Service Manual: Z-30/20N Z-30/20N RJ

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

Rev C
June 2008
Introduction June 2008
Introduction
Important Serial Number Information

Read, understand and obey the safety rules and Genie Industries offers the following Service
operating instructions in the Genie Z-30/20N Manuals for these models:
Operator's Manual before attempting any
maintenance or repair procedure. Title Part No.
This manual provides detailed scheduled Z-30/20N Service Manual
maintenance information for the machine owner (before serial number 5934) ................................ 35532
and user. It also provides troubleshooting fault
codes and repair procedures for qualified service Z-30/20N Service Manual
professionals. (after serial number 11499) ................................ 139378
Basic mechanical, hydraulic and electrical skills

are required to perform most procedures.
However, several procedures require specialized
skills, tools, lifting equipment and a suitable
workshop. In these instances, we strongly
recommend that maintenance and repair be
performed at an authorized Genie dealer service
center.
Technical Publications
Genie Industries has endeavored to deliver the
highest degree of accuracy possible. However,
continuous improvement of our products is a Genie
policy. Therefore, product specifications are
subject to change without notice.
Readers are encouraged to notify Genie of errors
and send in suggestions for improvement. All
communications will be carefully considered for
future printings of this and all other manuals.
Contact Us: Copyright © 1996 by Genie Industries
106373 Rev C June 2008

http://www.genieindustries.com Second Edition, Third Printing
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 Z-30/20N • Z-30/20N RJ Part No. 106373

June 2008
INTRODUCTION
Serial Number Legend
Model: Z-30/20N
Serial number: Z30N05-12345
Model year: 2005 Manufacture date: 04/12/05
Electrical schematic number: ESXXXX
Machine unladen weight:
Rated work load (including occupants): XXX lb / XXX kg

Maximum number of platfrm occupants: X
Maximum allowable side force : XXX lb / XXX N
Maximum allowable inclination of the chassis:
0 deg Z30N 05 - 12345
Maximum wind speed : XX mph/ XX m/s
Maximum platform height : XX ft / XX m
Model Sequence
Maximum platform reach : XX ft / XX m
number
Gradeability: N/A
Country of manufacture: USA Year of
manufacture
This machine complies with:
Serial label
(located under cover)
Serial number
Genie Industries stamped on chassis
18340 NE 76th Street
Redmond, WA 98052
USA
PN - 77055
Part No. 106373 Z-30/20N • Z-30/20N RJ iii

June 2008
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iv Z-30/20N • Z-30/20N RJ Part No. 106373

June 2008 Section 1 • Safety Rules
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. 106373 Z-30/20N • Z-30/20N RJ v

Section 1 • Safety Rules June 2008
SAFETY RULES
Personal Safety Workplace Safety

Any person working on or around a machine must Be sure to keep sparks, flames and
be aware of all known safety hazards. Personal lighted tobacco away from flammable and
safety and the continued safe operation of the combustible materials like battery gases
machine should be your top priority. and engine fuels. Always have an approved fire
extinguisher within easy reach.
Be sure that all tools and working areas

Read each procedure thoroughly. This
are properly maintained and ready for
manual and the decals on the machine,
use. Keep work surfaces clean and free of
use signal words to identify the following:
debris that could get into machine components and
Safety alert symbol—used to alert cause damage.
personnel to potential personal
Be sure any forklift, overhead crane or
injury hazards. Obey all safety
other lifting or supporting device is fully
messages that follow this symbol
capable of supporting and stabilizing the
to avoid possible injury or death.
weight to be lifted. Use only chains or straps that
Indicates an imminently hazardous are in good condition and of ample capacity.
situation which, if not avoided, will
Be sure that fasteners intended for one
result in death or serious injury.
time use (i.e., cotter pins and self-locking
Indicates a potentially hazardous nuts) are not reused. These components
situation which, if not avoided, may fail if they are used a second time.
could result in death or serious
injury. Be sure to properly dispose of old oil or
other fluids. Use an approved container.
Indicates a potentially hazardous Please be environmentally safe.
situation which, if not avoided,
may cause minor or moderate Be sure that your workshop or work area
injury. is properly ventilated and well lit.
Indicates a potentially hazardous

may result in property damage.
Be sure to wear protective eye wear and

other protective clothing if the situation
warrants it.
Be aware of potential crushing hazards

such as moving parts, free swinging or
unsecured components when lifting or
placing loads. Always wear approved steel-toed
shoes.
vi Z-30/20N • Z-30/20N RJ Part No. 106373

Section 1 • Safety Rules
Table of Contents
Introduction
Important Information ................................................................................................... ii
Serial Number Information ............................................................................................ ii
Serial Number Legend ................................................................................................. iii
Section 1 Safety Rules

General Safety Rules .................................................................................................. v
Section 2 Rev Specifications

E Machine Specifications .......................................................................................... 2 - 1
Performance Specifications ................................................................................... 2 - 1
Hydraulic Oil Specifications ................................................................................... 2 - 2
Hydraulic Component Specifications ...................................................................... 2 - 3
Manifold Component Specifications ....................................................................... 2 - 3
Machine Torque Specifications .............................................................................. 2 - 4
Hydraulic Hose and Fitting Torque Specifications .................................................. 2 - 5
SAE and Metric Fasteners Torque Charts .............................................................. 2 - 6
Section 3 Rev Scheduled Maintenance Procedures

Introduction ............................................................................................................ 3 - 1
Pre-Delivery Preparation ........................................................................................ 3 - 3
Maintenance Inspection Report .............................................................................. 3 - 5
D Checklist A Procedures
A-1 Inspect the Manuals and Decals .................................................................. 3 - 6
A-2 Perform Pre-operation Inspection ................................................................ 3 - 7
A-3 Perform Function Tests ............................................................................... 3 - 7
A-4 Perform 30 Day Service ............................................................................... 3 - 8
A-5 Grease the Turntable Rotation Bearing and Worm Drive Gear ...................... 3 - 8
A-6 Replace the Drive Hub Oil ............................................................................ 3 - 9
vii
TABLE OF CONTENTS
Section 3 Rev Scheduled Maintenance Procedures, continued

E Checklist B Procedures
B-1 Check the Batteries .................................................................................... 3 - 10
B-2 Inspect the Electrical Wiring ....................................................................... 3 - 11
B-3 Test the Key Switch ................................................................................... 3 - 12
B-4 Check the Tires, Wheels and Lug Nut Torque ............................................ 3 - 13
B-5 Confirm the Proper Brake Configuration ...................................................... 3 - 13
B-6 Check the Oil Level in the Drive Hubs and Mounting Bolt Torque ............... 3 - 14
B-7 Test the Ground Control Override ............................................................... 3 - 14
B-8 Test the Platform Self-leveling ................................................................... 3 - 15
B-9 Test the Drive Brakes ................................................................................ 3 - 15
B-10 Test the Drive Speed - Stowed Position ..................................................... 3 - 16
B-11 Test the Drive Speed - Raised or Extended Position .................................. 3 - 16
B-12 Test the Alarm Package (if equipped) ........................................................ 3 - 17
B-13 Test the Turntable Rotation Stop ................................................................ 3 - 18
B-14 Check the Electrical Contactors ................................................................. 3 - 18
B-15 Perform Hydraulic Oil Analysis ................................................................... 3 - 19
D Checklist C Procedures
C-1 Grease the Platform Overload Mechanism (if equipped) ............................. 3 - 20
C-2 Test the Platform Overload System (if equipped) ....................................... 3 - 20
viii
TABLE OF CONTENTS
Section 3 Rev Scheduled Maintenance Procedures, continued

D Checklist D Procedures
D-1 Check the Primary Boom Wear Pads ......................................................... 3 - 23
D-2 Check the Free-wheel Configuration ........................................................... 3 - 24
D-3 Check the Turntable Rotation Bearing Bolts ............................................... 3 - 25
D-4 Replace the Drive Hub Oil .......................................................................... 3 - 26
D-5 Replace the Hydraulic Tank Return Filter Element ..................................... 3 - 26
D-6 Inspect for Turntable Bearing Wear ............................................................ 3 - 27
C Checklist E Procedures
E-1 Test or Replace the Hydraulic Oil ............................................................... 3 - 29
E-2 Grease the Steer Axle Wheel Bearings ...................................................... 3 - 31
Section 4 Rev Repair Procedures

Introduction ............................................................................................................ 4 - 1
B Platform Controls
1-1 Controllers .................................................................................................... 4 - 2
C Platform Components
2-1 Platform Leveling Slave Cylinder .................................................................. 4 - 4
2-2 Platform Rotator ........................................................................................... 4 - 5
2-3 Platform Overload System ........................................................................... 4 - 7
B Jib Boom Components
3-1 Jib Boom ...................................................................................................... 4 - 9
3-2 Jib Boom Bell Crank (models without rotating jib boom) ............................. 4 - 10
3-3 Jib Boom Rotator (models with rotating jib boom) ....................................... 4 - 11
3-4 Jib Boom Lift Cylinder ................................................................................ 4 - 13
ix
TABLE OF CONTENTS
Section 4 Rev Repair Procedures, continued

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

Introduction ............................................................................................................ 5 - 1
A Fault Code Chart .................................................................................................... 5 - 3
x
TABLE OF CONTENTS
Section 6 Rev Schematics

Introduction ............................................................................................................ 6 - 1
A Load Sensor Option Diagram (before serial number 6290) ...................................... 6 - 2
B Electrical Symbols Legend .................................................................................... 6 - 3
B Hydraulic Symbols Legend .................................................................................... 6 - 4
A Power Cable Diagram (before serial number 6290) ................................................. 6 - 5
B Power Cable Diagram (from serial number 6290 to 8354) ....................................... 6 - 6
A Power Cable Diagram (after serial number 8354) .................................................... 6 - 7
A Power Panel Wiring Diagram (before serial number 6290) ...................................... 6 - 8
A Power Panel Wiring Diagram (from serial number 6290 to 8354) ............................ 6 - 9
A Power Panel Wiring Diagram (after serial number 8354) ....................................... 6 - 10
B Electrical Schematic (before serial number 6290) ................................................ 6 - 11
B Electrical Schematic (from serial number 6290 to 8354) ....................................... 6 - 13
A Electrical Schematic (from serial number 8355 to 9346) ....................................... 6 - 15
A Electrical Schematic - CE Models (from serial number 8355 to 9346) .................. 6 - 17
A Electrical Schematic (after serial number 9346) ................................................... 6 - 19
A Electrical Schematic - CE Models (after serial number 9346) ............................... 6 - 21
A Ground Control Panel Wiring Diagram (before serial number 6290) ....................... 6 - 23
A Ground Control Panel Wiring Diagram (from serial number 6290 to 8354) ............. 6 - 24
A Ground Control Panel Wiring Diagram (after serial number 8354) ......................... 6 - 25
A Ground Control Panel Terminal Strip Wiring Diagram
(after serial number 8354) ................................................................................... 6 - 26
A Platform Control Box Wiring Diagram (before serial number 6290) ..................... 6 - 27
A Platform Control Box Wiring Diagram (from serial number 6290 to 8354) ........... 6 - 28
A Platform Control Box Wiring Diagram (after serial number 8354) ........................ 6 - 29
A LVI/BCI Option Wiring DIagram (from serial number 8355 to 9346) .................... 6 - 30
A LVI/BCI Option Wiring DIagram (after serial number 9346) ................................... 6 - 31
C Hydraulic Schematic ............................................................................................ 6 - 32
xi
xii
June 2008 Section 2 • Specifications
REV E
Specifications
Machine Specifications Performance Specifications
Tires and wheels Drive speed, maximum
Tire size (solid rubber) 22 x 7 x 18.4 in Stowed position 3.3 mph

56 x 18 x 47 cm 5.3 km/h
40 ft / 8.2 sec
Load range 7600 lbs 12.2 m / 8.2 sec
3447 kg
Boom raised or extended 0.6 mph
Overall tire diameter 22 in 1 km/h
56 cm 40 ft / 44 sec
12.2 m / 44 sec
Wheel diameter 18.4 in
47 cm Braking distance, maximum
Wheel width 7 in High range on paved surface 2 to 4 ft
18 cm 0.6 to 1.2m
Wheel lugs Gradeability See Operator's Manual
Front 8@ 5/8
-18
Rear 9 @ 5/8 -18
Boom function speeds, maximum from platform
Lug nut torque, dry 125 ft-lbs controls (with rated load secured to platform)
169.5 Nm
Jib boom up 26 to 32 seconds
Lug nut torque, lubricated 94 ft-lbs
127.4 Nm Jib boom down 23 to 29 seconds
Fluid Capacities Jib boom rotate, 200°

(before serial number 8333) 12 to 18 seconds
Hydraulic tank capacity 4 gallons
15.1 liters Jib boom rotate, 180°
(after serial number 8332) 12 to 18 seconds
Hydraulic system capacity 6 gallons
(including tank) 22.7 liters Primary boom up 14 to 22 seconds
Drive hubs Primary boom down 12 to 20 seconds

61:1 23 ounces 0.68 liter
Primary boom extend
62.5:1 25.6 ounces 0.76 liter
(models with rotating jib boom) 14 to 24 seconds
Drive hub oil type: (models without rotating jib boom) 9 to 15 seconds
SAE 90 multipurpose hypoid gear oil API service
Primary boom retract 12 to 18 seconds
classification GL5
Secondary boom up 11 to 18 seconds
Continuous improvement of our products is a Secondary boom down 7 to 15 seconds

Genie policy. Product specifications are
subject to change without notice. Turntable rotate, 355° 62 to 68 seconds
Platform rotate, 160° 5 to 11 seconds
Platform level up 14 to 19 seconds
Platform level down 13 to 18 seconds
Part No. 106373 Z-30/20N • Z-30/20N RJ 2-1

Section 2 • Specifications June 2008
SPECIFICATIONS REV E
Hydraulic Oil Specifications

Hydraulic Oil Specifications
Hydraulic oil type Chevron Rykon MV equivalent

Viscosity grade Multi-viscosity
Viscosity index 200
Cleanliness level, minimum 15/13
Water content, maximum 200 ppm
Chevron Rykon MV oil is fully compatible and

mixable with Shell Donax TG (Dexron III) oils.
Genie specifications require hydraulic oils which are
designed to give maximum protection to hydraulic
systems, have the ability to perform over a wide
temperature range, and the viscosity index should
exceed 140. They should provide excellent antiwear,
oxidation, corrosion inhibition, seal conditioning, and
foam and aeration suppression properties.
Optional fluids
Biodegradable Petro Canada Environ MV46

Statoil Hydra Way Bio Pa 32
BP Biohyd SE-S
Fire resistant UCON Hydrolube HP-5046

Quintolubric 822
Mineral based Shell Tellus T32

Shell Tellus T46
Chevron Aviation A
Continued use of Chevron

Aviation A hydraulic fluid when
ambient temperatures are
consistently above 32°F / 0°C may
result in component damage.
Note: Use Chevron Aviation A hydraulic fluid when
ambient temperatures are consistently below
0°F / -18°C.
Note:Use Shell Tellus T46 hydraulic oil when oil

temperatures consistently exceed 205°F / 96°C.
Note:Genie specifications require additional
equipment and special installation instructions for Continuous improvement of our products is a
the approved optional fluids. Consult the Genie Genie policy. Product specifications are
Industries Service Department before use. subject to change without notice.
2-2 Z-30/20N • Z-30/20N RJ Part No. 106373

REV E SPECIFICATIONS
Hydraulic Component Manifold Component

Specifications Specifications
Function pump Plug torque
Type: Fixed displacement gear pump SAE No. 2 36 in-lbs / 4 Nm
Displacement 0.183 cu in SAE No. 4 10 ft-lbs / 13 Nm

3 cc
SAE No. 6 14 ft-lbs / 19 Nm
Flow rate @ 2.1 gpm
2800 psi / 172 bar 7.9 L/min SAE No. 8 38 ft-lbs / 51 Nm
Hydraulic tank 10 micron with SAE No. 10 41 ft-lbs / 55 Nm

return filter 25 psi / 1.7 bar bypass
SAE No. 12 56 ft-lbs / 76 Nm
Function manifold
Valve Coil Resistance
System relief valve pressure 2800 psi
Note: The following coil resistance specifications are at
193 bar
an ambient temperature of 68°F / 20°C. As valve coil
Primary boom down relief pressure 1600 psi resistance is sensitive to changes in air temperature,
110 bar the coil resistance will typically increase or decrease by
4% for each 18°F / 10°C that your air temperature
Secondary boom down relief pressure 1600 psi increases or decreases from 68°F / 20°C.
110 bar
Valve Coil Resistance Specification
Primary boom extend relief pressure 1800 psi
Models with rotating jib 124 bar Description Specification
Turntable rotate relief pressure 1100 psi Solenoid valve, 3 position 4 way, 20V DC 22 Ω
76 bar (schematic items A, J, K, U, V, Y, AA, BB and CC)
Auxiliary pump Proportional solenoid valve, 24V DC 19.5 Ω

(schematic item H)
Type: Fixed displacement gear pump
Solenoid valve, N.C. poppet, 20V DC 23.5 Ω
Displacement 0.3 gpm (schematic item M)
1.14 L/min
Solenoid valve, N.O. poppet, 20V DC 23.5 Ω
(schematic item P)
Continuous improvement of our products is a
Part No. 106373 Z-30/20N • Z-30/20N RJ 2-3

Machine Torque Specifications

Platform rotator and jib boom rotator (Z-30/20N RJ)
1-8 center bolt, GR 5, lubricated 480 ft-lbs

(Jib boom rotator) 650 Nm
3 /4
-10 bolt, GR 8, lubricated 280 ft-lbs
(Platform rotator) 379 Nm
3 /8
-16 bolts, GR 5, lubricated 23 ft-lbs
(Platform rotator) 31 Nm
1 /2-13 bolts, GR 5, lubricated 57 ft-lbs
(Jib boom rotator) 77 Nm
Platform rotator (Z-30/20N)

3 /4 -10 bolt, GR 8, lubricated 280 ft-lbs
379 Nm
3 /8 -16 bolts, GR 5, lubricated 23 ft-lbs
31 Nm
Turntable rotate bearing
Rotate bearing mounting bolts, lubricated 180 ft-lbs

244 Nm
Drive hubs, brakes and motors
Drive hub mounting bolts, lubricated 180 ft-lbs

244 Nm
Brake mounting bolts, lubricated 93 ft-lbs

126 Nm
Drive motor mounting bolts 31 ft-lbs

42 Nm
Continuous improvement of our products is a

2-4 Z-30/20N • Z-30/20N RJ Part No. 106373

REV E 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. Note: The O-rings used in the Parker Seal Lok®
fittings and hose ends are custom-size O-rings.
They are not standard SAE size O-rings. They are
SAE O-ring Boss Port available in the O-ring field service kit (Genie part
(tube fitting - installed into Aluminum) number 49612).
SAE Dash size Torque
2 Lubricate the O-ring before installation.
-4 11 ft-lbs / 14.9 Nm 3 Be sure that the face seal O-ring is seated and
-6 23 ft-lbs / 31.2 Nm retained properly.
-8 40 ft-lbs / 54.2 Nm 4 Position the tube and nut squarely on the face
seal end of the fitting and tighten the nut finger
-10 69 ft-lbs / 93.6 Nm tight.
-12 93 ft-lbs / 126.1 Nm 5 Tighten the nut or fitting to the appropriate
torque per given size as shown in the table.
-16 139 ft-lbs / 188.5 Nm
6 Operate all machine functions and inspect the
-20 172 ft-lbs / 233.2 Nm hoses and fittings and related components to
-24 208 ft-lbs / 282 Nm 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
Part No. 106373 Z-30/20N • Z-30/20N RJ 2-5

SAE FASTENER TORQUE CHART

• This chart is to be used as a guide only unless noted elsewhere in this manual •
A574 High Strength
SIZE THREAD Grade 5 Grade 8
Black Oxide Bolts
LUBED DRY LUBED DRY LUBED
in- lbs Nm in- lbs Nm in- lbs Nm in- lbs Nm in- lbs Nm
1/4 20 80 9 100 11.3 110 12.4 140 15.8 130 14.7

28 90 10.1 120 13.5 120 13.5 160 18 140 15.8
LUBED DRY LUBED DRY LUBED
f t - lbs Nm f t - lbs Nm f t - lbs Nm f t - lbs Nm f t - lbs Nm
5/16 18 13 17.6 17 23 18 24 25 33.9 21 28.4

24 14 19 19 25.7 20 27.1 27 36.6 24 32.5
3/8 16 23 31.2 31 42 33 44.7 44 59.6 38 51.5
24 26 35.2 35 47.4 37 50.1 49 66.4 43 58.3
7/16 14 37 50.1 49 66.4 50 67.8 70 94.7 61 82.7
20 41 55.5 55 74.5 60 81.3 80 108.4 68 92.1
1/2 13 57 77.3 75 101.6 80 108.4 110 149 93 126
20 64 86.7 85 115 90 122 120 162 105 142
9/16 12 80 108.4 110 149 120 162 150 203 130 176
18 90 122 120 162 130 176 170 230 140 189
5/8 11 110 149 150 203 160 217 210 284 180 244
18 130 176 170 230 180 244 240 325 200 271
3/4 10 200 271 270 366 280 379 380 515 320 433
16 220 298 300 406 310 420 420 569 350 474
7/8 9 320 433 430 583 450 610 610 827 510 691
14 350 474 470 637 500 678 670 908 560 759
8 480 650 640 867 680 922 910 1233 770 1044
1
12 530 718 710 962 750 1016 990 1342 840 1139
7 590 800 790 1071 970 1315 1290 1749 1090 1477
1 1/8
12 670 908 890 1206 1080 1464 1440 1952 1220 1654
7 840 1138 1120 1518 1360 1844 1820 2467 1530 2074
1 1/4
12 930 1260 1240 1681 1510 2047 2010 2725 1700 2304
6 1460 1979 1950 2643 2370 3213 3160 4284 2670 3620
1 1/2
12 1640 2223 2190 2969 2670 3620 3560 4826 3000 4067
METRIC FASTENER TORQUE CHART

• This chart is to be used as a guide only unless noted elsewhere in this manual •
Size Class 4.6 4.6 Class 8.8 8.8 Class 10.9 10.9 Class 12.9 12.9
(m m ) LUBED DRY LUBED DRY LUBED DRY LUBED DRY

in- lbs Nm in-lbs Nm in- lbs Nm in- lbs Nm in- lbs Nm in- lbs Nm in- lbs Nm in- lbs Nm
5 16 1.8 21 2.4 41 4.63 54 6.18 58 6.63 78 8.84 68 7.75 91 10.3
6 19 3.05 36 4.07 69 7.87 93 10.5 100 11.3 132 15 116 13.2 155 17.6
7 45 5.12 60 6.83 116 13.2 155 17.6 167 18.9 223 25.2 1.95 22.1 260 29.4
LUBED DRY LUBED DRY LUBED DRY LUBED DRY
f t - lbs Nm f t -lbs Nm f t - lbs Nm f t - lbs Nm f t - lbs Nm ft - lbs Nm f t - lbs Nm f t - lbs Nm
8 5.4 7.41 7.2 9.88 14 19.1 18.8 25.5 20.1 27.3 26.9 36.5 23.6 32 31.4 42.6
10 10.8 14.7 14.4 19.6 27.9 37.8 37.2 50.5 39.9 54.1 53.2 72.2 46.7 63.3 62.3 84.4
12 18.9 25.6 25.1 34.1 48.6 66 64.9 88 69.7 94.5 92.2 125 81 110 108 147
14 30.1 40.8 40 54.3 77.4 105 103 140 110 150 147 200 129 175 172 234
16 46.9 63.6 62.5 84.8 125 170 166 226 173 235 230 313 202 274 269 365
18 64.5 87.5 86.2 117 171 233 229 311 238 323 317 430 278 377 371 503
20 91 124 121 165 243 330 325 441 337 458 450 610 394 535 525 713
22 124 169 166 225 331 450 442 600 458 622 612 830 536 727 715 970
24 157 214 210 285 420 570 562 762 583 791 778 1055 682 925 909 1233
2-6 Z-30/20N • Z-30/20N RJ Part No. 106373

