T 4

AUXILIARY PRIMARY
PUMP PUMP
0.5 gpm / 2.1 gpm /
BRAKES STEER TURNTABLE SECONDARY PRIMARY EXTENSION
1.9 L/min 7.9 L/min CYLINDER ROTATE CYLINDER CYLINDER CYLINDER
3000 psi /
M M
M M 207 bar 0.032 inch /
8:1 0.81 mm 5

10 100 5.9 CU. IN.

MASTER
MICRON MICRON /REV
CYLINDER
MESH

SS
HYDRAULIC TANK 6
N.O.
COM
N.C.
3000 psi / 3000 psi / 2500 psi /
207 bar 207 bar 172 bar
ZZ 1.5:1 3:1 3:1
P1 G1 BRAKE PS S1 S2 P2 L1 L2 TR1 TR2 SC1 SC2 PC1 PC2 EXT RET

UU KK LL MM NN
BOOM 2800 psi /
193 bar
FUNCTION 0.045 inch /
MANIFOLD 1.14 mm
TT 7
1600 psi / 1400 psi / 1800 psi /
YY
3000 psi / 1100 psi / 110 bar 97 bar 124 bar
QQ JJ II
XX
207 bar 76 bar
VV WW PP
3:1
0.060 inch /
OO 1.5 mm
AF AB AC RR
0.8 gpm / HH 1.5 gpm /
3.6 L/min AE
6.8 L/min AD 8

T1 T2
0.035 inch /
0.89 mm

Part No. 35532 Genie Z-30/20N 7 - 29

First Edition • Third Printing Section 7 • Schematics

Hydraulic Schematic
(from serial number 3447 to 4082)
 First Edition • Third Printing Section 7 • Schematics

Hydraulic Schematic
(from serial number 4083 to 5397)
N M L K J I H G F E D C B A

1
JIB BOOM
JIB ROTATE
OPTION PLATFORM ROTATE

JR1 JR2 EXT RET PR1 PR2

ROTATE MANIFOLD
(JIB)
3300 psi /
227.5 bar
3000 psi /
207 bar
3300 psi /
227.5 bar
ROTATE MANIFOLD
3:1 3:1 3:1 (PLATFORM)

JR1 JR2 J1 J2 PR1 PR2

3
BA
BE
0.025 inch /
0.635 mm
BC BB
P

BD
PLATFORM LEVELING 0.3 gpm /
SLAVE 1.14 L/min

4
JIB BOOM MANIFOLD

SECONDARY BOOM PRIMARY BOOM EXTENSION CYLINDER

CYLINDER CYLINDER
STEER
CYLINDER 0.032 inch /
M BRAKES M 0.81 mm
TURNTABLE ROTATE 5
MOTOR

3000 psi /
207 bar
8:1
5.9 cu in/rev
96.7 cc/rev
MASTER

3000 psi /
207 bar 6
SS 1.5:1 2500 psi /
3000 psi /
207 bar 172 bar
N.O. 3:1
COM 3:1
ZZ N.C.

BRAKE PS SC1 SC2

S1
P1 G1 P2 L1 L2 TR1 TR2 PC1 PC2 EXT

S2
UU RET
KK

0.045 inch /
PRIMARY 2800 psi / 1.14 mm
PUMP 193 bar TT LL MM NN
M 2.1 gpm / M
1600 psi / 1400 psi / 1800 psi /
AUXILIARY
7.95 L/min
YY 110 bar 96.5 bar 124 bar 7
PUMP
3000 psi / 1100 psi /
0.5 gpm / WW PP QQ II
1.89 L/min JJ 207 bar 75.8 bar
VV 3:1
XX

0.045 inch /
1.14 mm
10 MICRON
100 MESH HH AF AB AC RR
0.8 gpm /
AE 3 L/min 1.5 gpm /
OO 5.7 L/min

HYDRAULIC RESERVOIR 8
AD
0.035 inch /
0.89 mm
T1 T2

FUNCTION MANIFOLD

Part No. 35532 Genie Z-30/20N 7 - 30

First Edition • Third Printing Section 7 • Schematics

Hydraulic Schematic
(from serial number 4083 to 5397)
 First Edition • Third Printing Section 7 • Schematics