June 2008 Section 3 • Scheduled Maintenance Procedures
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.
Observe and Obey: Symbols Legend
Maintenance inspections shall be completed by Safety alert symbol—used to alert

a person trained and qualified on the personnel to potential personal
maintenance of this machine. injury hazards. Obey all safety
Scheduled maintenance inspections shall be to avoid possible injury or death.
completed daily, quarterly, six months, annually
and every 2 years as specified on the Indicates an imminently hazardous
Maintenance Inspection Report. situation which, if not avoided, will
Failure to properly complete each
inspection when required could Indicates a potentially hazardous
result in death, serious injury or situation which, if not avoided,
substantial machine damage. could result in death or serious
injury.
Immediately tag and remove from service a
damaged or malfunctioning machine.
Repair any machine damage or malfunction may cause minor or moderate
before operating machine. injury.
Use only Genie approved replacement parts. Indicates a potentially hazardous

Unless otherwise specified, perform each may result in property damage.
procedure with the machine in the following
configuration: Indicates that a specific result is expected after
performing a series of steps.
• Machine parked on a firm, level surface
Indicates that an incorrect result has occurred
• Boom in the stowed position
after performing a series of steps.
• Turntable rotated with the boom between the
non-steer wheels
• Key switch in the off position with the
key removed
• Wheels chocked
• All external AC power supply disconnected
from the machine
Part No. 106373 Z-30/20N • Z-30/20N RJ 3-1

Section 3 • Scheduled Maintenance Procedures June 2008
SCHEDULED MAINTENANCE PROCEDURES
Maintenance Symbols Legend Maintenance Schedule

The following symbols have been used in this There are five types of maintenance inspections
manual to help communicate the intent of the that must be performed according to a schedule—
instructions. When one or more of the symbols daily, quarterly, six months, annual, and two year.
appear at the beginning of a maintenance The Scheduled Maintenance Procedures Section
procedure, it conveys the meaning below. and the Maintenance Inspection Report have been
divided into five subsections—A, B, C, D and E.
Use the following chart to determine which
Indicates that tools will be required to group(s) of procedures are required to perform a
perform this procedure. scheduled inspection.
Inspection Checklist
Indicates that new parts will be required
to perform this procedure. Daily or every 8 hours A
Quarterly or every 250 hours A+B
Indicates that a cold motor or pump will Six months or every 500 hours A+B+C
be required to perform this procedure.
Annual or every 1000 hours A+B+C+D
Two year or every 2000 hours A+B+C+D+E

Indicates that dealer service will be
required to perform this procedure.
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. Maintain completed
forms for a minimum of 4 years or in compliance
with employer, jobsite and govermental regulations
and requirements.
3-2 Z-30/20N • Z-30/20N RJ Part No. 106373

Pre-Deliver
Pre-Delivery
June 2008 y Preparation Section 3 • Scheduled Maintenance Procedures
Fundamentals Instructions
It is the responsibility of the dealer to perform the Use the operator’s manual on your machine.
Pre-delivery Preparation.
The Pre-delivery Preparation consists of completing the
The Pre-delivery Preparation is performed prior to each Pre-operation Inspection, the Maintenance items and the
delivery. The inspection is designed to discover if anything Function Tests.
is apparently wrong with a machine before it is put into
service. Use this form to record the results. Place a check in the
appropriate box after each part is completed. Follow the
A damaged or modified machine must never be used. If instructions in the operator’s manual.
damage or any variation from factory delivered condition is
discovered, the machine must be tagged and removed If any inspection receives an N, remove the machine from
from service. service, repair and re-inspect it. After repair, place a check
in the R box.
Repairs to the machine may only be made by a qualified
service technician, according to the manufacturer's Legend
specifications. Y = yes, completed
Scheduled maintenance inspections shall be performed by N = no, unable to complete
qualified service technicians, according to the R = repaired
manufacturer's specifications and the requirements listed Comments
in the responsibilities manual.
Pre-Delivery Preparation Y N R
Pre-operation inspection completed
Maintenance items completed
Function tests completed
Model
Serial number
Date
Machine owner
Inspected by (print)
Inspector signature
Inspector title
Inspector company
Genie Industries USA Genie UK

18340 NE 76th Street The Maltings, Wharf Road
PO Box 97030 Grantham, Lincolnshire
Redmond, WA 98073-9730 NG31- 6BH England
Part No. 106373
(425) 881-1800 Z-30/20N • Z-30/20N RJ
(44) 1476-584333 3-3
Copyright © 2002 by Genie Industries. Genie® is a registered trademark of Genie Industries.
Rev B
3-4 Z-30/20N • Z-30/20N RJ Part No. 106373

Maintenance Inspection Report
Model Checklist A - Rev D Y N R Checklist C - Rev D Y N R
A-1 Manuals and decals C-1 Grease platform
Serial number overload (if equipped)
A-2 Pre-operation
Date inspection C-2 Test platform
A-3 Function tests overload (if equipped)
Hour meter Perform after 40 hours:
A-4 30 Day Service Checklist D - Rev D Y N R
Machine owner D-1 Boom wear pads
Perform every 100 hours:
Inspected by (print) A-5 Grease rotation D-2 Free-wheel
bearing configuration
Inspector signature Perform after 150 hours: D-3 Turntable bearing bolts
A-6 Replace drive hub oil D-4 Drive hub oil
Inspector title D-5 Hydraulic return filter
Inspector company Checklist B - Rev E Y N R D-6 Turntable bearing

wear
B-1 Batteries
Instructions
B-2 Electrical wiring
• Make copies of this page to use for Checklist E - Rev D Y N R
each inspection. B-3 Key switch
E-1 Hydraulic oil
B-4 Tires and Wheels
• Select the appropriate checklist(s) for E-2 Wheel bearings
the type of inspection to be B-5 Brake configuration
performed. B-6 Drive hub oil level
B-7 Ground control
Daily or 8 hour
override
Inspection: A
B-8 Platform leveling
Quarterly or 250 hour
Inspection: A+B B-9 Drive brakes
Six Month or 500 hour B-10 Drive speed-stowed

Inspection: A+B+C B-11 Drive speed-raised
Annual or 1000 hours B-12 Alarm package
Inspection: A+B+C+D (if equipped)
2 Year or 2000 hour B-13 Turntable rotation stop
Inspection: A+B+C+D+E B-14 Electrical contactors
B-15 Hydraulic oil analysis
• Place a check in the appropriate box
after each inspection procedure is
completed. Comments
• 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
Checklist A Procedures REV D
A-1 3 Open the operator's manual to the decals

inspection section. Carefully and thoroughly
Inspect the Manuals and Decals inspect all decals on the machine for legibility
Note: Genie specifications require that this and damage.
procedure be performed daily or every 8 hours, Result: The machine is equipped with all
whichever comes first. required decals, and all decals are legible and
Maintaining the operator’s and safety manuals in in good condition.
good condition is essential to safe machine Result: The machine is not equipped with all
operation. Manuals are included with each required decals, or one or more decals are
machine and should be stored in the container illegible or in poor condition. Remove the
provided in the platform. An illegible or missing machine from service until the decals are
manual will not provide safety and operational replaced.
information necessary for a safe operating
condition. 4 Always return the manuals to the storage
container after use.
In addition, maintaining all of the safety and
instructional decals in good condition is mandatory Note: Contact your authorized Genie distributor or
for safe machine operation. Decals alert operators Genie Industries if replacement manuals or decals
and personnel to the many possible hazards are needed.
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 Check to make sure that the operator's and

safety manuals are present and complete in the
storage container on the platform.
2 Examine the pages of each manual to be sure
that they are legible and in good condition.
Result: The operator's manual is appropriate for
the machine and all manuals are legible and in
good condition.
Result: The operator's manual is not
appropriate for the machine or all manuals are
not in good condition or are illegible. Remove
the machine from service until the manual is
replaced.
3-6 Z-30/20N • Z-30/20N RJ Part No. 106373

REV D CHECKLIST A PROCEDURES
A-2 A-3
Perform Pre-operation Perform Function Tests
Inspection Note: Genie specifications require that this
Note: Genie specifications require that this procedure be performed daily or every 8 hours,
procedure be performed daily or every 8 hours, whichever comes first.
whichever comes first. Completing the function tests is essential to safe
Completing a pre-operation inspection is essential machine operation. Function tests are designed to
to safe machine operation. The pre-operation discover any malfunctions before the machine is
inspection is a visual inspection performed by the put into service. A malfunctioning machine must
operator prior to each work shift. The inspection is never be used. If malfunctions are discovered, the
designed to discover if anything is apparently machine must be tagged and removed from
wrong with a machine before the operator performs service.
the function tests. The pre-operation inspection Complete information to perform this procedure is
also serves to determine if routine maintenance available in the appropriate Genie Z-30/20N
procedures are required. Operator's Manual. Refer to the Operator's Manual
Complete information to perform this procedure is on your machine.
available in the appropriate Genie Z-30/20N
Operator's Manual. Refer to the Operator's Manual
on your machine.
Part No. 106373 Z-30/20N • Z-30/20N RJ 3-7

CHECKLIST A PROCEDURES REV D
A-4 A-5
Perform 30 Day Service Grease the Turntable Rotation
Bearing and Worm Drive Gear
The 30 day maintenance procedure is a one-time

sequence of procedures to be performed after the Note: Genie specifications require that this
first 30 days or 40 hours of usage. After this procedure be performed every 100 hours.
interval, refer to the maintenance checklists for
continued scheduled maintenance. Frequent application of lubrication to the turntable
bearing and worm drive gear is essential to good
1 Perform the following maintenance procedures: machine performance and service life. Continued
• A-5 Grease the Turntable Rotation use of an insufficently greased gear will result in
Bearing and Worm Drive Gear component damage.
• B-4 Check the Tires, Wheels and Lug Nut 1 Locate the grease fitting on the tank side
Torque turntable cover bulkhead.
• D-3 Check the Turnable Rotation 2 Pump grease into the turntable rotation bearing.
Bearing Bolts Rotate the turntable in increments of 4 to 5
• D-5 Replace the Hydraulic Tank inches / 10 to 13 cm at a time and repeat this
Return Filter Element step until the entire bearing has been greased.
3 Locate the 2 grease fittings on top of the worm
drive housing.
a
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.
Grease Specification
Chevron Ultra-duty grease, EP NLGI 2 (lithium based)

or equivalent
3-8 Z-30/20N • Z-30/20N RJ Part No. 106373

REV D CHECKLIST A PROCEDURES
A-6
Replace the Drive Hub Oil
Note: Manufacturer drive hub specifications require

that this one-time procedure be performed after the
first 150 hours.
Replacing the drive hub oil is essential for good

machine performance and service life. Failure to
replace the drive hub oil after the first 150 hours of
use 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 into a
suitable container.
3 Drive the machine until one plug is at the top
and the other is at 90 degrees.
a drive hub plugs
4 Fill the hub with oil from the top hole until the oil
level is even with the bottom of the side plug
hole. Refer to Section 2, Specifications.
5 Install the plugs into the drive hub.
6 Repeat this procedure for the other drive hub.
Part No. 106373 Z-30/20N • Z-30/20N RJ 3-9

Checklist B Procedures REV E
B-1 5 Be sure that the battery retainers and cable

connections are tight.
Check the Batteries
6 Fully charge the batteries. Allow the batteries to
rest 24 hours before continuing this procedure
to allow the battery cells to equalize.
Note: Genie specifications require that this 7 Put on protective clothing and eye wear.
procedure be performed every 250 hours or
8 Remove the battery vent caps and check the
quarterly, whichever comes first.
specific gravity of each battery cell with a
Proper battery condition is essential to good hydrometer. Note the results.
machine performance and operational safety. 9 Check the ambient air temperature and adjust
Improper fluid levels or damaged cables and the specific gravity reading for each cell as
connections can result in component damage and follows:
hazardous conditions.
• Add 0.004 to the reading of each cell for
Electrocution/burn hazard. Contact every 10° / 5.5° C above 80° F / 26.7° C.
with hot or live circuits could result
in death or serious injury. Remove • Subtract 0.004 from the reading of each cell for
all rings, watches and other every 10° / 5.5° C below 80° F / 26.7° C.
jewelry. Result: All battery cells display an adjusted
Bodily injury hazard. Batteries specific gravity of 1.277 or higher. The battery
contain acid. Avoid spilling or is fully charged. Proceed to step 13.
contacting battery acid. Neutralize
Result: One or more battery cells display a
battery acid spills with baking soda specific gravity of 1.217 or below. Proceed to
and water. step 10.
1 Disconnect each battery pack from the 10 Perform an equalizing charge OR fully charge
machine. the batteries and allow the batteries to rest at
2 Release the battery pack latches and rotate least 6 hours.
each battery pack out and away from the 11 Remove the battery vent caps and check the
chassis. specific gravity of each battery cell with a
3 Remove the cover from each battery box. hydrometer. Note the results.
4 Be sure that the battery cable connections are

free of corrosion.
Note: Adding terminal protectors and a corrosion
preventative sealant will help eliminate corrosion
on the battery terminals and cables.
3 - 10 Z-30/20N • Z-30/20N RJ Part No. 106373

REV E CHECKLIST B PROCEDURES
12 Check the ambient air temperature and adjust B-2

the specific gravity reading for each cell as
follows: Inspect the Electrical Wiring
• Add 0.004 to the reading of each cell for
every 10° / 5.5° C above 80° F / 26.7° C.
• Subtract 0.004 from the reading of each cell for Note: Genie specifications require that this
every 10° / 5.5° C below 80° F / 26.7° C. procedure be performed every 250 hours or
Result: All battery cells display a specific gravity
of 1.277 or greater. The battery is fully charged. Maintaining electrical wiring in good condition is
Proceed to step 13. essential to safe operation and good machine
performance. Failure to find and replace burnt,
Result: The difference in specific gravity
chafed, corroded or pinched wires could result in
readings between cells is greater than 0.1 OR
unsafe operating conditions and may cause
the specific gravity of one or more cells is less
component damage.
than 1.217. Replace the battery.
13 Check the battery acid level. If needed, Electrocution/burn hazard. Contact
replenish with distilled water to 1/8 inch / 3 mm with hot or live circuits could result
below the bottom of the battery fill tube. Do not in death or serious injury. Remove
overfill. all rings, watches and other
jewelry.
14 Install the vent caps and neutralize any
electrolyte that may have spilled. 1 Remove the drive chassis cover from the
non-steer end of the machine.
2 Inspect the following areas for burnt, chafed,
corroded and loose wires:
• Electrical power panel
• Electrical relay panel
• Ground control panel
• Function manifold wiring
Part No. 106373 Z-30/20N • Z-30/20N RJ 3 - 11

CHECKLIST B PROCEDURES REV E
3 Turn the key switch to ground controls and pull B-3

out the red Emergency Stop button to the on
position at both the ground and platform Test the Key Switch
controls. Note: Genie specifications require that this
4 Raise the secondary boom until the mid-pivot is procedure be performed every 250 hours or
approximately 10 feet / 3 m off the ground. quarterly, whichever comes first.
5 Inspect the turntable center area for burnt, Proper key switch action and response is essential
chafed and pinched cables. to safe machine operation. The machine can be
operated from the ground or platform controls and
6 Lower the boom to the stowed position and turn the activation of one or the other is accomplished
the machine off. with the key switch. Failure of the key switch to
7 Inspect the following areas for burnt, chafed, activate the appropriate control panel could result
corroded, pinched and loose wires: in a hazardous operating situation.
• Cable track on the primary boom 1 Pull out the red Emergency Stop button to the
• Primary boom to platform cable harness on position at both the ground and platform
controls.
• Inside of the platform control box
2 Turn the key switch to platform controls.
8 Inspect for a liberal coating of dielectric grease
at the following location: 3 Check the machine functions from the ground
controls.
• All wire harness connectors to the platform
control box Result: The machine functions should not
• All wire harness connectors located under the operate.
ground control side turntable cover 4 Turn the key switch to ground controls.
• Harness connector to the drive motor
5 Check the machine functions from the platform
controller located in the non-steer end of the
controls.
drive chassis
Result: The machine functions should not
operate.
6 Turn the key switch to the off position.
Result: No function should operate.
3 - 12 Z-30/20N • Z-30/20N RJ Part No. 106373

B-4 B-5
Check the Tires, Wheels and Confirm the Proper
Lug Nut Torque Brake Configuration
Note: Genie specifications require that this Note: Genie specifications require that this
procedure be performed every 250 hours or procedure be performed every 250 hours or
quarterly, whichever comes first. quarterly, whichever comes first.
Maintaining the tires and wheels, including proper Proper brake configuration is essential to safe
wheel fastener torque, is essential to safe operation and good machine performance.
operation and good performance. Tire and/or Hydraulically-released, spring-applied individual
wheel failure could result in a machine tip-over. wheel brakes can appear to operate normally when
Component damage may also result if problems they are actually not fully operational.
are not discovered and repaired in a timely fashion.
1 Check each drive hub disconnect cap to be
1 Check the tire surface and sidewalls for cuts, sure it is in the engaged position.
cracks and unusual wear.
2 Check each wheel for damage, bends and
cracks. disengaged position
3 Check each lug nut for proper torque. Refer to

Section 2, Specifications.
engaged position
Part No. 106373 Z-30/20N • Z-30/20N RJ 3 - 13

B-6 B-7
Check the Oil Level in the Drive Test the Ground Control
Hubs and Mounting Bolt Torque Override
Note: Genie specifications require that this
procedure be performed every 250 hours or A properly functioning ground control override is
quarterly, whichever comes first. essential to safe machine operation. The ground
control override function is intended to allow
Failure to maintain proper drive hub oil levels, ground personnel to operate the machine from the
including proper drive hub fastener torque, may ground controls whether the red Emergency Stop
cause the machine to perform poorly and button on the platform controls is in the on or off
continued use may cause component damage. position. This function is particularly useful if the
1 Drive the machine to rotate the hub until one of operator at the platform controls cannot return the
the plugs is located on top and the other is at boom to the stowed position.
90 degrees. 1 Push in the red Emergency Stop button at the
a platform controls to the off position.
2 Turn the key switch to ground controls and pull
position.
3 Operate each boom function through a
partial cycle at the ground controls.
Result: All boom functions should operate.
a drive hub plugs
2 Remove the plug located at 90 degrees and

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. Refer to Section 2,
Specifications.
5 Check the torque of the drive hub bolts.
Refer to Section 2, Specifications.
6 Repeat this procedure for each drive hub.
3 - 14 Z-30/20N • Z-30/20N RJ Part No. 106373

B-8 B-9
Test the Platform Self-leveling Test the Drive Brakes
Automatic platform self-leveling throughout Proper brake action is essential to safe machine
the full cycle of boom raising and lowering is operation. The drive brake function should operate
essential for safe machine operation. The smoothly, free of hesitation, jerking and unusual
platform is maintained level by the platform leveling noise. Hydraulically-released individual wheel
slave cylinder which is controlled by the platform brakes can appear to operate normally when they
leveling master cylinder located at the base of the are actually not fully operational.
primary boom. A platform self-leveling failure
creates an unsafe working condition for platform Collision hazard. Be sure that the
and ground personnel. machine is not in free-wheel or
partial free-wheel configuration.
1 Turn the key switch to ground controls and pull Refer to B-5, Confirm the Proper
out the red Emergency Stop button to the on Brake Configuration.
position at both the ground and platform
1 Select a test area that is firm, level and free of
controls.
obstructions.
2 Lower the boom to the stowed position.
2 Mark a test line on the ground for reference.
3 Adjust the platform to a level position using the
3 Lower the boom to the stowed position.
platform leveling toggle switch.
4 Raise and lower the primary boom through
a full cycle. 5 Choose a reference point on the machine; i.e.,
contact patch of a tire, as a visual reference for
Result: The platform should remain level at
use when crossing the test line.
all times to within ±5 degrees.
6 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.
7 Measure the distance between the test line and
your machine reference point. Refer to
Note: The brakes must be able to hold the machine
on any slope it is able to climb.
Part No. 106373 Z-30/20N • Z-30/20N RJ 3 - 15

B-10 B-11
Test the Drive Speed - Test the Drive Speed -
Stowed Position Raised or Extended Position
Proper drive function movement is essential to Proper drive function movement is essential to
safe machine operation. The drive function should safe machine operation. The drive function should
respond quickly and smoothly to operator control. respond quickly and smoothly to operator control.
Drive performance should also be free of Drive performance should also be free of
hesitation, jerking and unusual noise over the hesitation, jerking and unusual noise over the
entire proportionally controlled speed range. entire proportionally controlled speed range.
1 Select a test area that is firm, level and free of 1 Select a test area that is firm, level and free of
obstructions. obstructions.
2 Create start and finish lines by marking two 2 Create start and finish lines by marking two
lines on the ground 40 feet / 12.2 m apart. lines on the ground 40 feet / 12.2 m apart.
3 Turn the key switch to platform control and pull 3 Turn the key switch to platform control and pull
out the red Emergency Stop button to the on out the red Emergency Stop button to the on
position at both the ground and platform position at both the ground and platform
controls. controls.
4 Choose a reference point on the machine; i.e., 4 Raise the primary boom more than
contact patch of a tire, as a visual reference for 5 feet / 1.5 m.
use when crossing the start and finish lines.
5 Choose a reference point on the machine; i.e.,
5 Bring the machine to maximum drive speed contact patch of a tire, as a visual reference for
before reaching the start line. Begin timing use when crossing the start and finish lines.
when your reference point on the machine
6 Bring the machine to maximum drive speed
crosses the start line.
before reaching the start line. Begin timing
6 Continue at full speed and note the time when when your reference point on the machine
your machine reference point passes over the crosses the start line.
finish line. Refer to Section 2, Specifications.
7 Continue at full speed and note the time when
your machine reference point passes over the
finish line. Refer to Section 2, Specifications.
3 - 16 Z-30/20N • Z-30/20N RJ Part No. 106373

B-12 4 Hold the function enable toggle switch to either

side, then move the jib boom toggle switch to
Test the Alarm Package the down position, hold for a moment then
(if equipped) release it.
Note: Genie specifications require that this Result: The descent alarm should sound when
procedure be performed every 250 hours or each control toggle switch is held down.
The alarm package includes:
Result: The flashing beacon should be on
• Travel alarm and flashing.
• Descent alarm 6 Press down the foot switch.
• Flashing beacon 7 Move the primary boom toggle switch to the
Alarms and a beacon are installed to alert operators down position, hold for a moment then release
and ground personnel of machine proximity and it.
motion. The alarm package is installed on the
8 Move the secondary boom toggle switch to the
ground controls side turntable cover.
down position, hold for a moment then release
1 Turn the key switch to ground controls and pull it.
out the red Emergency Stop buttons to the on
9 Move the jib boom toggle switch to the down
position at both ground and platform controls.
position, hold for a moment then release it.
Result: The flashing beacon should be on and
Result: The descent alarm should sound when
flashing.
each control toggle switch is held down.
2 Hold the function enable toggle switch to either
10 Move the drive joystick off center, hold for a
side, then move the primary boom toggle switch
moment then release it. Move the drive joystick
to the down position, hold for a moment then
off center in the opposite direction, hold for a
release it.
moment then release it.
3 Hold the function enable toggle switch to either
Result: The travel alarm should sound when the
side, then move the secondary boom toggle
switch to the down position, hold for a moment drive joystick is moved off center in either
then release it. direction.
Part No. 106373 Z-30/20N • Z-30/20N RJ 3 - 17

B-13 B-14
Test the Turntable Rotation Stop Check the Electrical Contactors
The turntable is capable of rotating the boom 359 procedure be performed every 250 hours or
degrees and is stopped midpoint between the steer quarterly, whichever comes first.
wheels by the rotation stop. Detecting a rotation
stop malfunction is essential to safe operation and Maintaining the electrical contactors in good
good machine performance. If the turntable rotates condition is essential to safe machine operation.
past the rotation stop, component damage may Failure to locate a worn or damaged contactor
result. could result in an unsafe working condition and
component damage.
1 Turn the key switch to platform controls and pull
out the red Emergency Stop buttons to the on Electrocution/burn hazard. Contact
position at both ground and platform controls. with hot or live circuits could result
in death or serious injury. Remove
2 Rotate the turntable to the left as far as it all rings, watches and other
will go. jewelry.
Result: Movement should stop when the 1 Remove the drive chassis cover from the non-
primary boom reaches midpoint between the steer end of the machine and locate the
steer tires. electrical contactors mounted on the electrical
component mounting panel.
3 Rotate the turntable to the right as far as it
will go. 2 Visually inspect the contact points of each
contactor for the following items:
Result: Movement should stop when the
primary boom reaches mid-point between the • Excessive burns
steer tires. • Excessive pitting
Note: Replace the contactors if any damage is
found.
3 - 18 Z-30/20N • Z-30/20N RJ Part No. 106373

B-15
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.
Note: 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 E-1,
Test or Replace the Hydraulic Oil.
Part No. 106373 Z-30/20N • Z-30/20N RJ 3 - 19

Checklist C Procedures REV D
C-1 C-2
Grease the Platform Overload Test the Platform Overload
Mechanism (if equipped) System (if equipped)
procedure be performed every 500 hours or 6 procedure be performed every 500 hours or six
months, whichever comes first. Perform this months, whichever comes first.
procedure more often if dusty conditions exist.
Testing the platform overload system regularly is
Application of lubrication to the platform overload essential to safe machine operation. Continued
mechanism is essential to safe machine operation. use of an improperly operating platform overload
Continued use of an improperly greased platform system could result in the system not sensing an
overload mechanism could result in the system not overloaded platform condition. Machine stablity
sensing an overloaded platform condition and will could be compromised resulting in the machine
result in component damage. tipping over.
1 Locate the grease fittings on each pivot pin of The platform overload system is designed to detect
the platform overload assembly. an overloaded platform and prevent machine
operation anytime the machine is turned on. When
2 Thoroughly pump grease into each grease
activated, the system halts all normal boom
fitting using a multi-purpose grease.
operation, giving visual and audible warning to the
operator.
Grease Specification
Models equipped with the platform overload option
Chevron Ultra-duty grease, EP NLGI 2 (lithium based) are provided with additional machine components:
or equivalent an adjustable spring-loaded platform support
subassembly, a limit switch, an electronic module
which receives the overload signal and interrupts
power, and an audio/visual warning indication to
alert the operator of the overload.
3 - 20 Z-30/20N • Z-30/20N RJ Part No. 106373

REV D CHECKLIST C PROCEDURES
The platform support subassembly utilizes two load 5 Carefully move the test weight to each
support arms that are opposed in a full remaining location. Refer to Illustration 1.
parallelogram link. This isolates platform loads into
Result: The platform overload indicator lights
a shear or vertical state, which translates into a
should be off at both the ground and platform
compressive load. A spring in the parallelogram
controls and the alarm should not sound.
link supports this purely compressive load
regardless of where the load is placed in the Result: The platform overload indicator lights
platform. are on and the alarm is sounding. Calibrate the
platform overload system. Refer to Repair
As weight is added to the platform, the spring will
Proceedure 2-3, How to Calibrate the Platform
compress until, when the platform is overloaded,
Overload System (if equipped).
the lower arm contacts a limit switch and thereby
activating the overload signal. When adjusted
correctly, the platform overload system will
deactivate normal boom operation at platform
capacity.
Note: Perform this procedure with the machine on

a firm, level surface.
1 Turn the key switch to platform control. Start the

engine and level the platform.
2 Determine the maximum platform capacity.
Refer to the machine serial plate. Illustration 1
3 Remove all weight, tools and accessories from 6 Using a suitable lifting device, place an
the platform. additional 10 lbs / 4.5 kg of weight onto the
platform.
Note: Failure to remove all weight, tools and
accessories from the platform will result in an Result: The alarm should sound.
inaccurate test. The platform overload indicator lights should be
flashing at both the ground and platform
4 Using a suitable lifting device, place a test controls.
weight equal to that of the available capacity
one of the locations shown. Result: The alarm does not sound and the
Refer to Illustration 1. platform overload indicator lights are not
flashing. Calibrate the platform overload
Result: The platform overload indicator lights system. Refer to Repair Proceedure 2-3,
should be off at both the ground and platform How to Calibrate the Platform Overload System
controls and the alarm should not sound. (if equipped).
Result: The platform overload indicator lights Note: There may be a 2 second delay before the
are on and the alarm is sounding. Calibrate the overload indicator lights flash and the alarm
platform overload system. Refer to Repair sounds.
Proceedure 2-3, How to Calibrate the Platform
Overload System (if equipped).
Part No. 106373 Z-30/20N • Z-30/20N RJ 3 - 21

CHECKLIST C PROCEDURES REV D
7 Carefully move the test weights to each 12 Using a suitable lifting device, lift the additional
remaining location on the platform. test weight from the platform.
Refer to Illustration 1.
Result: The platform overload indicator lights
Result: The alarm should sound. should turn off at both the ground and platform
The platform overload indicator lights should be controls and the alarm should not sound.
flashing at both the ground and platform
Note: There may be an 2 second delay before the
controls.
overload indicator lights and alarm turn off.
Result: The alarm does not sound and the
platform overload indicator lights are not 13 Start the engine and test all machine functions
flashing. Calibrate the platform overload from the ground controls.
system. Refer to Repair Proceedure 2-3, Result: All ground control functions should
How to Calibrate the Platform Overload operate normally.
System (if equipped).
14 Turn the key switch to platform control.
Note: There may be a 2 second delay before the
overload indicator lights flash and the alarm 15 Test all machine functions from the platform
sounds. controls.
8 Test all machine functions from the platform Result: All platform control functions should
controls. operate.
Result: All platform control functions should not Note: If the platform overload system is not
operate. operating properly, Refer to Repair Procedure 2-3,
How to Calibrate the Platform Overload System
9 Turn the key switch to ground control. (if equipped).
10 Test all machine functions from the ground 16 Using a suitable lifting device, remove the
controls. remaining test weights from the platform.
Result: All ground control functions should not
operate.
11 Using auxiliary power, test all machine functions
from the ground controls.
Result: All ground control functions should
operate.
3 - 22 Z-30/20N • Z-30/20N RJ Part No. 106373

REV D
Checklist D Procedures
D-1 Models without rotating jib boom:
Check the Primary Boom
Primary boom wear
Wear Pads pad specifications Minimum
Top and side wear pads 5/8inch

(extension end of boom) 15.9 mm
Note: Genie specifications require that this Bottom wear pads 5/8 inch
procedure be performed every 1000 hours or (extension end of boom) 15.9 mm
annually, whichever comes first.
Bottom and side wear pads 5/8inch
Maintaining the primary boom wear pads in good (pivot end of boom) 15.9 mm
condition is essential to safe machine operation.
Top wear pads 3/8 inch
Wear pads are placed on boom tube surfaces to
provide a low friction, replaceable wear pad (pivot end of boom) 9.5 mm
between moving parts. Improperly shimmed wear
pads or continued use of worn out wear pads may Models with rotating jib boom:
result in component damage and unsafe operating
conditions.
Primary boom wear
1 Measure each wear pad. Replace the wear pad pad specifications Minimum
once it reaches the minimum allowable
All wear pads 3/8 inch
thickness. If the wear pad is still within
specifications, shim as necessary to obtain 9.5 mm
minimum clearance with zero binding.
2 Extend and retract the primary boom through
the entire range of motion to check for tight
spots that could cause binding or scraping.
Note: Always maintain squareness between the
primary boom outer and inner tubes.
Part No. 106373 Z-30/20N • Z-30/20N RJ 3 - 23

CHECKLIST D PROCEDURES REV D
D-2 4 Disengage the drive hubs by turning over the

drive hub disconnect caps on each
Check the Free-wheel non-steer wheel hub.
Configuration
disengaged position

annually, whichever comes first.
engaged position
Proper use of the free-wheel configuration is
essential to safe machine operation. The
free-wheel configuration is used primarily for 5 Manually rotate each non-steer wheel.
towing. A machine configured to free-wheel Result: Each non-steer wheel should rotate with
without operator knowledge may cause death or minimum effort.
serious injury and property damage.
6 Engage the drive hubs by turning over
Collision hazard. Select a work the drive hub disconnect caps.
site that is firm and level.
7 Carefully remove the blocks, lower the machine
Component damage hazard. If the and remove the jack.
machine must be towed, do not
exceed 2 mph / 3.2 km/h. Collision hazard. Failure to engage
the drive hubs could result in
1 Chock the steer wheels to prevent the machine death or serious injury and
from rolling. property damage.
2 Center a lifting jack of ample capacity
(15,000 lbs / 7000 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.
3 - 24 Z-30/20N • Z-30/20N RJ Part No. 106373

REV D CHECKLIST D PROCEDURES
D-3 3 Raise the secondary boom and remove the

safety chock. Lower the secondary boom to the
Check the Turntable Rotation stowed position.
Bearing Bolts 4 Open the latch on the battery packs and swing
them out to expose the turntable bearing bolt
access hole.
Note: Genie specifications require that this 5 Confirm that each turntable bearing mounting
procedure be performed every 1000 hours or bolt is torqued in sequence to specification.
annually, whichever comes first. Refer to Section 2, Specifications.
Maintaining proper torque on the turntable bearing 1

bolts is essential to safe machine operation. 4 7
Improper bolt torque could result in an unsafe
operating condition and component damage.
1 Raise the secondary boom and place a safety 6 3
chock on the secondary boom lift cylinder.
Carefully lower the secondary boom onto the lift
cylinder safety chock. 2 5
Crushing hazard. Keep hands 8
away from the cylinder and all
moving parts when lowering the Bolt torque sequence
secondary boom.
Note: A lift cylinder safety chock is available
through Genie Service Parts (Genie part no.
36555).
2 Confirm that each turntable mounting bolt is
torqued in sequence to specification. Refer to
9 1
4 7
11
2 5
12
6 3
10
8
Bolt torque sequence
Part No. 106373 Z-30/20N • Z-30/20N RJ 3 - 25

D-4 D-5
Replace the Drive Hub Oil Replace the Hydraulic Tank
Return Filter Element

procedure be performed every 1000 hours or Note: Genie specifications require that this
annually, whichever comes first. procedure be performed every 1000 hours or
Replacing the drive hub oil is essential for good annually, whichever comes first. Perform this
machine performance and service life. Failure to procedure more often if dusty conditions exist.
replace the drive hub oil at yearly intervals may Replacement of the hydraulic return filter element is
cause the machine to perform poorly and essential for good machine performance and
continued use may cause component damage. service life. A dirty or clogged filter element may
1 Select the drive hub to be serviced. Drive the cause the machine to perform poorly and
machine until one of the two plugs is at the continued use may cause component damage.
lowest point. Extremely dirty conditions may require that the
filter element be replaced more often.
2 Remove both plugs and drain the oil into a
suitable container. Bodily injury hazard. Beware of
hot oil. Contact with hot oil may
3 Drive the machine until one plug is at the top cause severe burns.
and the other is at 90 degrees.
1 Locate the hydraulic return filter housing on top
of the hydraulic tank.
a
2 Clean the area around the oil filter housing cap
located on top of the reservoir.
3 Remove the cap from the housing.
4 Lift the handle on the filter element and rotate
the element counterclockwise to release the
element from the housing.
5 Remove the filter element from the filter
housing.
a drive hub plugs
4 Fill the hub with oil from the top hole until the oil
level is even with the bottom of the side plug
hole. Refer to Section 2, Specifications.
6 Repeat this procedure for the other drive hub.
3 - 26 Z-30/20N • Z-30/20N RJ Part No. 106373

REV D CHECKLIST D PROCEDURES
6 Install the new oil filter element into the filter D-6
housing.
Inspect for Turntable Bearing
7 Push the filter element down to be sure the o-
ring on the element is fully seated into the
Wear
housing.
8 Rotate the filter element clockwise to lock it in
place.
Note: Genie requires that this procedure be
9 Install the filter housing cap. performed every 1000 hours or annually, whichever
comes first.
10 Clean up any oil that may have spilled during
the replacement procedure. Periodic inspection of turntable bearing wear is
essential to safe machine operation, good machine
11 Use a permanent ink marker to write the date
performance and service life. Continued use of a
and number of hours from the hour meter on
worn turntable bearing could create an unsafe
the oil filter housing.
operating condition, resulting in death or serious
12 Turn the key switch to ground controls and pull injury and component damage.
position. 1 Grease the turntable bearing. See A-5, Grease
the Turntable Bearing and Rotate Gear.
13 Move and hold the function enable toggle switch
to either side and move and hold the primary 2 Torque the turntable bearing bolts to
boom toggle switch in the up direction. specification. See D-3, Check the Turntable
Rotation Bearing Bolts.
14 Inspect the filter housing and related
components to be sure that there are no leaks. 3 Raise the primary and secondary booms to full
height using the ground controls. Do not extend
the primary boom.
Part No. 106373 Z-30/20N • Z-30/20N RJ 3 - 27

4 Place a dial indicator between the drive chassis 7 Note the reading on the dial indicator.
and the turntable at a point that is directly
Result: The measurement is less than
under, or in line with, the boom and no more
0.055 inch / 1.4 mm. The bearing is good.
than 1 inch / 2.5 cm from the bearing.
Result: The measurement is more than
Note: To obtain an accurate measurement, place
0.055 inch / 1.4 mm. The bearing is worn and
the dial indicator no more than 1 inch / 2.5 cm from
needs to be replaced.
the turntable rotation bearing.
8 Fully retract the primary boom. Raise the
primary and secondary booms to full height.
a Visually inspect the the dial indicator to be sure
the needle returns to the "0" position.
9 Remove the dial indicator and rotate the
turntable 90°.
b
10 Repeat steps 4 through 9 until the rotation
bearing has been checked in at least four
c equally spaced areas 90° apart.
11 Lower the primary and secondary booms to the
stowed position and turn the machine off.
d
a turntable
12 Remove the dial indicator from the machine.
b dial indicator
c drive chassis
d turntable rotation bearing
5 Adjust the dial indicator to "0".

6 Lower the secondary boom to the stowed
position and lower the primary boom to a
horizontal position. Fully extend the primary
boom.
3 - 28 Z-30/20N • Z-30/20N RJ Part No. 106373

REV D
Checklist E Procedures
E-1 1 Close the hydraulic shutoff valve located at the
hydraulic tank.
Test or Replace the Hydraulic Oil
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
procedure be performed every 2000 hours or every
the tank valve is closed, remove
two years, whichever comes first. Perform this
the key from the key switch and
procedure more often if dusty conditions exist.
tag the machine to inform
Replacement or testing of the hydraulic oil is personnel of the condition.
essential for good machine performance and 2 Place a suitable container under the hydraulic
service life. Dirty oil and suction strainers may tank. Refer to Section 2, Specifications.
cause the machine to perform poorly and
continued use may cause component damage. 3 Tag, disconnect and plug the hydraulic hose
Extremely dirty conditions may require that the oil from the hydraulic tank shutoff valve.
be changed more often. Bodily injury hazard. Spraying
Note: Before replacing the hydraulic oil, the oil may hydraulic oil can penetrate and
be tested by an oil distributor for specific levels of burn skin. Loosen hydraulic
contamination to verify that changing the oil is connections very slowly to allow
necessary. If the hydraulic oil is not replaced at the oil pressure to dissipate
the two year inspection, test the oil quarterly. gradually. Do not allow oil to squirt
Replace the oil when it fails the test. or spray.
Note: When removing a hose assembly or fitting, 4 Open the valve on the hydraulic tank and
the O-ring on the fitting and/or hose end must be completely drain the oil into a suitable
replaced and then torqued to specification during container.
installation. Refer to Section 2, Hydraulic Hose and Bodily injury hazard. Beware of
Fitting Torque Specifications. hot oil. Contact with hot oil may
cause severe burns.
Part No. 106373 Z-30/20N • Z-30/20N RJ 3 - 29

CHECKLIST E PROCEDURES REV D
5 Tag, disconnect and plug the hydraulic hoses 13 Install the hydraulic hoses.
from the hydraulic tank return filter housing.
14 Fill the tank with hydraulic oil until the fluid is
Cap the fittings on the filter housing.
within the FULL and ADD marks on the hydraulic
Bodily injury hazard. Spraying tank. Do not overfill. Refer to Section 2,
hydraulic oil can penetrate and Specifications.
burn skin. Loosen hydraulic
15 Clean up any oil that may have spilled. Properly
connections very slowly to allow
discard of used oil.
the oil pressure to dissipate
gradually. Do not allow oil to squirt 16 Open the hydraulic tank shutoff valve.
or spray.
Component damage hazard. Be
Bodily injury hazard. Beware of sure to open the hydraulic tank
hot oil. Contact with hot oil may shutoff valve after installing the
cause severe burns. hydraulic tank.
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 and return filter assembly from
the tank.
8 Remove the suction strainer from the hydraulic
tank and clean it using a mild solvent.
9 Rinse out the inside of the tank with a mild
solvent.
10 Install the suction strainer into the tank.
11 Install the lid and return filer assembly onto the
hydraulic tank.
12 Install the hydraulic tank on the machine. Install
the hydraulic tank mounting fasteners and
torque them to 8 ft-lbs / 10.8 Nm.
hydraulic tank is plastic and may
become damaged if the tank
mounting fasteners are over
tightened.
3 - 30 Z-30/20N • Z-30/20N RJ Part No. 106373

REV D CHECKLIST E PROCEDURES
E-2 6 Remove the dust cap from the hub. Remove the
cotter pin from the castle nut.
Grease the Steer Axle
7 Tighten the castle nut to 158 ft-lbs / 214 Nm to
Wheel Bearings seat the bearings.
Note: Rotate the hub by hand while torquing the
castle nut to make sure the bearings seat properly.
Note: Genie requires that this procedure be 8 Loosen the castle nut one full turn and then
performed every 2000 hours or every two years, torque to 35 ft-lbs / 47 Nm.
whichever comes first.
9 Check for wheel bearing wear by attempting to
Maintaining the steer axle wheel bearings is move the wheel hub side to side, then up and
essential for safe machine operation and service down.
life. Operating the machine with loose or worn
Result: If there is no side to side or up and
wheel bearings may cause an unsafe operating
down movement, continue with step 10 to
condition and continued use may result in
grease the wheel bearings.
component damage. Extremely wet or dirty
conditions or regular steam cleaning and pressure Result: If there is side to side or up and down
washing of the machine may require that this movement, continue to step 10 and replace the
procedure be performed more often. wheel bearings with new ones.
1 Loosen the wheel lug nuts. Do not remove Note: When replacing a wheel bearing, both the
them. inner and outer bearings, including the pressed-in
races, must be replaced.
2 Block the non-steer wheels and center a lifting
jack under the steer axle. 10 Remove the castle nut.
3 Raise the machine 6 inches / 15 cm and place 11 Pull the hub off of the spindle. The washer and
blocks under the drive chassis for support. outer bearing should fall loose from the hub.
4 Remove the lug nuts. Remove the tire and 12 Place the hub on a flat surface and gently pry
wheel assembly. the bearing seal out of the hub. Remove the
rear bearing.
5 Check for wheel bearing wear by attempting to
move the wheel hub side to side, then up and 13 Pack both bearings with clean, fresh grease.
down.
Result: There should be no side to side or up Grease Specification
and down movement.
Chevron Ultra-duty grease, EP NLGI 2 (lithium based)
Skip to step 10 if there is no movement. or equivalent
Part No. 106373 Z-30/20N • Z-30/20N RJ 3 - 31

CHECKLIST E PROCEDURES REV D
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.
Note: Always replace the bearing grease seal
when the hub has been removed.
16 Slide the hub onto the yoke spindle.