Hydraulic Schematic
(after serial number 5397)
N M L K J I H G F E D C B A

JIB BOOM
JIB BOOM ROTATE
OPTION PLATFORM ROTATE
2

JR1 JR2 PR1 PR2

ROTATE MANIFOLD 3300 psi / 3000 psi / 3300 psi / ROTATE MANIFOLD
3
227.5 bar 207 bar 227.5 bar
(JIB BOOM) 3:1 1.5:1 3:1 (PLATFORM)
JR1 JR2 J1 J2 PR1 PR2

BA BC BB
BE
0.025 inch /
P 0.635 mm

PLATFORM LEVELING BD 0.3 gpm /

4
1.14 L/min
SLAVE
T

EXTENSION CYLINDER
JIB BOOM MANIFOLD (MODELS WITHOUT
ROTATING JIB BOOM) EXTENSION CYLINDER
SECONDARY BOOM PRIMARY BOOM (MODELS WITH
CYLINDER CYLINDER ROTATING JIB BOOM)
STEER
5
0.032 inch
BRAKES CYLINDER 0.81 mm
M M
TURNTABLE ROTATE
MOTOR

3000 psi /
207 bar
4.5:1 5.9 cu in/rev
96.7 cc/rev
MASTER
6
2500 psi /
172 bar
SS 3000 psi / 3000 psi / 2500 psi /
3:1
N.O. 207 bar 207 bar 172 bar
ZZ COM 1.5:1 3:1 3:1
N.C.

BRAKE PS SC1 SC2 EXT

S1

P1 G1 P2 L1 L2 TR1 TR2 PC1 PC2 RET

S2

UU KK
2800 psi /
193 bar 0.045 inch /
AUXILIARY
PRIMARY
PUMP
1.14 mm TT LL MM NN 7
PUMP M M 1800 psi /
2.1 gpm / 1600 psi / 1600 psi / 2800 psi /
0.5 gpm / 124 bar
1.89 L/min
7.95 L/min YY 110 bar 110 bar 193 bar
QQ 3000 psi / 1100 psi /
WW PP JJ 207 bar II 75.8 bar
XX VV 3:1

0.045 inch /
1.14 mm
10 MICRON
100 MESH HH AF AB AC RR
0.8 gpm /
AE 1.5 gpm /
3 L/min
OO 5.7 L/min
8
HYDRAULIC RESERVOIR
AD

T1 T2

FUNCTION MANIFOLD 0.035 inch /

0.89 mm

Part No. 35532 Genie Z-30/20N 7 - 31

First Edition • Third Printing Section 7 • Schematics

Hydraulic Schematic
(after serial number 5397)

Genie Scandinavia
Phone +46 31 575100
Fax +46 31 579020
Genie France
Phone +33 (0)2 37 26 09 99
Fax +33 (0)2 37 26 09 98
Genie Iberica
Phone +34 93 579 5042
Fax +34 93 579 5059
Genie Germany
Phone 0800 180 9017
Phone +49 422 149 1818
Fax +49 422 149 1820
Genie U.K.
Phone +44 (0)1476 584333
Fax +44 (0)1476 584334
Genie Mexico City
Phone +52 55 5666 5242
Fax +52 55 5666 3241
Genie North America
Phone 425.881.1800
Toll Free USA and Canada
Distributed By:
800.536.1800
Fax 425.883.3475
Genie Australia Pty Ltd.
Phone +61 7 3375 1660
Fax +61 7 3375 1002
Genie China
Phone +86 21 53852570
Fax +86 21 53852569
Genie Malaysia
Phone +65 98 480 775
Fax +65 67 533 544
Genie Japan
Phone +81 3 3453 6082
Fax +81 3 3453 6083
Genie Korea
Phone +82 25 587 267
Fax +82 25 583 910
Genie Brasil
Phone +55 11 41 665 755
Fax +55 11 41 665 754
Genie Holland
Phone +31 183 581 102
Fax +31 183 581 566