Component damage hazard. Do
not apply excessive force or
damage to the lip of the seal may
occur.
17 Fill the hub cavity with clean, fresh grease.
18 Place the outer bearing into the hub.
19 Install the washer and castle nut.
20 Tighten the castle nut to 158 ft-lbs / 214 Nm to
seat the bearings.
Note: Rotate the hub by hand while torquing the
21 Loosen the castle nut one full turn and then
torque to 35 ft-lbs / 47 Nm.
22 Install a new cotter pin. Bend the cotter pin
to lock it in.
Note: Always use a new cotter pin when installing
a castle nut.
23 Install the dust cap, then the tire and wheel
assembly. Torque the wheel lug nuts to
specification. Refer to Section 2, Specifications.
3 - 32 Z-30/20N • Z-30/20N RJ Part No. 106373

June 2008 Section 4 • 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.
Observe and Obey: Perform disassembly procedures to the point
where repairs can be completed. Then to
Repair procedures shall be completed by a re-assemble, perform the disassembly steps in
person trained and qualified on the repair of this reverse order.
machine.
Symbols Legend
Immediately tag and remove from service a
damaged or malfunctioning machine. Safety alert symbol—used to alert
Repair any machine damage or malfunction personnel to potential personal
before operating the machine. injury hazards. Obey all safety
Before Repairs Start: to avoid possible injury or death.
Indicates an imminently hazardous
Read, understand and obey the safety rules
situation which, if not avoided, will
and operating instructions in the appropriate
Genie Z-30/20N Operator’s Manual on your
machine. Indicates a potentially hazardous
Be sure that all necessary tools and parts are
available and ready for use.
injury.
Read each procedure completely and adhere
to the instructions. Attempting shortcuts may
produce hazardous conditions.
may cause minor or moderate
Unless otherwise specified, perform each injury.
repair procedure with the machine in the
following configuration:
• Machine parked on a firm, level surface may result in property damage.
• Boom in stowed position Indicates that a specific result is expected after
• Turntable rotated with the boom between performing a series of steps.
the non-steer wheels Indicates that an incorrect result has occurred
• Key switch in the off position with the after performing a series of steps.
key removed
• Wheels chocked
• All external AC power supply disconnected
from the machine
Part No. 106373 Z-30/20N • Z-30/20N RJ 4-1

Section 4 • Repair Procedures June 2008
Platform Controls REV B
1-1 Boom Function Speed Controller

Controllers Adjustments
Electrocution/burn hazard. Contact
The drive joystick is connected to the drive motor
with electrically charged circuits
controller, located under the drive chassis cover at
the non-steer end of the machine. Maintaining the
injury. Remove all rings, watches
boom function speed controller at the proper
and other jewelry.
settings is essential to safe machine operation.
The boom function speed controller should operate Note: Do not adjust the boom function speed
smoothly and provide proportional speed control controller unless the static battery supply voltage is
through its entire range of motion. For further above 24V DC.
information or assistance, contact the Genie
Industries Service Department. 1 Turn the key switch to platform controls and pull
controls.
2 Open the platform control box lid and locate the
boom function speed controller.
g a
f b
c
a
d
b e
a black/red wire
b diode
c c white/red wire
d boom function speed controller
e ramp rate trimpot
a boom function speed controller f threshold trimpot
b drive and brake printed circuit board g max out trimpot
c drive joystick
4-2 Z-30/20N • Z-30/20N RJ Part No. 106373

REV B PLATFORM CONTROLS
3 Locate the diode between the black/red wire 10 Set the ramp rate: Turn the ramp rate trimpot to
from 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/red 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/red wire.
of the multi-meter to the diode on the black/red
wire. Boom function speed
controller specifications
5 Turn the boom function speed controller to the
CREEP position. Threshold 0.28A
(controller turned to CREEP)
6 Set the threshold: Press down the foot switch
and move the primary boom toggle switch to Max out 0.65A
the up position. Adjust the amperage to 0.28A. (controller turned to 9)
Turn the threshold trimpot adjustment screw Ramp rate 2 seconds
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 0.65A. Turn the max out trimpot adjustment
screw clockwise to increase the amperage or
counterclockwise to decrease the amperage.
9 Start a timer and simultaneously press down
the foot switch and move the primary boom
toggle switch in the down direction. Note how
long it takes to reach 0.65A.
Part No. 106373 Z-30/20N • Z-30/20N RJ 4-3

Platform Components REV C
2-1 3 Tag and disconnect the hydraulic hoses to the

slave cylinder at the union and connect them
Platform Leveling Slave Cylinder together with a connector. Cap the fittings on
the cylinder hoses.
The slave cylinder and the rotator pivot are the
two primary supports for the platform. The slave Bodily injury hazard. Spraying
cylinder keeps the platform level through the hydraulic oil can penetrate and
entire range of primary boom motion. It operates in burn skin. Loosen hydraulic
a closed loop hydraulic circuit with the master connections very slowly to allow
cylinder. The slave cylinder is equipped with the oil pressure to dissipate
counterbalance valves to prevent platform gradually. Do not allow oil to
movement in the event of a hydraulic line failure. squirt or spray.
4 Remove the external snap rings from the
How to Remove the Slave rod-end pivot pin. Do not remove the pin.
Cylinder 5 Remove the external snap rings from the
Note: Before cylinder removal is considered, bleed barrel-end pivot pin.
the slave cylinder to be sure there is no 6 Place a block of wood under the barrel of the
air in the closed loop hydraulic circuit. slave cylinder for support.
Note: When removing a hose assembly or fitting, 7 Use a soft metal drift to remove the rod-end
the O-ring on the fitting and/or hose end must be pivot pin.
replaced and then torqued to specification during
installation. Refer to Section 2, Hydraulic Hose and Crushing hazard. The platform
Fitting Torque Specifications. could fall if not properly supported.
1 Extend the boom until the slave cylinder 8 Use a soft metal drift to remove the barrel-end
barrel-end pivot pin is accessible. pivot pin.
2 Raise the boom slightly and place blocks under 9 Carefully pull the cylinder with hydraulic hoses
the platform for support. Lower the boom until out of the boom.
the platform is resting on the blocks. Crushing hazard. The slave
cylinder could fall if not properly
supported.
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.
4-4 Z-30/20N • Z-30/20N RJ Part No. 106373

REV C PLATFORM COMPONENTS
2-2 6 Remove the pin retaining fasteners from the jib

boom and leveling links to platform rotator pivot
Platform Rotator pins. Do not remove the pins.
The platform rotator is a hydraulically activated 7 Support the jib boom, jib boom cylinder and
helical gear assembly used to rotate the platform leveling links with an overhead crane.
180 degrees. 8 Use a soft metal drift to drive both pins out, then
remove the platform rotator from the machine.
How to Remove the
Crushing hazard. The platform
Platform Rotator rotator may fall when the pins are
Note: When removing a hose assembly or fitting, removed if not properly supported.
the O-ring on the fitting and/or hose end must be Note: When installing the platform rotator, be sure
replaced and then torqued to specification during to torque the fasteners to specification. Refer to
installation. Refer to Section 2, Hydraulic Hose and Section 2, Specifications.
Fitting Torque Specifications.
1 Remove the platform. How to Bleed the Platform
2 Tag, disconnect and plug the hydraulic hoses
Rotator
from the platform rotate manifold. Note: This procedure will require two people.
Bodily injury hazard. Spraying 1 Move the function enable toggle switch to either
hydraulic oil can penetrate and side and activate the platform rotate toggle
burn skin. Loosen hydraulic switch to the right and then to the left through
connections very slowly to allow two platform rotation cycles. Then hold the
the oil pressure to dissipate switch to the right position until the platform is
gradually. Do not allow oil to squirt fully rotated to the right.
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. 106373 Z-30/20N • Z-30/20N RJ 4-5

PLATFORM COMPONENTS REV C
2 Connect a clear hose to the top bleed valve. 5 Connect the clear hose to the bottom bleed
Place the other end of the hose in a container valve and open the valve. Do not remove the
to collect any drainage. Secure the container to bleed valve.
the boom.
6 Move the function enable toggle switch to either
3 Open the top bleed valve on the rotator, but do side and hold the platform rotate toggle switch
not remove it. to the right position until the platform is fully
rotated to the right. Continue holding the toggle
a switch until air stops coming out of the bleed
valve. Close the bleed valve.
b Crushing hazard. Keep clear of
c the platform during rotation.
7 Remove the hose from the bleed valve and
clean up any hydraulic oil that may have spilled.
d
8 Rotate the platform fully in both directions and
inspect the bleed valves for leaks.
a clear hose
b top bleed valve
c bottom bleed valve
d container
4 Move the function enable toggle switch to either

side and hold the platform rotate toggle switch
to the left position until the platform is fully
rotated to the left. Continue holding the toggle
switch until air stops coming out of the bleed
valve. Close the bleed valve.
Crushing hazard. Keep clear of
the platform during rotation.
4-6 Z-30/20N • Z-30/20N RJ Part No. 106373

REV C PLATFORM COMPONENTS
2-3 5 Move the platform up and down by hand, so it

bounces approximately 2.5 to 5 cm / 1 to 2
Platform Overload System inches. Allow the platform to settle.
Result: The overload indicator lights are off and
How to Calibrate the Platform the alarm does not sound. Proceed to step 6.
Overload System
Result: The overload indicator lights are
Calibration of the platform overload system is flashing at the platform and ground controls,
essential to safe machine operation. Continued and the alarm is sounding. Slowly tighten the
use of an improperly calibrated platform overload load spring adjustment nut in a clockwise
system could result in the system failing to sense direction in 10° increments until the overload
an overloaded platform. The stability of the indicator light turns off, and the alarm does not
machine is compromised and it could tip over. sound. Proceed to step 8.
Note: Perform this procedure with the machine on Note: The platform will need to be moved up and
a firm, level surface. down and allowed to settle between each
adjustment.
1 Turn the key switch to platform control.
2 Determine the maximum platform capacity. platform overload indicator light and alarm
Refer to the machine serial plate. responds.
3 Remove all weight, tools and accessories from
6 Move the platform up and down by hand, so it
the platform.
Note: Failure to remove all weight, tools and inches. Allow the platform to settle.
accessories from the platform will result in an
Result: The overload indicator lights are off at
incorrect calibration.
the platform and ground controls, and the alarm
4 Using a suitable lifting device, place a test does not sound. Slowly loosen the load spring
weight equal to the maximum platform capacity adjustment nut in a counterclockwise direction
at the center of the platform floor. in 10° increments until the overload indicator
light flashes at both the platform and ground
controls, and the alarm sounds.
Proceed to step 7.
flashing at the platform and ground controls,
and the alarm is sounding. Repeat this
procedure beginning with step 5.
Note: The platform will need to be moved up and
down and allowed to settle between each
adjustment.

platform overload indicator lights and alarm
responds.
Part No. 106373 Z-30/20N • Z-30/20N RJ 4-7

PLATFORM COMPONENTS REV C
7 Move the platform up and down by hand, so it 10 Turn the key switch to ground control.
11 Test all machine functions from the ground
inches. Allow the platform to settle.
controls.
Result: The overload indicator lights are off and
Result: All ground control functions should not
the alarm does not sound. Proceed to step 8.
operate.
12 Using a suitable lifting device, lift the test weight
flashing at the platform and ground controls,
off the platform floor.
and the alarm is sounding. Repeat this
procedure beginning with step 5. Result: The platform overload indicator light
should be off at both the ground and platform
controls and the alarm should not sound.
platform overload indicator light and alarm
responds. Note: There may be a 2 second delay before the
overload indicator lights and alarm turn off.
8 Add an additional 10 lb / 4.5 kg test weight to
the platform. 13 Test all machine functions from the ground
controls.
Result: The overload indicator light is flashing at
both the ground and platform controls, and the Result: All ground control functions should
alarm is sounding. Proceed to step 9. operate normally.
Result: The overload indicator light is off at both 14 Turn the key switch to platform control.
the ground and platform controls, and the alarm
does not sound. Remove the additional 10 lb / 15 Test all machine functions from the platform
4.5 kg test weight. Repeat this procedure controls.
beginning with step 6. Result: All platform control functions should
Note: There may be a 2 second delay before the operate normally.
platform overload indicator light and alarm
responds.
9 Test all machine functions from the platform

controls.
Result: All platform control functions should not
operate.
4-8 Z-30/20N • Z-30/20N RJ Part No. 106373

REV B
Jib Boom Components
3-1 6 Models with rotating jib boom: Tag,
disconnect and plug the hydraulic hoses from
Jib Boom the jib boom rotator. Cap the fittings on the
rotator manifold.
How to Remove the Jib Boom Bodily injury hazard. Spraying
Note: When removing a hose assembly or fitting, hydraulic oil can penetrate and
the O-ring on the fitting and/or hose end must be burn skin. Loosen hydraulic
replaced and then torqued to specification during connections very slowly to allow
installation. Refer to Section 2, Hydraulic Hose and the oil pressure to dissipate
Fitting Torque Specifications. gradually. Do not allow oil to
squirt or spray.
1 Remove the platform.
7 Attach a lifting strap from an overhead crane to
2 Remove the platform mounting weldment the jib boom.
and the platform rotator. See 2-2, How to
Remove the Platform Rotator. 8 Models without rotating jib boom: Remove
the pin retaining fastener from the jib boom
3 Tag, disconnect and plug the jib boom lift pivot pin at the jib boom bellcrank. Use a soft
cylinder hydraulic hoses. Cap the fittings on the metal drift to remove the pin, then remove the
jib boom lift cylinder. jib boom from the jib boom bellcrank.
Bodily injury hazard. Spraying Crushing hazard. The jib boom
hydraulic oil can penetrate and could fall when the pin is removed
burn skin. Loosen hydraulic if not properly supported by the
connections very slowly to allow overhead crane.
gradually. Do not allow oil to Models with rotating jib boom: Remove the
squirt or spray. pin retaining fastener from the jib boom pivot
pin at the jib boom rotator. Use a soft metal drift
4 Remove the cable cover from the side of the to remove the pin, then remove the jib boom
jib boom. from the jib boom rotator.
5 Remove the mounting fasteners from the jib Crushing hazard. The jib boom
boom/platform rotate manifold and lay the could fall when the pin is removed
manifold to the side. Do not remove the hoses if not properly supported by the
or disconnect the wiring. overhead crane.
Component damage hazard.
Hoses and cables can be
damaged if they are kinked or
pinched.
Part No. 106373 Z-30/20N • Z-30/20N RJ 4-9

JIB BOOM COMPONENTS REV B
9 Remove the pin retaining fasteners from the jib 3-2

boom lift cylinder rod-end pivot pin. Do not
remove the pin. Jib Boom Bell Crank
10 Models without rotating jib boom: Remove
(models without rotating
both of the jib boom leveling links from the bell jib boom)
crank.
Models with rotating jib boom: Remove both How to Remove the Jib Boom
of the jib boom leveling links from the jib boom Bell Crank
rotator.
Note: Perform this procedure with the boom in the
11 Attach a lifting strap from an overhead crane to stowed position.
the rod-end of the jib boom lift cylinder.
Note: When removing a hose assembly or fitting,
12 Models without rotating jib boom: Use a soft
the O-ring on the fitting and/or hose end must be
metal drift to remove the jib boom lift cylinder
rod-end pivot pin. Remove the jib boom lift
installation. Refer to Section 2, Hydraulic Hose and
cylinder from the bell crank.
Models with rotating jib boom: Use a soft
1 Remove the Jib Boom, See 3-1, How to
metal drift to remove the jib boom lift cylinder
Remove the Jib Boom.
rod-end pivot pin. Remove the jib boom lift
cylinder from the jib boom rotator. 2 Support and secure the jib boom bell crank to
an appropriate lifting device.
Crushing hazard. The jib boom
lift cylinder could fall when the pin 3 Remove the pin retaining fasteners from the
is removed if not properly slave cylinder rod-end pivot pin. Do not remove
supported by the overhead crane. the pin.
4 Place a block of wood under the platform
leveling slave cylinder for support. Protect the
cylinder rod from damage.
5 Remove the pin retaining fasteners from the jib
boom bell crank at the extension boom. Use a
soft metal drift to remove the pin.
6 Use a soft metal drift to remove the slave
cylinder rod-end pivot pin.
7 Remove the jib boom bell crank from the
extension boom.
bell crank could become
unbalanced and fall when the pins
are removed if not properly
supported and secured to the
lifting device.
4 - 10 Z-30/20N • Z-30/20N RJ Part No. 106373

REV B JIB BOOM COMPONENTS
3-3 7 Place a block of wood under the platform

leveling slave cylinder for support. Protect the
Jib Boom Rotator cylinder rod from damage.
(models with rotating jib boom) 8 Remove the pin retaining fasteners from the jib
boom bell crank at the extension boom. Use a
The platform rotator is a hydraulically activated soft metal drift to remove the pin.
helical gear assembly used to rotate the jib boom
160 degrees. 9 Use a soft metal drift to remove the slave
cylinder rod-end pivot pin.
How to Remove the Jib Boom 10 Remove the jib boom bell crank from the
Rotator extension boom.
Note: When removing a hose assembly or fitting, Crushing hazard. The jib boom
the O-ring on the fitting and/or hose end must be bell crank could become
replaced and then torqued to specification during unbalanced and fall when the pins
installation. Refer to Section 2, Hydraulic Hose and are removed if not properly
Fitting Torque Specifications. supported and secured to the
lifting device.
1 Remove the jib boom, See 3-1, How to Remove
the Jib Boom.
2 Support and secure the jib boom rotator to an
appropriate lifting device.
3 Remove the eight mounting bolts from the jib
boom rotator mount.
4 Remove the center bolt. Carefully remove the
jib boom rotator from the machine.
rotator could become unbalanced
and fall when removed from the
machine if not properly supported
and secured to the lifting device.
Note: When installing the jib boom rotator, be sure
to torque the fasteners to specification. Refer to
5 Support and secure the jib boom bell crank to

an appropriate lifting device.
6 Remove the pin retaining fasteners from the
slave cylinder rod-end pivot pin. Do not remove
the pin.
Part No. 106373 Z-30/20N • Z-30/20N RJ 4 - 11

JIB BOOM COMPONENTS REV B
How to Bleed the Jib Boom 4 Move and hold the function enable switch to
either side and move and hold the jib boom
Rotator rotate toggle switch to the left for approximately
Note: This procedure will require two people. 5 seconds, then release it. Repeat three times.
5 Fully rotate the jib boom to the left and continue
1 Turn the key switch to ground controls and pull
holding the jib boom rotate toggle switch until
out the red Emergency Stop buttons to the on
air stops coming out of the bleed valve.
Immediately release the platform rotate toggle
controls.
switch and close the bleed valve.
2 Connect a clear hose to the top bleed valve.
Crushing hazard. Keep hands and
Place the other end of the hose in a container
head clear of the platform pivot
to collect any drainage. Open the top bleed
weldment during rotation.
valve, but do not remove it.
6 Rotate the jib boom to the right until the jib
a 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.
b
c
head clear of the jib boom during
rotation.
d 9 Close the bleed valve and remove the hose.

10 Rotate the jib boom full left and right and
a top bleed valve
b clear hose
inspect the bleed valves for leaks.
c container
d bottom bleed valve
3 Move and hold the function enable toggle switch weldment during rotation.
to either side and move and hold the jib boom
11 Turn the key switch to the off position and clean
rotate toggle switch to the right for
up any hydraulic oil that may have spilled.
approximately 5 seconds, then release it.
Repeat three times.
weldment during rotation.
4 - 12 Z-30/20N • Z-30/20N RJ Part No. 106373

REV B JIB BOOM COMPONENTS
3-4 4 Use a soft metal drift to tap the rod-end pivot

pin half way out and lower one of the leveling
Jib Boom Lift Cylinder links to the ground. Tap the pin the other
direction and lower the opposite leveling link.
How to Remove the Jib Boom Do not remove the pin.
Lift Cylinder 5 Attach a lifting strap from an overhead crane to
the rod end of the jib boom lift cylinder.
Note: When removing a hose assembly or
fitting, the O-ring on the fitting and/or hose end 6 Remove the pin retaining fasteners from the jib
must be replaced and then torqued to boom lift cylinder barrel-end pivot pin. Use a
specification during installation. Refer to soft metal drift to remove the barrel-end pivot
Section 2, Hydraulic Hose and Fitting Torque pin.
Specifications.
7 Use a soft metal drift to remove the jib boom lift
1 Raise the jib boom slightly and place blocks cylinder rod-end pivot pin. Remove the jib boom
under the platform mounting weldment for lift cylinder from the machine.
support. Lower the jib boom until the platform is
Crushing hazard. The jib boom lift
resting on the blocks.
cylinder could fall when the pins
2 Tag, disconnect and plug the jib boom lift are removed if not properly
cylinder hydraulic hoses. Cap the fittings on the supported by the overhead crane.
cylinder.
Bodily injury hazard. Spraying
hydraulic oil can penetrate and
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.
Part No. 106373 Z-30/20N • Z-30/20N RJ 4 - 13

Primary Boom Components REV B
4-1 4-2
Cable Track Primary Boom
The primary boom cable track guides the cables How to Shim the Primary Boom
and hoses running up the boom. It can be repaired
link by link without removing the cables and hoses 1 Extend the boom until the wear pads are
that run through it. Removing the entire primary accessible.
boom cable track is only necessary when
2 Loosen the wear pad mounting fasteners.
performing major repairs that involve removing the
primary boom. 3 Install the new shims under the wear pad to
obtain zero clearance and zero drag.
How to Repair the Plastic Cable
4 Tighten the mounting fasteners.
Track
5 Extend and retract the boom through an entire
Component damage hazard. The cycle. Check for tight spots that could cause
primary boom cable track can be scraping or binding.
damaged if it is twisted.
Note: Always maintain squareness between the
Note: A 7-link repair section of cable track is outer and inner boom tubes.
available through the Genie Industries Service
Parts (Genie part no. 58919).
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.
4 - 14 Z-30/20N • Z-30/20N RJ Part No. 106373

REV B PRIMARY BOOM COMPONENTS
How to Remove the 5 Tag, disconnect and cap the slave cylinder
hydraulic hoses at the union. Plug the hoses
Primary Boom from the slave cylinder.
Bodily injury hazard. This Bodily injury hazard. Spraying
procedure requires specific repair hydraulic oil can penetrate and
skills, lifting equipment and a burn skin. Loosen hydraulic
suitable workshop. Attempting this connections very slowly to allow
procedure without these skills and the oil pressure to dissipate
tools could result in death or gradually. Do not allow oil to
serious injury and significant squirt or spray.
component damage. Dealer
service is strongly recommended. 6 Remove the upper cable track mounting
fasteners from the platform end of the boom.
Note: Perform this procedure with the boom in the
stowed position. 7 Remove the cable track mounting fasteners,
then remove the cable track from the boom and
Note: When removing a hose assembly or fitting, lay it flat on the ground.
replaced and then torqued to specification during Component damage hazard. The
installation. Refer to Section 2, Hydraulic Hose and cable track can be damaged if it is
Fitting Torque Specifications. twisted.
1 Remove the platform.
Cables and hoses can be
2 Remove the platform rotator. See 2-3, How to damaged if they are kinked or
Remove the Platform Rotator. pinched.
3 Remove the jib boom. See 3-1, 8 Raise the secondary boom until the primary
How to Remove the Jib Boom. boom lift cylinder rod-end pivot pin is accessible
above the mid-pivot weldment. Turn the
4 Models without rotating jib boom: Remove machine off.
the jib boom bellcrank. See 3-2, How to
Remove the Jib Boom Bellcrank. 9 Disconnect the battery packs from the machine.
Models with rotating jib boom: Remove the 10 Remove all the hose and cable clamps from the
jib boom rotator. See 3-3, How to Remove the underside of the primary boom and at the pivot
Jib Boom Rotator. end of the primary boom.
Part No. 106373 Z-30/20N • Z-30/20N RJ 4 - 15

PRIMARY BOOM COMPONENTS REV B
11 Attach a lifting strap of ample capacity from an 21 Tag, disconnect and plug the extension cylinder
overhead 5 ton / 5000 kg crane to the primary hydraulic hoses. Cap the fittings on the
boom for support. cylinder.
12 Locate the cables from the primary boom cable Bodily injury hazard. Spraying
track to the platform control box. Number each hydraulic oil can penetrate and
cable and its entry location at the platform burn skin. Loosen hydraulic
control box. connections very slowly to allow
13 Open the platform conrol box.
gradually. Do not allow oil to
14 Tag and disconnect each wire from the cables squirt or spray.
in the platform control box.
15 Pull all the cables out of the platform control the primary boom lift cylinder.
box.
23 Place 2 x 4 x 18 inch / 5 x 10 x 46 cm support
16 Remove the front counterweight cover. blocks under the cylinder, across the secondary
boom.
17 Remove the extension boom drive limit switch
from the side of the primary boom at the pivot 24 Remove the pin retaining fastener from the
end. Do not disconnect the wiring. primary boom lift cylinder rod-end pivot pin. Use
a soft metal drift to remove the pin.
from the jib boom/platform rotate manifold. Crushing hazard. The primary
boom lift cylinder could fall when it
19 Pull all the electrical cables and hydraulic hoses is removed from the machine if not
out of the plastic cable track. Then pull all the properly supported.
electrical cables and hydraulic hoses out
through the boom rest pad. 25 Lower the rod end of the primary boom lift
cylinder onto support blocks. Protect the
Component damage hazard. cylinder rod from damage.
damaged if they are kinked or 26 Remove the pin retaining fastener from the
pinched. primary boom pivot pin.
20 Remove the pin retaining fastener from the 27 Remove the primary boom pivot pin with a soft
master cylinder rod-end pivot pin. Use a soft metal drift. Carefully remove the primary boom
metal drift to remove the pivot pin. Pull the assembly from the machine.
cylinder back and secure it from moving.
Crushing hazard. The primary
boom assembly could become
unbalanced and fall when
removed from the machine if not
properly supported by the
overhead crane.
4 - 16 Z-30/20N • Z-30/20N RJ Part No. 106373

How to Disassemble Note: During removal, the overhead crane strap

will need to be carefully adjusted for proper
the Primary Boom balancing.
Note: Complete disassembly of the boom is only 7 Remove the external snap rings from the slave
necessary if the outer or inner boom tubes must cylinder barrel-end pivot pin.
be replaced. The extension cylinder can be
removed without completely disassembling the 8 Use a soft metal drift and drive the slave
boom. See 4-4, How to Remove the Extension cylinder barrel-end pivot pin out.
Cylinder. 9 Remove the slave cylinder from the primary
1 Remove the primary boom. See 4-2, extension boom tube.
How to Remove the Primary Boom. 10 Remove the external snap rings from the
2 Place blocks under the extension cylinder for extension cylinder rod-end pivot pins at the
support. platform end of the extension tube. Use a soft
metal drift to remove the pins.
3 Remove the retaining fasteners from the
extension cylinder barrel-end pivot pin. Use a 11 Support and slide the extension cylinder out of
soft metal drift to remove the pin. the pivot end of the boom extension tube. Place
the extension cylinder on blocks for support.
4 Remove and label the location of the wear pads
from the top side of the boom tube at the Note: During removal, the overhead crane strap
platform end of the boom. will need to be carefully adjusted for proper
balancing.
Note: 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 could fall when
removed from the boom if not
properly supported.
6 Support and slide the extension tube out of the
primary boom tube. Place the extension tube
on blocks for support.
Part No. 106373 Z-30/20N • Z-30/20N RJ 4 - 17

4-3 4 Attach an overhead crane to the primary boom

at the platform end for support. Raise the
Primary Boom Lift Cylinder primary boom using the overhead crane just
enough to relieve the pressure on the primary
The primary boom lift cylinder raises and lowers boom lift cylinder rod-end pivot pin.
the primary boom. The primary boom lift cylinder is
equipped with counterbalance valves to prevent 5 Remove the counterweight cover fasteners.
movement in the event of a hydraulic line failure. Remove the counterweight cover from the
machine.
How to Remove the Primary 6 Place a block of wood between the
Boom Lift Cylinder counterweight plate on the leveling link and the
cross member of the upper secondary boom.
Bodily injury hazard. This Carefully lower the secondary boom onto the
procedure requires specific repair block.
skills, lifting equipment and a
suitable workshop. Attempting this Crushing hazard. Keep hands
procedure without these skills and away from the block and all
tools could result in death or moving parts when lowering the
serious injury and significant secondary boom onto the block.
component damage. Dealer 7 Remove the pin retaining fasteners from the
service is strongly recommended. primary boom lift cylinder rod-end pivot pin. Use
Note: When removing a hose assembly or fitting, a soft metal drift to remove the pin.
the O-ring on the fitting and/or hose end must be Crushing hazard. The primary
replaced and then torqued to specification during boom lift cylinder may fall if not
installation. Refer to Section 2, Hydraulic Hose and properly supported when the
Fitting Torque Specifications. rod-end pivot pin is removed.
1 Raise the secondary boom enough to access 8 Lower the rod end of the cylinder onto the
the primary boom lift cylinder barrel-end blocks that were placed on the upper
pivot pin. secondary boom.
2 Raise the primary boom enough to access the 9 Remove the pin retaining fastener from the
primary boom lift cylinder rod-end pivot pin. ground control side upper secondary leveling
3 Support the primary boom lift cylinder with a link pivot pin at the upper pivot (same side of
suitable lifting device. Place a block of wood machine as the primary boom lift cylinder
across the upper secondary boom to support barrel-end pivot pin retainer).
the cylinder when the rod-end pin is removed. 10 Place a rod through the upper secondary
leveling link pivot pin at the upper pivot and
twist to remove the pin.
4 - 18 Z-30/20N • Z-30/20N RJ Part No. 106373

11 Swing the leveling link up out of the way and

secure it from moving. 4-4
12 Tag, disconnect and plug the primary boom lift Extension Cylinder
cylinder hydraulic hoses. Cap the fittings on the
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.
gradually. Do not allow oil to squirt
How to Remove the
or spray. Extension Cylinder
13 Support the barrel end of the primary boom lift Bodily injury hazard. This
cylinder with straps or ropes to restrict it from procedure requires specific repair
swinging freely. skills, lifting equipment and a
suitable workshop. Attempting this
14 Remove the pin retaining fastener from the
procedure without these skills and
primary boom lift cylinder barrel-end pivot pin.
tools could result in death or
Do not remove the pivot pin.
serious injury and significant
15 Place a rod through the barrel-end pivot pin and component damage. Dealer
twist to remove the pin. service is strongly recommended.

boom lift cylinder may fall when Note: When removing a hose assembly or fitting,
the barrel-end pivot pin is removed the O-ring on the fitting and/or hose end must be
if not properly supported. replaced and then torqued to specification during
16 Attach an overhead crane or similar lifting Fitting Torque Specifications.
device to the lug on the rod-end of the primary
boom lift cylinder. Carefully loosen the straps 1 Raise the primary boom to the horizontal
and allow the primary boom lift cylinder to position. Extend the boom 3 to 4 feet / 1 m until
slowly swing down. the extension cylinder rod-end pivot pins are
accessible.
17 Carefully remove the cylinder from the machine.
2 Remove the external snap rings from the
extension cylinder rod-end pivot pins. Use a
boom lift cylinder will fall if not
soft metal drift to remove the pins.
properly supported when it is
removed from the machine. 3 Remove the counterweight cover fasteners.
Remove the counterweight cover from the
machine.
4 Raise the secondary boom until the master
cylinder rod-end pivot pin is accessible.
Part No. 106373 Z-30/20N • Z-30/20N RJ 4 - 19

5 Remove the primary boom extend drive limit 4-5

switch from the pivot end of the primary boom.
Do not disconnect the wiring. Platform Leveling Master
6 Remove the retaining fastener from the master
Cylinder
cylinder rod-end pivot pin. Use a soft metal drift
to remove the pin. The platform leveling master cylinder acts as a
pump for the slave cylinder. It is part of the closed-
7 Manually retract the master cylinder and push it loop hydraulic circuit that keeps the platform level
toward the platform end of the boom to obtain through the entire range of primary boom motion.
enough clearance for extension cylinder The platform leveling master cylinder is located
removal. inside the upper mid-pivot at the pivot end of the
primary boom.
8 Tag, disconnect and plug the extension cylinder
hydraulic hoses. Cap the fittings on the
cylinder.
How to Remove the Platform
Leveling Master Cylinder
hydraulic oil can penetrate and Bodily injury hazard. This
burn skin. Loosen hydraulic procedure requires specific repair
connections very slowly to allow skills, lifting equipment and a
the oil pressure to dissipate suitable workshop. Attempting this
gradually. Do not allow oil to squirt procedure without these skills and
or spray. tools could result in death or
serious injury and significant
9 Remove the retaining fastener from the
extension cylinder barrel-end pivot pin. Use a
service is strongly recommended.
soft metal drift to remove the pin.
10 Carefully pull out and properly support the
extension cylinder from the primary boom with
a lifting strap from an overhead crane.
Crushing hazard. The cylinder Fitting Torque Specifications.
could fall if not properly supported
when it is pulled out of the Note: Before cylinder removal is considered, bleed
extension tube. the cylinder to be sure that there is no air in the
closed loop. See 2-2, How to Bleed the Slave
Note: To make installation of the extension cylinder Cylinder.
easier, be sure that the cylinder rod is extended
3 to 4 feet / 1 m. 1 Remove the counterweight cover.
Note:During removal, the overhead crane strap will 2 Raise the secondary boom until the master
need to be carefully adjusted for proper balancing. cylinder barrel-end pivot pin is above the
turntable counterweights.
3 Raise the primary boom until the master
cylinder rod-end pivot pin is accessible.
4 - 20 Z-30/20N • Z-30/20N RJ Part No. 106373

4 Attach an overhead crane to the pivot end of

the primary boom for support. 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.
or spray.
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 pivot).
master cylinder rod-end pivot pin. Use a soft
metal drift to remove the pin.
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 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 pivot.
Crushing hazard. The upper
secondary boom and the upper
pivot could 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. 106373 Z-30/20N • Z-30/20N RJ 4 - 21

Secondary Boom Components REV B
i
c
h
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 counterweight
i upper secondary boom
4 - 22 Z-30/20N • Z-30/20N RJ Part No. 106373

REV B SECONDARY BOOM COMPONENTS
5-1 6 Locate the cables from the primary boom cable

track to the platform control box. Number each
Secondary Boom cable and its entry location at the platform
control box.
How to Disassemble the 7 Open the platform control box.
Secondary Boom
8 Tag and disconnect each wire from the cables
Bodily injury hazard. The in the platform control box.
procedures in this section require
specific repair skills, lifting
equipment and a suitable
workshop. Attempting this
procedure without these skills and
and other jewelry.
tools could result in death or
serious injury and significant 9 Pull the cables out of the platform control box.
service is required. 10 Pull all of the electrical cables out of the plastic
cable track. Do not pull out the hydraulic hoses.
the O-ring on the fitting and/or hose end must be 11 Remove the hose clamps from the bottom side
replaced and then torqued to specification during of the primary boom.
installation. Refer to Section 2, Hydraulic Hose and 12 Before serial number 5945: Tag, disconnect
Fitting Torque Specifications. and plug the platform rotator hydraulic hoses at
the union located on the bottom side of the
1 Remove the counterweight cover.
primary boom. Cap the fittings on the union.
2 Place a suitable lifting device under the platform
After serial number 5944: Tag, disconnect and
for support.
plug the hydraulic hoses from the "P" and "T"
3 Disconnect the battery packs from the machine. ports at the jib boom/rotate manifold. Cap the
fittings on the manifold.
4 Remove the cable cover from the side of the jib
boom. Bodily injury hazard. Spraying
5 Remove the wire loom from the cables at the burn skin. Loosen hydraulic
platform control box. connections very slowly to allow
or spray.
Part No. 106373 Z-30/20N • Z-30/20N RJ 4 - 23

SECONDARY BOOM COMPONENTS REV B
13 Remove the hose clamp from the side of the 21 Position a lifting strap from the overhead crane
primary boom at the pivot end. approximately 2 feet / 60 cm from the platform
end of the primary boom. Measure from the
14 Remove the primary boom extend drive speed
platform end of the primary boom tube.
limit switch (LS1) mounted on the side of the
primary boom at the pivot end. Do not 22 Remove the pin retaining fasteners from the
disconnect the wiring. upper pivot to upper secondary compression
arm pivot pins. Use a soft metal drift to remove
the pins.
the pivot end of the primary boom.
23 Swing the compression arms down and out of
16 Carefully lift the secondary and primary boom
the way. Secure them from moving.
assembly with the overhead crane until the
master cylinder and primary boom lift cylinder 24 Remove the pin retaining fasteners from the
hydraulic hoses are accessible. upper pivot to the upper secondary boom pivot
pin. Use a soft metal drift to remove the pin.
17 Remove the cable covers from the top of the
upper secondary boom. 25 Carefully remove the entire primary boom
assembly from the machine (primary boom
18 Tag, disconnect and plug the primary boom lift
assembly, jib boom assembly, platform, master
cylinder and master cylinder hydraulic hoses.
cylinder, primary lift cylinder and upper pivot).
Cap the fittings on the cylinders.
boom assembly could become
overhead crane. Do not remove
the assembly from the machine
or spray.
until it is properly balanced.
19 Lower the secondary boom to the fully stowed
Note: During removal, the overhead crane strap
position.
will need to be carefully adjusted for proper
20 Pull all the cables and hoses through the upper balancing.
pivot.
26 Place the entire assembly onto a structure
Component damage hazard. capable of supporting it.
damaged if they are kinked or
pinched.
4 - 24 Z-30/20N • Z-30/20N RJ Part No. 106373

27 Remove the pin retaining fasteners from the 32 Tag, disconnect and plug the hydraulic hose
upper secondary compression arm pivot pins. from the hydraulic tank return filter housing.
Do not remove the pins. Cap the fitting on the filter housing.
28 Position a lifting strap from an overhead crane Bodily injury hazard. Spraying
at the center of the control box side upper hydraulic oil can penetrate and
secondary compression arm. burn skin. Loosen hydraulic
29 Use a soft metal drift to remove the upper
secondary boom compression arm pivot pins
and remove the compression arm from the
or spray.
machine. Repeat this step for the hydraulic tank
side upper secondary compression arm. Bodily injury hazard. Beware of
cause severe burns.
secondary compression arm could
become unbalanced and fall when 33 Remove the hydraulic tank mounting fasteners.
removed from the machine if not Remove the hydraulic tank from the machine.
34 Open the ground controls side turntable cover.
overhead crane.
35 Remove the terminal strip cover retaining
30 Close the hydraulic tank shutoff valve. Tag,
fasteners. Remove the cover.
disconnect and plug the hydraulic hose from
the hydraulic tank shutoff valve. 36 Remove the terminal strip retaining fasteners.
Do not disconnect the wiring.
hydraulic oil can penetrate and 37 Remove the plastic plug in the bulkhead to
burn skin. Loosen hydraulic access the secondary boom lift cylinder rod-end
connections very slowly to allow pivot pin.
gradually. Do not allow oil to squirt 38 Remove the pin retaining fastener from the rod
or spray. end of the secondary boom lift cylinder. Use a
soft metal drift to remove the pin through the
31 Open the valve on the hydraulic tank and drain access holes in the bulkheads. Secure the
the oil into a container of suitable capacity. cylinder from moving.
Refer to Section 2, Specifications.
Bodily injury hazard. Beware of lower pivot pin on the compression link. Use a
hot oil. Contact with hot oil may soft metal drift to remove the pin.
cause severe burns.
Part No. 106373 Z-30/20N • Z-30/20N RJ 4 - 25

40 Attach a lifting strap from an overhead crane to 45 Remove the mounting fasteners from the
the upper secondary boom. function manifold and slide the function
manifold to the side. This will allow access to
the secondary boom lift cylinder barrel-end
mid-pivot to upper secondary boom pivot pin.
pivot pin.
Use a soft metal drift to remove the pin.
46 Remove the mounting fasteners from the
42 Remove the upper secondary boom with
auxiliary power unit. Do not disconnect the
compression link from the machine.
electrical cables or hydraulic hoses.
47 Slide the auxiliary power unit to the side to
secondary boom with
access the other secondary boom lift cylinder
compression link could become
barrel-end pivot pin.
removed from the machine if not 48 Remove the retaining fasteners from the
properly supported by the secondary boom lift cylinder barrel-end pivot
overhead crane. pins.
43 Remove the mounting fasteners from the 49 Attach a lifting strap from an overhead crane to
counterweight attached to the lower leveling the lug on the rod end of the secondary boom
link. lift cylinder.
44 Attach a lifting strap from an overhead crane to 50 Tag, disconnect and plug the hydraulic hoses
the counterweight. Remove the counterweight from the secondary boom lift cylinder. Cap the
from the lower leveling link. fittings on the cylinder.
Tip-over hazard. The Bodily injury hazard. Spraying
counterweight is critical to hydraulic oil can penetrate and
machine stability. If the burn skin. Loosen hydraulic
counterweight is not installed connections very slowly to allow
during re-assembly of the the oil pressure to dissipate
machine, the machine will become gradually. Do not allow oil to squirt
unstable and tip over. or spray.
Crushing hazard. The 51 Use a slide hammer to remove the barrel-end
counterweight could become pivot pins (access the pins from the access
unbalanced and fall when holes in the bulkheads, one on each side).
removed from the machine if not Remove the secondary boom lift cylinder from
properly supported by the the machine.
overhead crane.
Crushing hazard. The secondary
boom lift cylinder could become
overhead crane.
4 - 26 Z-30/20N • Z-30/20N RJ Part No. 106373

52 Attach a lifting strap from an overhead crane to 60 Attach a lifting strap from an overhead crane to
the mid-pivot for support. the lower secondary boom.
53 Remove the pin retaining fasteners from the 61 Remove the pin retaining fastener from the
mid-pivot to the lower secondary compression lower secondary boom to turntable riser pivot
arm pivot pins. Use a slide hammer and pin. Use a soft metal drift to remove the pin.
remove the pins. Lower the compression arms
62 Remove the lower secondary boom from the
down.
machine.
54 Remove the pin retaining fasteners from the
Crushing hazard. The lower
mid-pivot to the lower secondary boom pivot
secondary boom could become
pin. Use a soft metal drift to remove the pins.
55 Remove the mid-pivot from the machine. removed from the machine if not
Crushing hazard. The mid-pivot
overhead crane.
could become unbalanced and fall
when removed from the machine if
not properly supported by the
overhead crane.
56 Remove the secondary boom drive speed limit
switch (LS4) mounted to the turntable riser on
the ground controls side. Do not disconnect the
wiring.
the ground control side lower secondary boom
compression arm.
lower secondary boom compression arm to
turntable riser pivot pin.
59 Use a slide hammer and remove the pin.
Remove the compression arm from the
machine. Repeat for the hydraulic tank side
lower secondary boom compression arm.
Crushing hazard. The lower
secondary compression arm could
become unbalanced and fall when
overhead crane.
Part No. 106373 Z-30/20N • Z-30/20N RJ 4 - 27

5-2 5 Open the hydraulic tank side turntable cover.

Secondary Boom Lift Cylinder 6 Tag and disconnect the power cables on the
auxiliary power unit.
The secondary boom lift cylinder raises and Electrocution/burn hazard. Contact
lowers the secondary boom. The secondary with electrically charged circuits
boom lift cylinder is equipped with counterbalance could result in death or serious
valves to prevent movement in the event of a injury. Remove all rings, watches
hydraulic line failure. and other jewelry.
How to Remove the Secondary 7 Close the hydraulic tank shutoff valve. Tag and
disconnect and plug the hydraulic hose from
Boom Lift Cylinder the hydraulic tank shutoff valve.
Bodily injury hazard. This Bodily injury hazard. Spraying
procedure requires specific repair hydraulic oil can penetrate and
skills, lifting equipment and a burn skin. Loosen hydraulic
suitable workshop. Attempting this connections very slowly to allow
procedure without these skills and the oil pressure to dissipate
tools could result in death or gradually. Do not allow oil to squirt
serious injury and significant or spray.
service is strongly recommended. 8 Open the valve on the hydraulic tank and drain
the oil into a container of suitable capacity.
Note: When removing a hose assembly or fitting, Refer to Section 2, Specifications.
replaced and then torqued to specification during Bodily injury hazard. Beware of
installation. Refer to Section 2, Hydraulic Hose and hot oil. Contact with hot oil may
Fitting Torque Specifications. cause severe burns.
1 Rotate the turntable to either side until the boom 9 Tag, disconnect and plug the hydraulic hose
is centered between the steer and non-steer from the hydraulic tank return filter housing.
tires. Cap the fitting on the filter housing.
2 Raise the primary boom to full height. Do not Bodily injury hazard. Spraying
extend it. hydraulic oil can penetrate and
3 Swing out the battery pack that is directly below connections very slowly to allow
the secondary boom lift cylinder. the oil pressure to dissipate
4 Disconnect the battery packs from the machine. gradually. Do not allow oil to squirt
or spray.
Bodily injury hazard. Beware of
cause severe burns.
4 - 28 Z-30/20N • Z-30/20N RJ Part No. 106373

10 Remove the hydraulic tank mounting fasteners. 21 Use a soft metal drift to remove the secondary
Remove the hydraulic tank from the machine. boom rod-end pivot pin.
11 Open the ground controls side turntable cover. Crushing hazard. The secondary
boom lift cylinder may fall when
12 Remove the terminal strip cover retaining
the rod-end pivot pin is removed if
fasteners. Remove the cover.
not properly supported by the
13 Remove the terminal strip retaining fasteners. overhead crane.
Do not disconnect the wiring.
22 Carefully lower the cylinder down through the
14 Remove the plastic plug in the bulkhead to secondary boom, enough to access the
access the secondary boom lift cylinder rod-end hydraulic hoses. Do not pinch the hoses.
pivot pin.
15 Remove the mounting fasteners from the Hoses can be damaged if they are
function manifold and slide the manifold to the kinked or pinched.
side This will allow access to the hydraulic tank
side barrel-end pivot pin.
from the secondary boom lift cylinder. Cap the
16 Attach a lifting strap from an overhead crane to fittings on the cylinder.
the lug on the rod end of the secondary boom
lift cylinder.
17 From the bottom side of the cylinder, remove burn skin. Loosen hydraulic
the retaining fasteners from the secondary connections very slowly to allow
boom lift cylinder barrel-end pivot pins. the oil pressure to dissipate
18 Remove the hose clamp under the lower or spray.
secondary boom.
24 Remove the cylinder through the top of the
19 Use a slide hammer to remove both barrel-end secondary boom.
pivot pins (access the pins from the access
holes in the bulkheads, one on each side). Crushing hazard. The secondary
boom lift cylinder could become
20 Remove the pin retaining fastener from the unbalanced and fall when
secondary boom lift cylinder rod-end pivot pin. removed from the machine if not
overhead crane.
Part No. 106373 Z-30/20N • Z-30/20N RJ 4 - 29

Hydraulic Pumps REV A
6-1
Auxiliary and Function Pump
How to Remove the Auxiliary

Pump or Function Pump
1 Close the hydraulic shutoff valve located at the
hydraulic tank.
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.
from the pump. Cap the fittings on the pump.
or spray.
3 Remove the pump mounting bolts from the
pump. Carefully remove the pump from the
electric motor.
4 - 30 Z-30/20N • Z-30/20N RJ Part No. 106373

Part No. 106373 Z-30/20N • Z-30/20N RJ 4 - 31

Manifolds REV D
7-1
Function Manifold Components
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 ....... A ........... Platform level up/down ..................... 20-25 ft-lbs / 27-34 Nm
2 Counterbalance valve ........................ B ........... Platform level down .......................... 20-25 ft-lbs / 27-34 Nm
3 Counterbalance valve ....................... C ........... Platform level up ............................... 20-25 ft-lbs / 27-34 Nm
4 Relief valve, 1100 psi / 75.8 bar ....... D ........... Turntable rotate left/right ................... 30-35 ft-lbs / 41-47 Nm
5 Relief valve, 1600 psi / 110 bar ......... E ........... Secondary boom down ..................... 20-25 ft-lbs / 27-34 Nm
6 Relief valve, 1600 psi / 110 bar ......... F ........... Primary boom down .......................... 20-25 ft-lbs / 27-34 Nm
7 Proportional solenoid valve .............. H ........... System flow regulating circuit ........... 30-35 ft-lbs / 41-47 Nm
8 Check valve ....................................... I ............ Brake circuit ...................................... 10-12 ft-lbs / 14-16 Nm
9 Solenoid valve, 3 position 4 way ....... J ............ Steer left/right .................................... 20-25 ft-lbs / 27-34 Nm
10 Solenoid valve, 3 position 4 way ....... K ........... Primary boom extend/retract ............ 20-25 ft-lbs / 27-34 Nm
11 Pressure switch ................................. L ........... Brake circuit
12 Solenoid valve, N.C. poppet ............. M ........... Brake circuit ...................................... 20-25 ft-lbs / 27-34 Nm
13 Orifice, 0.045 inch / 1.14 mm ........... N ........... Brake circuit
This list continues. Please turn the page.
4 - 32 Z-30/20N • Z-30/20N RJ Part No. 106373

REV D MANIFOLDS
1 2 3 4 5 6 7 8 9
10
11
12
13
14
15
16
17
18
19
20
24 23 22 21
Part No. 106373 Z-30/20N • Z-30/20N RJ 4 - 33

MANIFOLDS REV D
Function Manifold Components, continued

The function manifold is locate behind the ground controls turntable cover.
Index Schematic
14 Orifice, 0.045 inch / 1.14 mm ........... O ........... Brake and steer circuit
15 Solenoid valve, N.O. poppet .............. P ........... Brake circuit ...................................... 20-25 ft-lbs / 27-34 Nm
16 Differential sensing valve ................. Q ........... Differential sensing circuit ................. 30-35 ft-lbs / 41-47 Nm
17 Relief valve, 2800 psi / 193 bar ........ R ........... System relief ..................................... 20-25 ft-lbs / 27-34 Nm
18 Orifice, 0.035 inch / 0.89 mm ............ S ........... Tank return circuit
19 Diagnostic fitting ................................ T ........... Testing
20 Solenoid valve, 3 position 4 way ...... U ........... Secondary boom up/down ................ 20-25 ft-lbs / 27-34 Nm
21 Solenoid valve, 3 position 4 way ....... V ........... Primary boom up/down ..................... 20-25 ft-lbs / 27-34 Nm
22 Flow regulator valve,
1.5 gpm / 5.7 L/min
(before serial number 10808)
Flow regulator valve,
1.8 gpm / 6.8 L/min
(after serial number 10807) ............. W ........... Turntable rotate circuit ...................... 20-25 ft-lbs / 27-34 Nm
0.8 gpm / 3 L/min ............................... X ........... Jib boom/platform rotate circuit ......... 20-25 ft-lbs / 27-34 Nm
24 Solenoid valve, 3 position 4 way ....... Y ........... Turntable rotate left/right ................... 20-25 ft-lbs / 27-34 Nm
4 - 34 Z-30/20N • Z-30/20N RJ Part No. 106373

REV D MANIFOLDS
1 2 3 4 5 6 7 8 9
10
11
12
13
14
15
16
17
18
19
20
24 23 22 21
Part No. 106373 Z-30/20N • Z-30/20N RJ 4 - 35

MANIFOLDS REV D
7-2 How to Adjust the Primary Boom

Valve Adjustments - Down Relief Valve
Function Manifold 1 Connect a 0 to 3000 psi / 0 to 200 bar pressure
gauge to the test port on the function manifold.
How to Adjust the System Relief 2 Turn the key switch to ground control and pull
Valve out the red Emergency Stop button to the on
position.
1 Connect a 0 to 5000 psi / 0 to 350 bar pressure
gauge to the test port on the function manifold. 3 Move and hold the function enable toggle switch
to either side and move and hold the primary
2 Turn the key switch to ground control and pull boom up/down toggle switch in the down
out the red Emergency Stop button to the on direction with the primary boom fully lowered.
position. Observe the pressure reading on the pressure
3 Move and hold the function enable toggle switch gauge. Refer to Section 2, Specifications.
to either side and move and hold the primary 4 Turn the machine off. Hold the primary down
boom extend/retract toggle switch in the retract relief valve with a wrench and remove the cap
direction with the primary boom fully retracted. (item F).
Observe the pressure reading on the pressure
gauge. Refer to Section 2, Specifications. 5 Adjust the internal hex socket. Turn it clockwise
to increase the pressure or counterclockwise to
4 Turn the machine off. Hold the system relief decrease the pressure. Then install the relief
valve with a wrench and remove the cap valve cap.
(item R).
Tip-over hazard. Do not adjust
5 Adjust the internal hex socket. Turn it clockwise the relief valve higher than
to increase the pressure or counterclockwise to specified.
decrease the pressure. Install the relief valve
cap. 6 Repeat steps 2 and 3 to confirm the relief valve
pressure setting.
the relief valve higher than
specified.
6 Repeat steps 2 and 3 to confirm the relief valve
pressure setting.
4 - 36 Z-30/20N • Z-30/20N RJ Part No. 106373

REV D MANIFOLDS
How to Adjust the Secondary How to Adjust the Primary Boom

Boom Down Relief Valve Extend Relief Valve
1 Connect a 0 to 3000 psi / 0 to 200 bar pressure 1 Connect a 0 to 3000 psi / 0 to 200 bar pressure
gauge to the test port on the function manifold. gauge to the test port on the function manifold.
2 Turn the key switch to ground control and pull 2 Turn the key switch to ground control and pull
out the red Emergency Stop button to the on out the red Emergency Stop button to the on
position. position.
3 Move and hold the function enable toggle switch 3 Move and hold the function enable toggle switch
to either side and move and hold the secondary to either side and move and hold the primary
boom up/down toggle switch in the down boom extend/retract toggle switch in the extend
direction with the secondary boom fully direction with the primary boom fully extended.
lowered. Observe the pressure reading on the Observe the pressure reading on the pressure
pressure gauge. Refer to Section 2, gauge. Refer to Section 2, Specifications.
Specifications.
4 Turn the machine off. Hold the primary booom
4 Turn the machine off. Hold the secondary boom extend relief valve with a wrench and remove
down relief valve with a wrench and remove the the cap (item G).
cap (item E).
5 Adjust the internal hex socket. Turn it clockwise
5 Adjust the internal hex socket. Turn it clockwise to increase the pressure or counterclockwise to
to increase the pressure or counterclockwise to decrease the pressure. Install the relief valve
decrease the pressure. Install the relief valve cap.
cap.
Tip-over hazard. Do not adjust the relief valves higher than
the relief valve higher than specified.
specified.
6 Repeat steps 2 and 3 to confirm the relief valve pressure setting.
pressure setting.
Part No. 106373 Z-30/20N • Z-30/20N RJ 4 - 37

MANIFOLDS REV D
How to Adjust the Turntable

Rotate Relief Valve
1 Connect a 0 to 3000 psi / 0 to 200 bar pressure
gauge to the test port on the function manifold.
2 Turn the key switch to ground control and pull
position.
3 Move and hold the function enable toggle switch
to either side and 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. Refer to Section 2, Specifications.
4 Turn the machine off. Hold the turntable relief
valve(s) with a wrench and remove the cap
(item D).
5 Adjust the internal hex socket. Turn it clockwise
to increase the pressure or counterclockwise to
decrease the pressure. Install the relief valve
cap.
the relief valve higher than
specified.
pressure setting.
4 - 38 Z-30/20N • Z-30/20N RJ Part No. 106373

REV D MANIFOLDS
7-3
Jib Boom and Platform / Jib Boom Rotate Manifold Components
The jib boom/platform rotate manifold is mounted to the jib boom.
Index Schematic
1 Solenoid valve, 3 position 4 way ..... AA .......... Jib boom up/down ............................. 20-25 ft-lbs / 27-34 Nm
2 Solenoid valve, 3 position 4 way ..... BB .......... Platform rotate left/right .................... 20-25 ft-lbs / 27-34 Nm
3 Solenoid valve, 3 position 4 way ..... CC .......... Jib boom rotate left/right ................... 20-25 ft-lbs / 27-34 Nm
0.3 gpm / 1.14 L/min ........................ EE .......... Platform rotate circuit ........................ 20-25 ft-lbs / 27-34 Nm
5 Orifice plug, 0.025 inch / 0.64 mm ... DD .......... Jib boom rotate circuit
(located under plug)
1 2 3 4
1
4
Models without
rotating jib boom
Models with
rotating jib boom 5
Part No. 106373 Z-30/20N • Z-30/20N RJ 4 - 39

MANIFOLDS REV D
7-4 Valve Coil Resistance

Valve Coils Specification
Note: The following coil resistance specifications
How to Test a Coil are at an ambient temperature of 68°F / 20°C. As
A properly functioning coil provides an valve coil resistance is sensitive to changes in air
electromotive force which operates the solenoid temperature, the coil resistance will typically
valve. Critical to normal operation is continuity increase or decrease by 4% for each 18°F / 10°C
within the coil that provides this force field. that your air temperature increases or decreases
from 68°F / 20°C.
with electrically charged circuits Valve Coil Resistance Specification
Description Specification
and other jewelry. Solenoid valve, 3 position 4 way, 20V DC 22 Ω
(schematic items A, J, K, U, V, Y, AA, BB and CC)
1 Tag and disconnect the wiring from the coil to
be tested. Proportional solenoid valve, 24V DC 19.5 Ω
(schematic item H)
2 Test the coil resistance.
Solenoid valve, N.C. poppet, 20V DC 23.5 Ω
Coils with 2 terminals: Connect the leads from
(schematic item M)
the ohmmeter to the valve coil terminals.
Solenoid valve, N.O. poppet, 20V DC 23.5 Ω
Coils with 1 terminal: Connect the positive
(schematic item P)
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.
4 - 40 Z-30/20N • Z-30/20N RJ Part No. 106373

REV D MANIFOLDS
How to Test a Coil Diode COIL

a
Genie incorporates spike suppressing diodes in all d
MULTI
METER
of its valve coils. Properly functioning coil diodes
protect the electrical circuit by suppressing voltage
spikes. Voltage spikes naturally occur within a c -
function circuit following the interruption of
+
b
electrical current to a coil. Faulty diodes can fail to 10 W 9V
protect the electrical system, resulting in a tripped RESISTOR BATTERY
circuit breaker or component damage.
+
c - b
could result in death or serious a multimeter
b 9V DC battery
injury. Remove all rings, watches c 10Ω resistor
and other jewelry. d coil
1 Test the coil for resistance. See How to Test a Note: Dotted lines in illustration indicate a
Coil. reversed connection as specified in
step 6
2 Connect a 10Ω resistor to the negative terminal
of a known good 9V DC battery. Connect the 3 Set a multimeter to read DC current.
other end of the resistor to a terminal on the Note: The multimeter, when set to read DC
coil. current, should be capable of reading up to 800
Note: The battery should read 9V DC or more mA.
when measured across the terminals. 4 Connect the negative lead to the other terminal
on the coil.
Ω
Resistor, 10Ω
Genie part number 27287 Note: If testing a single-terminal coil, connect the
negative lead to the internal metallic ring at either
end of the coil.
5 Momentarily connect the positive lead from the
multimeter to the positive terminal on the 9V DC
battery. Note and record the amperage reading.
6 At the battery or coil terminals, reverse the
connections. Note and record the current
reading.
Result: Both current readings are greater than
0 mA and are different by a minimum of 20%.
The coil is good.
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
internal diode are faulty and the coil should be
replaced.
Part No. 106373 Z-30/20N • Z-30/20N RJ 4 - 41

Turntable Rotation Components REV B
8-1
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
from the turntable rotation motor. Cap the
fittings on the motor.
or spray.
2 Remove the turntable rotation motor mounting
bolts. Remove the motor from the machine.
4 - 42 Z-30/20N • Z-30/20N RJ Part No. 106373

REV C
Steer Axle Components
9-1 How to Install the Hub
Hub and Bearings and Bearings
Note: When replacing a wheel bearing, both the
How to Remove the inner and outer bearings, including the pressed-in
Hub and Bearings races, must be replaced.
1 Loosen the wheel lug nuts. Do not remove 1 Be sure that both bearings are packed
them. with clean, fresh grease.
2 Block the non-steer wheels and place a lifting 2 Place the large inner bearing into the rear of the
jack under the steer axle. hub.
3 Raise the machine. Place blocks under 3 Install a new bearing grease seal into the hub
the drive chassis for support. by pressing it evenly into the hub until it is flush.
4 Remove the lug nuts. Remove the tire Note: Always replace the bearing grease seal
and wheel assembly. when removing the hub.
5 Remove the dust cap, cotter pin and 4 Slide the hub onto the yoke spindle.
castle nut.
Component damage hazard. Do
Note: Always use a new cotter pin when installing a not apply excessive force or
castle nut. damage to the lip of the seal may
occur.
6 Pull the hub off the yoke spindle. The washer
and outer bearing should fall loose from the 5 Fill the hub cavity with clean, fresh grease.
hub.
6 Place the outer bearing into the hub.
7 Place the hub on a flat surface and gently pry
7 Install the washer and castle nut.
the grease seal out of the hub. Remove the
inner bearing. 8 Tighten the castle nut to 158 ft-lbs / 214 Nm
to seat the bearings.
Note: When removing a bearing, always use a new
inner bearing seal. Note: Rotate the hub by hand while torquing the
9 Loosen the castle nut one full turn and then
torque to 35 ft-lbs / 47 Nm.
10 Install a new cotter pin. Bend the cotter pin to
lock it in place.
Note: Always use a new cotter pin when installing a
castle nut.
11 Install the dust cap, then the tire and wheel
assembly.
12 Lower the machine and remove the blocks.
13 Torque the wheel lug nuts to specification. Refer
to Section 2, Specifications.
Part No. 106373 Z-30/20N • Z-30/20N RJ 4 - 43

Motor Controller REV B
10-1 5 Connect the leads from an ohmmeter to test

each motor controller terminal combination
Motor Controller listed below and check the forward / reverse
bias (diode test).
The drive motor controller is located under the non-
steer end drive chassis cover. The drive motor Result: All desired results must be within the
controller can recognize machine drive specified range. If any test has a result not
malfunctions and display controller fault codes by within the specified range, replace the motor
flashing a LED at the ground controls and on the controller.
motor controller. See the Fault Code section of this Forward Bias:
manual for a list of fault codes and additional
information. There are no adjustments needed on Test Desired result
the drive joystick controller. For further information
or assistance, consult the Genie Industries Service Positive Lead Negative Lead
Department.
M- B+ 0.4 to 0.45
How to Test the Motor Controller B- M- 0.4 to 0.45
Note: Use the following procedure to test the motor F1 B+ 0.45 to 0.5
controller. If the motor controller is found to be
faulty, note which test failed and which fault code F2 B+ 0.45 to 0.5
(if any) was present at the time of failure. B- F1 0.45 to 0.5
1 Turn the key switch to the off position and B- F2 0.45 to 0.5
disconnect the battery packs from the machine.
2 Tag and disconnect all power cables from the
motor controller. Reverse Bias:
Electrocution/burn hazard. Contact Test Desired result

could result in death or serious Positive Lead Negative Lead
injury. Remove all rings, watches B+ M- Rises to .0L V
and other jewelry.
M- B- Rises to .0L V
3 Press the release tab on the motor controller
harness connector and remove the motor B+ F1 Rises to .0L V
controller harness connector from the motor
B+ F2 Rises to .0L V
controller.
F1 B- Rises to .0L V
4 Set an ohmmeter to diode test mode.
F2 B- Rises to .0L V
4 - 44 Z-30/20N • Z-30/20N RJ Part No. 106373

June 2008 Section 5 • Fault Codes
Fault Codes
Before Troubleshooting:
Read, understand and obey the safety rules and
operating instructions printed in the
Genie Z-30/20N Operator’s Manual on your
machine.
Observe and Obey: Be sure that all necessary tools and test
equipment are available and ready for use.
Troubleshooting and repair procedures shall be
completed by a person trained and qualified on Be aware of the following hazards and follow
the repair of this machine. generally accepted safe workshop practices.
Immediately tag and remove from service a Crushing hazard. When testing
damaged or malfunctioning machine. or replacing any hydraulic
component, always support
Repair any machine damage or malfunction the structure and secure it
before operating the machine. from movement.
Unless otherwise specified, perform each Electrocution/burn hazard. Contact
repair procedure with the machine in the with electrically charged circuits
following configuration: could result in death or serious
• Machine parked on a firm, level surface injury. Remove all rings, watches
• Boom in stowed position and other jewelry.
• Turntable rotated with the boom between Bodily injury hazard. Spraying
the non-steer wheels hydraulic oil can penetrate and
• Key switch in the off position with the
key removed
• Wheels chocked gradually. Do not allow oil to
• All external AC power supply disconnected squirt or spray.
from the machine Note: Perform all troubleshooting on a firm, level
surface.
Note: Two persons will be required to safely

perform some troubleshooting procedures.
Part No. 106373 Z-30/20N • Z-30/20N RJ 5-1

Section 5 • Fault Codes June 2008
FAULT CODES REV A
Tip-over hazard. When adjusting The controller status indicator light will flash a fault
the raised drive speed settings, code to aid in troubleshooting. This indicator light
the maximum raised drive speed is mounted on the tilt level sensor mounting
must not exceed 0.6 mph / 1Km/h bracket, located behind the cover on the ground
or 40 feet/45 seconds / controls side.
12.2 meters / 45 seconds. If the
machine is allowed to drive faster Fault codes are two digits. The controller status
than specification, the machine indicator light will blink the first digit of a two digit
could become unstable and will tip code, pause for 1 second, and then blink the
over. second digit. There will be a 2 second pause
between codes.
Note: Additional troubleshooting of the fault codes

may by accomplished by using the hand-held For example: the indicator light blinks 4
pendant motor controller programmer (Genie part consecutive times, pauses for 1 second, and then
number 56303). blinks 1 time. That would indicate Fault Code 41.
Note: 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.
5-2 Z-30/20N • Z-30/20N RJ Part No. 106373

REV A
Fault Code Chart
Programmer
Fault Code Condition Possible Causes Solution
Diagnostic Display
Push in the ground

control red Emergency
The key switch or Stop button to the off
Emergency Stop position and wait for 5
Fault code LED button(s) was cycled on seconds. Pull out the
COMMUNICATION
is off or is on, ERROR
Machine will not drive. and off faster than 5 ground control red
but not blinking seconds OR controller Emergency Stop button
sensed an internal error to the on position. If
during start up. problem persists,
replace the motor
controller.
01 Normal operation.
The motor controller Replace the motor
12 HW FAILSAFE 1-2-3 Machine will not drive.
failed self test. controller.
The motor controller
Test the motor
has a internal short
13 M- SHORTED Machine will not drive.
between M- and B-
controller. See Repair
Section.
terminals.
Check for loose or open
connections at the drive
Motor wiring is loose motors and motor
OR motor is defective controller OR replace
FIELD OPEN Machine will not drive.
OR motor controller has the defective drive
an internal short. motor OR test the motor
controller. See Repair
Section.
Defective motor Replace the motor
ARM SENSOR Machine will not drive.
controller. controller.
Defective motor Replace the motor
FLD SENSOR Machine will not drive.
controller. controller.
Part No. 106373 Z-30/20N • Z-30/20N RJ 5-3

FAULT CODE CHART REV A
Programmer
Diagnostic Display
Open in wht/red wire

#32 at pin 14 or red/wht
wire #29 at pin 16 on
the motor controller
going from drive joystick
Consult Genie
to pins 14 and 16 at the
21 THROTTLE FAULT 1 Machine will not drive.
motor controller OR pin
Industries Service
Department.
14 is internally shorted
to power or ground OR
the potentiometer on
the drive joystick is
defective.
Pin 14 (wht/red #32) is

shorted to power or
Consult Genie
ground OR the
THROTTLE FAULT 2 Machine will not drive. Industries Service
potentiometer on the
Department.
drive joystick is
defective.
Main contactor (PR1) Replace main contactor

coil defective OR brake PR1 or brake release
31 CONT DRVR OC Machine will not drive.
release relay CR5 relay CR5 OR replace
defective. the motor controller.
Main contactor (PR1)

contacts stuck closed
OR grn wire at pin 17 on
motor controller shorted Consult Genie
32 MAIN CONT WELDED Machine will not drive. to ground OR open in Industries Service
motor armature wiring Department.
OR motor controller has
an internal short to
ground.
Repair short between

B+ terminal on motor
controller and ground
External short between
OR replace motor
B+ terminal on motor
controller.
33 PRECHARGE FAULT Machine will not drive. controller and ground
Note: Short can be on
OR motor controller is
any part of circuit
defective.
connected to the B+
terminal on the motor
controller.
5-4 Z-30/20N • Z-30/20N RJ Part No. 106373

REV A FAULT CODE CHART
Programmer
Diagnostic Display
Motor controller does
Consult Genie
not detect the main
34 MISSING CONTACTOR Machine will not drive.
contactor PR1 or brake
Industries Service
Department.
release relay CR5.
Main contactor PR1 or

brake release relay CR5
did not close OR open
Consult Genie
in org/red wire to PR1
MAIN CONT DNC Machine will not drive. Industries Service
and/or CR5 OR main
Department.
contactor and/or brake
release relay is
defective.
Completely charge
batteries OR check
Battery supply voltage battery cable condition
LOW BATTERY
41 VOLTAGE
Machine will not drive. to motor controller less OR check for corrosion
than 32V DC. or loose connections at
battery terminals and
motor controller.
Battery supply voltage

to motor controller more Be sure the battery
than 55V DC OR charger is disconnected
42 OVERVOLTAGE Machine will not drive. machine is being OR check for loose
operated with the battery cables or poor
battery charger plugged connections.
in.
Operate machine within

Machine being operated
specified temperature
outside of temperature
limits OR check for
range of -13°F to
debris around motor
185°F / -25°C to 85°C
controller preventing
43 THERMAL CUTBACK Machine will not drive. OR machine being
proper cooling of the
driven under excessive
controller OR check for
load OR motor
mechanical restrictions
controller is not being
causing excessive load
cooled sufficently.
on the machine.
Part No. 106373 Z-30/20N • Z-30/20N RJ 5-5

5-6 Z-30/20N • Z-30/20N RJ Part No. 106373

June 2008 Section 6 • Schematics
Schematics
About This Section
There are two groups of schematics in this section.
Electrical Schematics
Observe and Obey: could result in death or serious
Troubleshooting and repair procedures shall be and other jewelry.
completed by a person trained and qualified on
Hydraulic Schematics
the repair of this machine.
Immediately tag and remove from service a Bodily injury hazard. Spraying
damaged or malfunctioning machine.
Repair any machine damage or malfunction connections very slowly to allow
before operating the machine. the oil pressure to dissipate
Before Troubleshooting: or spray.
Read, understand and obey the safety rules General Repair Process
and operating instructions printed in the
Genie Z-30/20N Operator's Manual on your
machine.
Be sure that all necessary tools and test Malfunction Identify Troubleshoot
equipment are available and ready for use. discovered symptoms
problem
still exists
Return to Inspect Perform

service problem and test repair
solved
Part No. 106373 Z-30/20N • Z-30/20N RJ 6-1

Section 6 • Schematics June 2008
Load Sensor Option Diagram

(before serial number 6290) REV A
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
BRN
TS9 TS13 TS16

1 2 3 4 5 6 7 8 9 10
R
+
LABEL DESCRIPTION L1 L2 L
P2 EMERGENCY STOP BUTTON
P3 HORN BUTTON
DP1 DRIVE CONTROLLER
BP1 BOOM FUNCTION SPEED CONTROLLER
TS1 AUXILIARY TOGGLE SWITCH
TS7 PLATFORM ROTATE TOGGLE SWITCH
TS8 JIB BOOM UP/DOWN TOGGLE SWITCH
TS9 PLATFORM LEVEL TOGGLE SWITCH
NO NC NC
TS10 SECONDARY BOOM TOGGLE SWITCH
TS11 PRIMARY BOOM TOGGLE SWITCH
TS12 TURNTABLE ROTATE TOGGLE SWITCH
TS1
P3 P2 DP1
TS13 BOOM EXTEND TOGGLE SWITCH
TS15 DRIVE ENABLE TOGGLE SWITCH
TS16 JIB ROTATE TOGGLE SWITCH (OPTION)
L1 DRIVE ENABLE LIGHT
L2 OVERLOAD LIGHT (OPTION)
6-2 Z-30/20N • Z-30/20N RJ Part No. 106373

June 2008 Section 6 • Schematics
Electrical Symbols Legend

REV B
P1
+
P4
Emergency
ORG/BLK-1
Stop button HORN
normaly closed LED -
Horn button
Wire color 6V DC normally open
with cable TB17
Battery
number
FS1
FB BLK
GRN/BLK
TB20
Foot switch
Flashing
beacon
Terminal Tilt sensor PSI
+
Pressure
Ground HM RED switch
GRN
AP1 supression _
circuit
BLK/RED
WHT
Hour meter
Quick disconnect BP1
terminal
Circuit breaker Boom function
speed controller Horn
BLK #21 TB21 J1
CR4
T-circuit Brake release NC NO

connects at terminal jack LS3
Relay contact
normaly open Solenoid or
Limit switch
relay coil
TS3
T-circuit
START
ENGINE
connected PR4 Fuse

Relay contact Toggle switch
normally closed SPDT
Relay panel PLATFORM
KS1
contactor
Connection TS6 GROUND
no terminal A2 S2
Key switch
LEFT
RIGHT
LS1 (before serial number 6290)

NOHC
A1 S1
Toggle switch
DPDT Limit switch
Drive motor normally open
Circuits crossing
no connection held closed
PUMP
PLATFORM
KS1
Auxiliary / Primary GROUND

Diode lift pump Key switch
(after serial number 6289)
Part No. 106373 Z-30/20N • Z-30/20N RJ 6-3

Section 6 • Schematics June 2008
Hydraulic Symbols Legend

REV B
Hydraulic filter Fixed displacement

pump Normally closed
poppet valve
Counterbalance valve
(dual)
Check valve
Flow regulator valve
Normally open
poppet valve
0.045 /
1.14 mm
Counterbalance valve
Orifice (single)
Relief valve
Brake
Regen circuit
Differential
sensing valve
Dual relief valve
Shutoff valve
Double acting
cylinder
Solenoid operated
Filter with by-pass proportional valve
M check valve
Pump prime mover
(motor)
N.O.
COM
N.C.
Bi-directional motor
Solenoid operated 3 position,

4 way, directional valve
Pressure switch
6-4 Z-30/20N • Z-30/20N RJ Part No. 106373

April 2007 Section 6 • Schematics
Power Cable Diagram

Section 6 • Schematics April 2007
Power Cable Diagram

A B C D E F G H I J K L M N
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
+ A2 +
RED (4 Ga)
BLK (4 Ga)
4 LIFT PUMP
(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
CONTROLLER
AUXILIARY
(PR1) F3
F1 LIFT PUMP
F2 100A
500A CONTACTOR
6 100A (PR3)
PRIMARY 3 DIODES
LIFT PUMP 48V DC

BLK (2 Ga)
CONTACTOR (PR2)
MOTOR
CONTROLLER
7 RED (10 Ga) F1 F2
(10 Ga)
B- M- B+
RED
BLK (2 Ga)
F1
8 A1
F2 A2
LEFT SIDE BLK (2 Ga) BLK (2 Ga) RIGHT SIDE
F1 F2
DRIVE MOTOR A1 A2 DRIVE MOTOR
RED (10 Ga)
6-5 Z-30/20N • Z-30/20N RJ Part No. 106373

Power Cable Diagram

REV B (from serial number 6290 to 8354)
N M L K J I H G F E D C B A
LEFT SIDE AMMETER RIGHT SIDE 1

BATTERY PACK BLK (10) + BATTERY PACK
- WHT (10) -
-
+ +
BLK (2)
BLK (2)
- -
AC
BATTERY
+ +
CHARGER
- -
PRIMARY
LIFT PUMP 3
+ +
A1 D1 BLK (4)
- D1 -
WHT (10)
BLK (10)
AUXILIARY
+ A2 +
PUMP
RED (4)
BLK (4)
4
RED (4)
RED (2)
RED (2)
AP2 AP1
RED (2) BLK (2)
+ + - -
BLK (2) RED (2)
- - + + 5
24V DC
BATTERY
CONTROLLER 3 DIODES F3
AUXILIARY PUMP
100A
DRIVE CONTACTOR (PR3)
F2 F1
PRIMARY LIFT 100A CONTACTOR
500A
PUMP CONTACTOR (PR2) (PR1) BLK (2) 6
48V DC
MOTOR
CONTROLLER
NOTES:
9. WIRE GAUGE NOTED IN PARENTHESES AFTER
WIRE COLOR. RED (10) F1 10 F2 RED (10) 7
B- M- B+
10 DO NOT ROUTE POWER CABLES ACROSS
FRONT OF MOTOR CONTROLLER. DOING SO
CAN AFFECT INTERNAL CURRENT SENSORS, RIGHT SIDE
CAUSING REDUCED MOTOR PERFORMANCE. DRIVE MOTOR
BLK (2)
F2 F1 8
A2 A1
LEFT SIDE BLK (2) BLK (2)

F1 F2
DRIVE MOTOR
A1 A2
RED (10)
Part No. 106373 Z-30/20N • Z-30/20N RJ 6-6

Power Cable Diagram

(from serial number 6290 to 8354)
Power Cable Diagram

Power Cable Diagram

(after serial number 8354) REV A
LEFT SIDE AMMETER RIGHT SIDE
BATTERY PACK BK (10) BATTERY PACK
+
1
_ WH (10) _ _
+ +
_ _
2 AC
+ +
BATTERY
CHARGER
_ _
+ PRIMARY +
LIFT PUMP
3 A1 D1 BK (4)
_
_ D1 _
+ AUXILIARY
A2 +
LIFT PUMP
RD (4)
BK (4)
WH (10)
BK (10)
RD (4)
RD (2)
BK (2)
4
BK (2)
RD (2)
AP2 AP1
RD (2) BK (2)
+ + _ _
_ _ BK (2) RD (2)
+ +
24V
5 BATTERY
CONTROLLER 3 DIODES F3
100A
DRIVE CONTACTOR
F2 F1 (PR1)
100A 500A
AUXILIARY LIFT
BK (2) PUMP CONTACTOR
48V (PR3)
PRIMARY LIFT
6 NOTE: WIRE GAUGE NOTED IN PAENTHESES AFTER WIRE COLOR.
PUMP CONTACTOR
(PR2)
CURTIS / SEPEX
MOTOR CONTROLLER
RD (10) F1 F2 RD (10)
B- M- B+
7
BK (2)
F2 A2 A1 F1
BK (2) BK (2)
8 F1 F2
A1 A2
RD (10)
LEFT SIDE RIGHT SIDE
DRIVE MOTOR DRIVE MOTOR
6-7 Z-30/20N • Z-30/20N RJ Part No. 106373

Power Panel Diagram

REV A (before serial number 6290)
RED #CR3
1
RED #CB1
GRN/WHT #CR3
WHT/RED #32
RED/WHT #29
2
RED/BLK #CR5
ORG/RED #42
ORG/RED #CR20
3
F4
10A
48V DC 24V DC
MOTOR
CONTROLLER 4
ORG/RED #CR2
ORG/RED #CR20
ORG/RED
ORG/RED
PR2 PR3
AUXILIARY
PRIMARY
LIFT PUMP
PR1
PUMP
5
DRIVE
CONTACTOR CONTACTOR CONTACTOR
24 23 22 21 20 19 18 17 16 15 14 13 GRN/WHT #CR3 BRN

12 11 10 9 8 7 6 5 4 3 2 1
GRN
BLK GRN/WHT #PR2 CR20
LIFT PUMP
CONTACTOR 6
RELAY
GRN/WHT #PR2
BRN CR20 LIFT PUMP CONTACTOR

BRN RELAY SOCKET WIRING
(WIRE INSERTION SIDE SHOWN)
7
BRN #CB2
WHT/BLK #31
WHT #30 8
BLK #L3
ORG #40
BLU/WHT #12
ORG/RED #CR2
Part No. 106373 Z-30/20N • Z-30/20N RJ 6-8

Power Panel Diagram

Power Panel Diagram

Power Panel Diagram

(from serial number 6290 to 8354) REV A
RED #CR3
1 RED #CB1
GRN/WHT #CR3
WHT/RED #32
RED/WHT #29
2 RED/BLK #CR5
ORG/RED #42
ORG/RED #CR20
F4
10A
48V DC 24V DC
MOTOR
CONTROLLER
4
ORG/RED #CR2
ORG/RED #CR20
ORG/RED
ORG/RED
PR2 PR3
PRIMARY PR1 AUXILIARY
LIFT PUMP DRIVE PUMP
5 CONTACTOR CONTACTOR CONTACTOR
24 23 22 21 20 19 18 17 16 15 14 13 GRN/WHT #CR3 BRN

12 11 10 9 8 7 6 5 4 3 2 1
GRN
BLK GRN/WHT #PR2 CR20
LIFT PUMP
CONTACTOR
6 RELAY
GRN/WHT #PR2
BRN CR20 LIFT PUMP CONTACTOR

BRN RELAY SOCKET WIRING
7
BRN #CB2
WHT/BLK #31
WHT #30
8
BLK #L3
ORG #40
BLU/WHT #12
ORG/RED #CR2
6-9 Z-30/20N • Z-30/20N RJ Part No. 106373

Power Panel Diagram

REV A (after serial number 8354)
C49-1 R27AUX RD
1
C49-11 C19LPE GR/WH
C49-6 C32JSL WH/RD
C49-3 C29JSH RD/WH
C49-2 C48BRK RD/BK

2
C49-10 R42BAT OR/RD
OR/RD #CR20
3
F4
10A
48V 24V
CURTIS SEPEX
MOTOR CONTROLLER
4
C49
OR/RD
OR/RD
OR/RD #CR2 P42BAT
OR/RD #CR20
PR2 PR1 PR3
PRIMARY DRIVE AUXILIARY
LIFT PUMP CONTACTOR LIFT PUMP
CONTACTOR GR CONTACTOR
5
24 23 22 21 20 19 18 17 16 15 14 13 SEE
12 11 10 9 8 7 6 5 4 3 2 1 DETAIL-A
P182BAT BK R42BAT GR/WH #PR2 CR20

LIFT PUMP
CONTACTOR
RELAY
GR/WH #CR3 C19LPE BR

6
BR
BR
GR/WH #PR2 R42BAT
C49-5 C31REV WH/BK

DETAIL-A
7
CR20
C49-4 C30FWD WH
RELAY SOCKET WIRING
C49-7 C178CSL BK
C49-9 C4OLS OR
C49-8 C12FTS BL/WH
C48-3 01GND BR 8
C48-2 P42BAT OR/RD
C48
C48-1 P182BAT RD
Part No. 106373 Z-30/20N • Z-30/20N RJ 6 - 10

Power Panel Diagram

Electrical Schematic
(before serial number 6290) REV B
P2 FS1
1 BLK-FS
WHT-FS
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
2 HORN
+ A1
KS1 PLT BLK #22
WHT-2
10 A P1 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
4 21
LS4
RED
BLU/WHT #12
ORG/RED #42
ORG/RED
RED/BLK-1
ORG/RED
RED/WHT
F4
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
+
TB28 30 86
-
RED/BLK
F2 + RED
ORG/RED
PR1 PR1 ENABLE
100A CR2
OFF-LIMIT SPEED INPUT
21
L3 87 85
5 LS2
+
-
RED #CB1
22
DIODE RETURN
86 30
+48V DC INPUT
BLK-6
TB9
+
CR1
-
2-WIRE POT. 16
INTERLOCK
BRAKE/REL
FORWARD
BLK
GRN
POT. LOW
REVERSE
BLK
85 87
RED/WHT #23
RED/BLK #28
BLK/RED #CR4
TB49
BLK-7
+
-
2
9
10
11
14
20
1
AP2 BLK 17
14
BLK BLK
F3 CURTIS 1244 5 STATUS LED
RED RED 100A * Shown LS1*
6 SEPEX CONTROLLER B- 13
WHT-7
24V DC with
AP1
BLK #22
F1 M- B+ F2 boom
+24V DC PR3 PR2 extended
RED
WHT
LS1
+
BOOM
EXTEND/ 30
CR4 86
RETRACT
F2 A2 A2 F1
RED
RED
WHT
LS2 87 85
MOTOR
+
BLK/RED
-
PRIMARY
MOTOR BOOM FB
+
UP/DOWN
-
BLK
F1 A1 A1 F2
BLK
PUMP PUMP
7 LS4
SECONDARY
BRN
BOOM
BRN
+
UP/DOWN
-
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
RELAY
POWER
48V DC
AP1 TB52
8 BRN
BLK (24V DC)
6 - 11 Z-30/20N • Z-30/20N RJ Part No. 106373

REV B (before serial number 6290)
1
LVI/BCI OPTION JP1 (REMOVE FOR CE MODELS)
WHT
ORG/RED-1 DP1
RED
WHT
WHT
ORG/RED
BCI
4 5 3 1 6
TURNTABLE SECONDARY PRIMARY PRIMARY JIB BOOM LIFT
ORG
JIB
O/B
PLATFORM
O/R
TS12 ROTATE TS10 BOOM TS11 BOOM TS13 BOOM TS9 TS7 PLATFORM TS8 TS16 ROTATE BLK 2 7
LEVEL ROTATE BOOM
3 REV 8
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 10 TS15 DRIVE
7
CR19
RESET
L.V.I.
DISCHARGE STEER
ENABLE 2
6 CR19 5 CR19 AUX
SET TO "B" SET TO "N" ORG/RED
RED BRN ON +
4 3 8 L1
ORG/RED
DRIVE
ENABLE
WHT-1 LED
WHT/BLK-1
RED/WHT-1 RED
BLU-JIB RED-JIB
BLK-JIB BP1 BCI OPTION
3
GRN/BLK-3
WHT/RED-1 YEL-JIB 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
BLU/RED-3
WHT-3
ORG-JIB WHT-JIB ROTARY

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

RED TS51
PRESSURE SWITCH
BRAKE RELEASE
AUX PLATFORM
POWER CONTROL BOX
GROUND
87
TB13 4
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
BRN-2
BLK-5
RED/WHT
WHT-5
ORG/RED
BOOM LVL ROT
RED DN UP DN RET EXT DN UP R DN UP
RIGHT
L UP L
LEFT
R
PS1
RED GRN/WHT #19 GRN/WHT #19
TB5 TB19
TB27
TB7 TB18 TB43 TB47
GRN/WHT
ORG/RED (48V)
TB4 TB11 TB10 TB2 TB1 TB8 RED/WHT
TB17 TB44 TB46
TB48
JIB BOOM ROTATE OPTION
5
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 LS3
WHT #4
14
WHT/BLK #5
TB15 21 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
BRN-5
RED-5
PLATFORM LEVEL 87A * Shown
+
GRN/WHT
5 6 CR10 CUTOUT with boom
7
HM rotated past
CE VERSION
RED
8 either
1 2 ONLY non-steer
+ wheel
ORG/BLK #15
ORG #14
TB16
CR20
30 85 6
87 86
A3 +
A2
(GND)
FUNCTION
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
7
BRN
BLK (24V DC)
COIL
CONTACTOR
PUMP
AUXILIARY
PR3
8
Part No. 106373 Z-30/20N • Z-30/20N RJ 6 - 12

(from serial number 6290 to 8354) REV B
1
BL/WH-1
TB134 P2 FS1
BLK-2 BLK-FS
WHT-FS WHT
1 3
4 5
ORG/RED-1
5
RED/WHT-3
5
U33
ORG/RED-1
6 7 LS18 7
RED
KS1
2 CB1
WHT-2
12 8 + TILT
PLT TB22
10A P1 BLK #22
P3 D39 ALARM
HORN (A1) L4
L48
GND A6 L45 D40
BLU/RED-1 6
RED 5
5
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 RED
21
BLU/WHT #12
ORG/RED #42
ORG/RED
ORG/RED
4 F4
WHT-8
F1 85 CR5
AP2 10A
RED RED 48V DC 500A
RED/BLK-1
86
BLK/RED-3
PR1 TB50 TS55
+48V DC
FUNCTION
3
WHT-6
ENABLE
-
+
RED/WHT
F2
RED/WHT
RED/BLK
+
CONTACTOR
DRIVE
OFF-LIMIT SPEED INPUT
100A
TB23 TB28
21 RED
LS2
+
DIODE RETURN
RED #CB1
22
+48V DC INPUT
5 BLK-6
CR2
2-WIRE POT.
-
TB9
+
INTERLOCK
BRAKE/REL
30 86
FORWARD
POT. LOW
REVERSE
BLK
GRN
ORG/RED
BLK
RED/WHT #23
RED/BLK #28
BLK/RED #CR4
TB49 87 85
BLK-7
+
2
9
10
11
CR1
14
16
20
86 30
1
AP2BLK BLK 17
BLK 14
F3 5 STATUS LED
CURTIS 1244 LS1 2
(L3)
STATUS LED
CONTROLLER
DRIVE
COIL-PR1
CONTACTOR
DRIVE
100A 85 87
RED RED SEPEX CONTROLLER B- 13
WHT-7
24V DC
AP1 A C
BLK #22
F1 M- B+ F2
6 +24V DC PR3 PR2
RED
WHT
-
+
30
CR4 86
F2 A2 A2 F1
RED
RED
WHT
87 85
BLK/RED
+
FB
-
+
BLK
F1 A1 A1 F2
BLK
PUMP PUMP
LEFT RIGHT B
MOTOR MOTOR
BRN
BRN
7
+
(GND)
GROUND
BLK
BLK
BLK
10 A
BLK BLK BRN BRN (GND)
UP/DOWN
SECONDARY
LS4
UP/DOWN
PRIMARY
LS2
LS1 - EXT/RET
HORN
HORN RELAY
LIFT PUMP
AUXILIARY
CHARGER
48V DC BATTERY
LIFT PUMP
PRIMARY
TILT SENSOR
RELAY CR1
POWER
48V DC
RELAY CR2
POWER
48V DC
TB52
AP1 CB2
OPTION
BEACON
FLASHING
BRN
BLK (24V DC)
8
NOTES:
1. ALL LIMIT SWITCHES WITH BOOM IN STOWED POSITION EXCEPT AS NOTED 5 CE & PLATFORM LOAD SENSE OPTION.
2 SWITCH SHOWN WITH BOOM EXTENDED 6 ADD D40 ONLY IF UNIT HAS BOTH L4 & L48.
3 REDUNDANT COIL SUPPRESION DIODE FOR PR1 IS INSIDE CONTROLLER BETWEEN J1-9 AND J1-17. 7 ANSI/CSA ONLY
6 - 13 Z-30/20N • Z-30/20N RJ Part No. 106373

REV B (from serial number 6290 to 8354)
LVI/BCI OPTION JP1 (REMOVE FOR CE VERSION)

WHT
ORG/RED-1 DP1
RED
WHT
WHT
ORG/RED
BCI
4 5 3 1 6
SECONDARY JIB JIB BOOM LIFT
ORG
TURNTABLE PRIMARY PRIMARY
O/R
O/B
TS12 TS10 TS11 TS13 TS9 PLATFORM TS7 PLATFORM TS8 TS16 2 7
BLK
L
ROTATE
R DN
BOOM
UP DN
BOOM
UP RET
BOOM
EXT DN
LEVEL
UP L
ROTATE
R DN
BOOM
UP L
ROTATE
R
3 REV
DRIVE
8 2
4 9
8 7 6 5 4 3 2 1 TS1 FWD R L TS15
5 10 DRIVE
STEER
RESET DISCHARGE ENABLE
7 CR19 L.V.I.
6 CR19 5 CR19 AUX
SET TO "B" SET TO "N" ORG/RED
BRN ON +
4 3 8 DRIVE
ORG/RED ENABLE
LED (L1)
WHT-1
WHT/BLK-1
3
RED/WHT-1 RED
BLU-JIB BLK-JIB RED-JIB BCI OPTION
BP1
GRN/BLK-3
WHT/RED-1 YEL-JIB RED
BLU/BLK-1
BLU-1
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
BLU/RED-3
WHT-3
ORG-JIB WHT-JIB ROTARY

OEM
+
ORG-1
ORG/BLK-1
GRN BRN
GRN/BLK-1
GRN-1
F
GRN-3
FLOW
JIB CONTROL BLK/RED E
BCI
MANIFOLD
BRN-JIB
GROUND
TB12
4
BLU/WHT #12
RED TS51
PRESSURE SWITCH
BRAKE RELEASE
AUX PLATFORM
ON CONTROL BOX 87
GROUND TB13
TB36
GRN/WHT-3
WHT/RED-3
RED
CR5 30
TURN SEC PRI PRI JIB
TS62 TS60 TS61 TS63 TS59 PLAT TS57 PLAT JIB
ROT BOOM BOOM BOOM TS58 BOOM TS66 TB37
BRN-2
BLK-5
RED/WHT
WHT-5
ORG/RED
LVL ROT ROT
RED L R DN UP DN UP RET EXT DN UP L R DN UP L R
PS1
RED GRN/WHT #19 GRN/WHT #19
TB5
TB7
TB19
TB27 5
TB18 TB43 TB47
GRN/WHT
ORG/RED (48V)
TB4 TB11 TB10 TB2 TB1 TB8 RED/WHT
TB17 TB44 TB46
TB48
JIB 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 LS3
WHT #4
14
WHT/BLK #5
TB15 21
DRIVE
LS2 5 ENABLE
ORG-6 WHT/RED #6 TB6 30 LIMIT
CR3 86 13 22
14 13 SWITCH
RED-6
87
WHT/RED #6
85
BRN-5
RED-5
PLATFORM LEVEL 87A
+
GRN/WHT
5 6 CR10 7 CUTOUT
CE VERSION HM 6
RED
1 2 8 ONLY
+
ORG/BLK #15
ORG #14
TB16
30 CR20 85
87 86
A3 +
A2
(GND)
FUNCTION
(GND)
MANIFOLD
GROUND
7
N.O. COIL
BRAKE RELEASE
COIL
BOOM DOWN
SECONDARY
BOOM UP COIL
SECONDARY
DOWN COIL
PRIMARY BOOM
UP COIL
PRIMARY BOOM
STEER LEFT COIL
TRAVEL ALARM (A2)

BRAKE RELEASE
N.C. COIL
BRAKE RELEASE
COIL
ROTATE LEFT
TURNTABLE
COIL
ROTATE RIGHT
TURNTABLE
STEER RIGHT COIL

RETRACT COIL
PRIMARY BOOM
EXTEND COIL
PRIMARY BOOM
COIL
FLOW CONTROL
PROPORTIONAL
DOWN COIL
PLATFORM LEVEL
UP COIL
PLATFORM LEVEL
RELAY COIL
AUXILIARY CONTROL
HOUR METER
PR2
CONTACTOR COIL
LIFT PUMP
CR20
CONTACTOR RELAY
LIFT PUMP
TB52
OPTION
ALARM
DESCENT
RELAY COIL
CUTOUT
PLATFORM LEVEL
BRN
BLK (24V)
8
CONTACTOR COIL
AUXILIARY PUMP
PR3
NOTES:
5 SWITCH SHOWN WITH BOOM ROTATED PAST EITHER NON-STEER WHEEL
Part No. 106373 Z-30/20N • Z-30/20N RJ 6 - 14

1 C29JSH RD/WH
C32JSL WH/RD
C31REV WH/BK
C30FWD WH
TB134 FS1
P2 RD-(FS) C9P-3
C7P-1 C9P-1 BK BK-(FS)
WH-(FS) C9P-2 P24BAT WH
P26BAT RD
R42BAT OR/RD
2 C132PLI BL/WH
C1P-12
RD
RD
+
P22BAT BK
TILT
ALARM
C1B-12
P3 H1 L48
PLATFORM TB22 HORN
10 A P1
P182BAT RD KS1
CB2
GROUND
C3P-3
C7P-2
C1P-2
C2P-4
C7B-1
C3P-9
C1P-4
C1P-5
C1P-6
C1P-3
C2P-1
1 3
4 5
P22BAT BK
RD
C30FWD WH
C31REV WH/BK
C32JSL WH/RD
C29JSH RD/WH
U33
R42BAT OR/RD
P23BAT WH
C9HRN BK/RD
C133PLA BL/RD
C28TTA RD/BK
C3BAT RD/WH
3 6 7
5
12 8
C7B-2
C2B-1
C3B-9
C1B-2
C3B-3
C2B-4
C1B-4
C1B-5
C1B-6
C1B-3
GR/BK
C48-1 P182BAT RD
RD
C49-4
C49-5
C49-6
C49-3
TB40
4 C40LS C134PWR RD TB134
CR5
C12FTS C12DRE BL/WH
P42BAT OR/RD P42BAT OR/RD C19LPE GR/WH C19LPE GR/WH
C49-10 R42BAT OR/RD TB42 RD
R42BAT OR/RD
RD/WH
OR/RD
WH
WH/RD
OR/RD
WH/BK
OR/RD
F5
10 A F4 P42BAT OR/RD C48-2
C49-8
C49-9
AP2 48V 500 A
86 30
PR1 86 CR2
LED L3
CONTROLLER STATUS
+48 V
C9HRN BK/RD
RD
RD/BK
+
85
PR1
CR5
F2 87
85 30
100 A
OR/RD
BL/WH
CR3 30
5 86
RD 20
87 CR1
C49-2 C48BRK RD/BK
87a
BK
J2-BK
C52-2 WH-8
C52-1 BK-8
P22LS BK
C49-7 C178CSL BK
OFF-LIMT SPD INP
+
LEFT 85 87
DIODE RETURN
BOX
C49-11 C19LPE GR/WH

C182PWR GR
C49-1 R27AUX RD
+
INTERLOCK
+48V INPUT
FORWARD
POT. LOW
REVERSE
POT. HI
LS4 21
(SEC)
+
10
11
14
16
17
20
22
AP2
30
RD/WH
86
U6A
MOTOR CONTROLLER CR4
24 V
6 AP1 F3
100 A
F1 M- B+ F2 B-
J1-WH 87 85
30
CR20
86
+24 V PR3 PR2 A C
87
85
+
33
C11-3 BK-6
C11-4 WH-6
C10-2 WH-7
C10-1 BK-7
RD
WH
+
R19LPE GR/WH
+ FB
PR3
A2 A2 H2
LEFT F2 F1
+
MOTOR
-
RIGHT
WH
RIGHT
BOX F2 F1 A1 A1 MOTOR 21 13
+
+ LS2 LS1
PUMP PUMP CHARGER
(PRI) (EXT) 33
22 14 2
- BK
BRN
7 PR2
BK
+
B
-
BRN
BRN
BRN
GROUND
AC POWER
BK 2 GA 10A TB52
C48-3 GND BR
CB3
AP1 P182BAT BK CR3
LS2-PRI. UP/DWN
RELAY
HORN
LIFT PUMP
PRIMARY
CONTACTOR
PR1 DRIVE
CHASSIS GROUND
PUMP PR3
AUXILIARY LIFT
OPTION
FLASHING BEACON
LIFT PUMP
AUXILIARY
RELAY CR5
BRAKE RELEASE
LS1-EXT/RET
CONTACTOR RELAY
PRIMARY LIFT PUMP
BOX GROUND
BASE CONTROL
HORN
PUMP PR2
PRIMARY LIFT
LS4-SEC. UP/DWN
RELAY CR1
48V POWER
RELAY CR2
48V POWER
TILT SENSOR
8
NOTES:
1. ALL LIMIT SWITCHES SHOWN WITH BOOM IN STOWED POSITION EXCEPT AS NOTED.
2 SWITCH SHOWN WITH BOOM EXTENDED.
3 SWITCH SHOWN WITH BOOM ROTATED PAST EITHER NON-STEER WHEEL.
4. ALL SOLENOID AND RELAY COILS ARE 24VDC EXCEPT WHERE NOTED.
6 - 15 Z-30/20N • Z-30/20N RJ Part No. 106373

REV A (from serial number 8355 to 9346)
C29JSH RD/WH C29JSH RD/WH 1

C32JSL WH/RD C32JSL WH/RD
C31REV WH/BK C31REV WH/BK
C30FWD WH C30FWD WH
LVI/BCI OPTION
P24BAT WH P24BAT WH
R42BAT OR/RD
DP1
TURNTABLE SECONDARY PRIMARY PRIMARY PLATFORM PLATFORM JIB JIB BCI
2
RD-AUX
20K
OR/RD
WH
4 5 3 DRIVE
RD
TS12 ROTATE TS10 BOOM TS11 BOOM TS13 BOOM TS9 LEVEL TS7 ROTATE TS8 BOOM TS16 ROTATE 1
OR/BK
OR/RD
ORG
ENABLE
LEFT
RIGHT
DOWN
DOWN
RIGHT
RIGHT
UP
DOWN
UP
UP
LEFT
RETRACT
LEFT
EXTEND
DOWN
UP
2 TS15
REV 3
FWD 4
7 8 7 6 5 4 3 2 1 5
6 AUXILIARY
CR19 RESET DISCHARGE 6
PUMP L1
2 5 CR19 8 L.V.I. TS1 LIFT
CR19 7 CE OPTION:
SET TO "B" SET TO "N"
1 8 REMOVE
DRIVE
9 JUMPER
L R 10 AND ADD
C1P-10
C4P-1
C3P-12
C4P-4
C1P-1
C1P-11
BP1 RD STEER
RELAY
C3P-11
C2P-6
C2P-5
C2P-3
C3P-10
C4P-5
C4P-6
C47-2
C47-1
C47-4
C47-3
C2P-5
C2P-5
C2P-2
C3P-8
C3P-7
C4P-3
C4P-2
C3P-4
C3P-5
C3P-2
C3P-1
ROTARY
OEM
FLOW
GR
BK/RD
BRN 3
C4P-7
C3P-6
CONTROL +
C27AUX RD
C37SCW BL/BK
C36SCC BL
C12FTS BL/WH
C13DEL BL/RD
C16DE OR/RD
F
C8PBR BK/WH
C15PLD OR/BK
C44JD WH
C7PBE BK
C14PLU OR
C4TRL WH
C5TRR WH/BK
C1PBU RD
C2PBD RD/BK
C18PRL OR
C43JU BK
C44JD GR/BK
C10SBU BL
C43JU GR
C17PRR BL
C46JRL OR
C47JRR OR/BK
C18PRR GR/BK
C46JRL YL
C11SBD BL/BK
C17PRL GR
C47JRR RD
BCI
E
C19LPE GR/WH
C6MFV WH/RD
C1B-1
C3B-12
C1B-11
C1B-10
C4B-1
BCI OPTION
C4B-4
C3B-8
C3B-7
C4B-3
C4B-2
C3B-5
C4B-6
C3B-4
C3B-11
C3B-1
C3B-2
C4B-5
C3B-10
RD
C2B-3
C2B-2
C2B-6
C4B-7
C2B-5
C3B-6
CR5
JIB MANIFOLD
4
C12DRE BL/WH
C19LPE GR/WH TB12
AUXILIARY
RD PUMP
TS51
TS55 FUNCTION
RD
C16DE OR/RD
C12FTS BL/WH
C13DEL BL/RD
ENABLE
BRN
TURNTABLE SECONDARY PRIMARY PRIMARY PLATFORM PLATFORM JIB JIB
ROTATE BOOM BOOM BOOM LEVEL ROTATE BOOM ROTATE
RD
C19LPE GR/WH
TS62 TS60 TS61 TS63 TS59 TS57 TS58 TS66 30
OR/RD
CR5
RIGHT
EXTEND
DOWN
RETRACT
LEFT
RIGHT
UP
UP
RIGHT
DOWN
UP
DOWN
UP
DOWN
LEFT
LEFT
TB37
TB27
C27AUX RD TB36
87
5
PS1
C8-3
C8-4
C7P-3 BATGND BRN

GR/WH C19LPE GR/WH TB19 GR/WH TB48
RD
TB19
TB4 TB5 TB11 TB10 TB2 TB1 TB8 TB7 TB15 TB14
R48BRK
86
TB6 CR3
85
WH-5
BK-5
JIB ROTATE OPTION
TB16
CE OG/BK C11-2 BR-6
WH
WH/BK
BL/BK
BL
RD/BK
RD
BK/WH
BK
WH/BK
BL/BK
BL
R48BRK RD/WH
RD/WH
13
14
LS2 LS3
21
3
6
CE RD C11-1 RD-6 13
30 DRIVE
WH/RD
CR10A 86 14 22 ENABLE
BRN-5
LIMIT
RD-5
87 85
30 86 SWITCH
CR10B
87 85
+
C8-1
C8-2
C7B-3 BATGND BRN

HM
OR
OR/BK
OR
_
+ +
A2
A3 7
(GND)
TB52
CR3
NO COIL
BRAKE RELEASE
NC COIL
BRAKE RELEASE
CONTROL VALVE
PROPORTIONAL
OPTION
DESCENT ALARM
BOOM DOWN
PRIMARY
STEER LEFT
PRESSURE SWITCH
BRAKE RELEASE
BOOM DOWN
SECONDARY
STEER RIGHT
HOUR METER
BOOM UP
PRIMARY
BOOM EXTEND
TRAVEL ALARM
ROTATE RIGHT
TURNTABLE
BOOM UP
SECONDARY
BOOM RETRACT
DOWN COIL
PLATFORM LEVEL
JIB BOOM DOWN

PLATFORM ROTATE LEFT/
ROTATE LEFT
TURNTABLE
UP COIL
PLATFORM LEVEL
CUT-OUT OPTION
PLATFORM LEVEL
JIB BOOM UP
PLATFORM ROTATE RIGHT/
RELAY
AUXILIARY CONTROL
8
NOTES:
1. ALL LIMIT SWITCHES SHOWN WITH BOOM IN STOWED POSITION EXCEPT AS NOTED. 4. ALL SOLENOID AND RELAY COILS ARE 24VDC EXCEPT WHERE NOTED.
2 SWITCH SHOWN WITH BOOM EXTENDED. 5 SETUP ENABLE: USE TO SET THE BATTERY INDICATOR PROFILES.
Part No. 106373 Z-30/20N • Z-30/20N RJ 6 - 16

Electrical Schematic - CE Models

C29JSH RD/WH
1 C32JSL WH/RD
C31REV WH/BK
C30FWD WH
TB134 FS1
P2 RD-(FS) C9P-3
P26BAT RD
R42BAT OR/RD
C132PLI BL/WH C1P-12 RD

2
RD
+
P22BAT BK
LS18 TILT
L4 ALARM L48
C1B-12
P3 H1
PLATFORM TB22 HORN 5
10 A P1
P182BAT RD KS1
D39 6 D40
CB2
GROUND
C3P-3
C7P-2
C1P-2
C2P-4
C2P-1
C7B-1
C3P-9
C1P-4
C1P-5
C1P-6
C1P-3
1 3
4 5
P22BAT BK
RD
C30FWD WH
C31REV WH/BK
C32JSL WH/RD
C29JSH RD/WH
U33
R42BAT OR/RD
P23BAT WH
C9HRN BK/RD
C133PLA BL/RD
C28TTA RD/BK
C3BAT RD/WH
6 7
5
3 12 8
H6
C7B-2
C2B-1
C3B-9
C1B-2
C3B-3
C2B-4
L45
C1B-4
C1B-5
C1B-6
C1B-3
GR/BK
C48-1 P182BAT RD
RD
C49-4
C49-5
C49-6
C49-3
TB40
C40LS C134PWR RD TB134
CR5
4 P42BAT OR/RD
C12FTS
C19LPE GR/WH
C12DRE BL/WH
C19LPE GR/WH
P42BAT OR/RD
C49-10 R42ABT OR/RD TB42 RD
R42BAT OR/RD
RD/WH
OR/RD
WH
WH/RD
OR/RD
WH/BK
OR/RD
F5
C49-8
C49-9
AP2 48V 500 A
86 30
PR1 86 CR2
LED L3
CONTROLLER STATUS
+48 V
C9HRN BK/RD
RD
RD/BK
+
85
PR1
CR5
F2 87
85 30
100 A
OR/RD
BL/WH
CR3 30
86
RD 20
87 CR1
C49-2 C48BRK RD/BK
87a
BK
J2-BK
C52-2 WH-8
C52-1 BK-8
P22LS BK
5
C49-7 C178CSL BK
OFF-LIMT SPD INP
+
LEFT 85 87
DIODE RETURN
BOX
C49-11 C19LPE GR/WH

C182PWR GR
C49-1 R27AUX RD
+
INTERLOCK
+48V INPUT
FORWARD
POT. LOW
REVERSE
POT. HI
LS4 21
(SEC)
+
10
11
14
16
17
20
22
AP2
30
RD/WH
86
U6A
24 V
J1-WH 87 85
F3 30 86
AP1 F1 M- B+ F2 B-
+24 V 100 A CR20
6 PR3 PR2
87
85
A C
+
33
C11-3 BK-6
C11-4 WH-6
C10-2 WH-7
C10-1 BK-7
RD
WH
+
R19LPE GR/WH
+ FB
PR3
A2 A2 H2
LEFT F2 F1
+
MOTOR
-
RIGHT
WH
RIGHT
+
+ LS2 LS1
PUMP PUMP CHARGER
(PRI) (EXT) 33
22 14 2
BK
-
BRN
PR2
BK
+
B
-
BRN
BRN
BRN
7 GROUND
AC POWER
BK 2 GA 10A TB52
C48-3 GND BR
CB3
AP1 P182BAT BK CR3
LS2-PRI. UP/DWN
RELAY
HORN
LIFT PUMP
PRIMARY
CONTACTOR
PR1 DRIVE
CHASSIS GROUND
PUMP PR3
AUXILIARY LIFT
OPTION
FLASHING BEACON
LIFT PUMP
AUXILIARY
RELAY CR5
BRAKE RELEASE
LS1-EXT/RET
CONTACTOR RELAY
PRIMARY LIFT PUMP
BOX GROUND
BASE CONTROL
HORN
PUMP PR2
PRIMARY LIFT
LS4-SEC. UP/DWN
RELAY CR1
48V POWER
RELAY CR2
48V POWER
TILT SENSOR
8 NOTES:
1. ALL LIMIT SWITCHES SHOWN WITH BOOM IN STOWED POSITION EXCEPT AS NOTED. 5 CE & PLATFORM LOAD SENSE OPT.
2 SWITCH SHOWN WITH BOOM EXTENDED. 6 ADD D40 ONLY IF UNIT HAS L4 AND L48.
6 - 17 Z-30/20N • Z-30/20N RJ Part No. 106373


C29JSH RD/WH C29JSH RD/WH

1
C32JSL WH/RD C32JSL WH/RD
C31REV WH/BK C31REV WH/BK
C30FWD WH C30FWD WH
LVI/BCI OPTION
P24BAT WH P24BAT WH
R42BAT OR/RD
DP1
TURNTABLE SECONDARY PRIMARY PRIMARY PLATFORM PLATFORM JIB JIB BCI
2
RD-AUX
20K
OR/RD
WH
4 5 3 DRIVE
RD
TS12 ROTATE TS10 BOOM TS11 BOOM TS13 BOOM TS9 LEVEL TS7 ROTATE TS8 BOOM TS16 ROTATE 1
OR/BK
OR/RD
ORG
ENABLE
LEFT
RIGHT
DOWN
DOWN
RIGHT
RIGHT
UP
DOWN
UP
UP
LEFT
RETRACT
LEFT
EXTEND
DOWN
UP
2 TS15
REV 3
FWD 4
7 8 7 6 5 4 3 2 1 5
6 AUXILIARY
CR19 RESET DISCHARGE 6
PUMP L1
2 5 CR19 8 L.V.I. TS1 LIFT
CR19 7 CE OPTION:
SET TO "B" SET TO "N"
1 8 REMOVE
DRIVE
9 JUMPER
L R 10 AND ADD
C1P-10
C4P-1
C3P-12
C4P-4
C1P-1
C1P-11
BP1 RD STEER
RELAY
C3P-11
C2P-6
C2P-5
C2P-3
C3P-10
C4P-5
C4P-6
C47-2
C47-1
C47-4
C47-3
C2P-5
C2P-5
C2P-2
C3P-8
C3P-7
C4P-3
C4P-2
C3P-4
C3P-5
C3P-2
C3P-1
ROTARY
OEM
FLOW
GR
BK/RD
BRN 3
C4P-7
C3P-6
CONTROL +
C27AUX RD
C37SCW BL/BK
C36SCC BL
C12FTS BL/WH
C13DEL BL/RD
C16DE OR/RD
F
C8PBR BK/WH
C15PLD OR/BK
C44JD WH
C7PBE BK
C14PLU OR
C4TRL WH
C5TRR WH/BK
C1PBU RD
C2PBD RD/BK
C18PRL OR
C43JU BK
C44JD GR/BK
C10SBU BL
C43JU GR
C17PRR BL
C46JRL OR
C47JRR OR/BK
C18PRR GR/BK
C46JRL YL
C11SBD BL/BK
C17PRL GR
C47JRR RD
BCI
E
C19LPE GR/WH
C6MFV WH/RD
C1B-1
C3B-12
C1B-11
C1B-10
C4B-1
BCI OPTION
C4B-4
C3B-8
C3B-7
C4B-3
C4B-2
C3B-5
C4B-6
C3B-4
C3B-11
C3B-1
C3B-2
C4B-5
C3B-10
RD
C2B-3
C2B-2
C2B-6
C4B-7
C2B-5
C3B-6
CR5
JIB MANIFOLD
4
C12DRE BL/WH
C19LPE GR/WH TB12
AUXILIARY
RD PUMP
TS51
TS55 FUNCTION
RD
C16DE OR/RD
C12FTS BL/WH
C13DEL BL/RD
ENABLE
BRN
TURNTABLE SECONDARY PRIMARY PRIMARY PLATFORM PLATFORM JIB JIB
ROTATE BOOM BOOM BOOM LEVEL ROTATE BOOM ROTATE
RD
C19LPE GR/WH
TS62 TS60 TS61 TS63 TS59 TS57 TS58 TS66 30
OR/RD
CR5
RIGHT
EXTEND
DOWN
RETRACT
LEFT
RIGHT
UP
UP
RIGHT
DOWN
UP
DOWN
UP
DOWN
LEFT
LEFT
TB37
TB27
C27AUX RD TB36
87 5
PS1
C8-3
C8-4
C7P-3 BATGND BRN

GR/WH C19LPE GR/WH TB19 GR/WH TB48
RD
TB19
TB4 TB5 TB11 TB10 TB2 TB1 TB8 TB7 TB15 TB14
R48BRK
86
TB6 CR3
85
WH-5
BK-5
JIB ROTATE OPTION
TB16
CE OG/BK C11-2 BR-6
6
WH
WH/BK
BL/BK
BL
RD/BK
RD
BK/WH
BK
WH/BK
BL/BK
BL
R48BRK RD/WH
RD/WH
13
14 21
LS2 LS3
3
CE RD C11-1 RD-6 13
30 DRIVE
WH/RD
CR10A 86 14 22 ENABLE
BRN-5
LIMIT
RD-5
87 85
30 86 SWITCH
CR10B
87 85
+
C8-1
C8-2
C7B-3 BATGND BRN

HM
OR
OR/BK
OR
_
+ +
A3
A2
7
(GND)
TB52
CR3
NO COIL
BRAKE RELEASE
NC COIL
BRAKE RELEASE
CONTROL VALVE
PROPORTIONAL
OPTION
DESCENT ALARM
BOOM DOWN
PRIMARY
STEER LEFT
PRESSURE SWITCH
BRAKE RELEASE
BOOM DOWN
SECONDARY
STEER RIGHT
HOUR METER
BOOM UP
PRIMARY
BOOM EXTEND
TRAVEL ALARM
ROTATE RIGHT
TURNTABLE
BOOM UP
SECONDARY
BOOM RETRACT
DOWN COIL
PLATFORM LEVEL
JIB BOOM DOWN

ROTATE LEFT
TURNTABLE
UP COIL
PLATFORM LEVEL
CUT-OUT OPTION
PLATFORM LEVEL
JIB BOOM UP
PLATFORM ROTATE RIGHT/
RELAY
AUXILIARY CONTROL
8
NOTES:
1. ALL LIMIT SWITCHES SHOWN WITH BOOM IN STOWED POSITION EXCEPT AS NOTED. 4. ALL SOLENOID AND RELAY COILS ARE 24VDC EXCEPT WHERE NOTED.
2 SWITCH SHOWN WITH BOOM EXTENDED. 5 SETUP ENABLE: USE TO SET THE BATTERY INDICATOR PROFILES.
Part No. 106373 Z-30/20N • Z-30/20N RJ 6 - 18


C29JSH RD/WH
1 C32JSL WH/RD
C31REV WH/BK
C30FWD WH
TB134 FS1
P2 RD-(FS) C9P-3
P26BAT RD
R42BAT OR/RD
C132PLI BL/WH RD
C1P-12
2
RD
+
P22BAT BK
TILT
ALARM
C1B-12
P3 H1 L48
PLATFORM TB22 HORN
10 A P1
P182BAT RD KS1
CB2
GROUND
C3P-3
C7P-2
C1P-2
C2P-4
C7B-1
C3P-9
C1P-4
C1P-5
C1P-6
C1P-3
C2P-1
1 3
4 5
P22BAT BK
RD
C30FWD WH
C31REV WH/BK
C32JSL WH/RD
C29JSH RD/WH
U33
R42BAT OR/RD
P23BAT WH
C9HRN BK/RD
C133PLA BL/RD
C28TTA RD/BK
C3BAT RD/WH
6 7
3 12
5
8
C7B-2
C2B-1
C3B-9
C1B-2
C3B-3
C2B-4
C1B-4
C1B-5
C1B-6
C1B-3
GR/BK
C48-1 P182BAT RD
RD
C49-4
C49-5
C49-6
C49-3
TB40
CR5
4 P42BAT OR/RD
C12FTS
P42BAT OR/RD C19LPE GR/WH
C12DRE BL/WH
C19LPE GR/WH
R42BAT OR/RD
RD/WH
OR/RD
WH
WH/RD
OR/RD
WH/BK
OR/RD
F5
C49-8
C49-9
AP2 48V 500 A
86 30
PR1 86 CR2
LED L3
CONTROLLER STATUS
+48 V
C9HRN BK/RD
RD
RD/BK
+
85
PR1
CR5
F2 87
85 30
100 A
OR/RD
BL/WH
CR3 30
86
RD 20
87 CR1
C49-2 C48BRK RD/BK
87a
BK
J2-BK
C52-2 WH-8
C52-1 BK-8
P22LS BK
C49-7 C178CSL BK
OFF-LIMT SPD INP
+
5 LEFT 85 87
DIODE RETURN
BOX
C49-11 C19LPE GR/WH

C182PWR GR
C49-1 R27AUX RD
+
INTERLOCK
+48V INPUT
FORWARD
POT. LOW
REVERSE
POT. HI
LS4 21
(SEC)
+
10
11
14
16
17
20
22
AP2
30
RD/WH
86
U6A
24 V
J1-WH 87 85
F3 30 86
AP1 F1 M- B+ F2 B-
+24 V 100 A CR20
PR3 PR2 A C
6 87
85
+
33
C11-3 BK-6
C11-4 WH-6
C10-2 WH-7
C10-1 BK-7
RD
WH
+
R19LPE GR/WH
+ FB
PR3
A2 A2 H2
LEFT F2 F1
+
MOTOR
-
RIGHT
WH
RIGHT
+
+ LS2 LS1
PUMP PUMP CHARGER
(PRI) (EXT) 33
22 14 2
BK
-
BRN
PR2
BK
+
B
-
BRN
BRN
GROUND BRN
7 AC POWER
BK 2 GA 10A TB52 GND BR

C48-3
CB3
AP1 P182BAT BK CR3
LS2-PRI. UP/DWN
RELAY
HORN
LIFT PUMP
PRIMARY
CONTACTOR
PR1 DRIVE
CHASSIS GROUND
PUMP PR3
AUXILIARY LIFT
OPTION
FLASHING BEACON
LIFT PUMP
AUXILIARY
RELAY CR5
BRAKE RELEASE
LS1-EXT/RET
CONTACTOR RELAY
PRIMARY LIFT PUMP
BOX GROUND
BASE CONTROL
HORN
PUMP PR2
PRIMARY LIFT
LS4-SEC. UP/DWN
RELAY CR1
48V POWER
RELAY CR2
48V POWER
TILT SENSOR
NOTES:
8 1. ALL LIMIT SWITCHES SHOWN WITH BOOM IN STOWED POSITION EXCEPT AS NOTED.
2 SWITCH SHOWN WITH BOOM EXTENDED.
6 - 19 Z-30/20N • Z-30/20N RJ Part No. 106373

1
8
Section 6 • Schematics
6 - 20
ENABLE
SWITCH
DRIVE
3
LIMIT
TB52
L1
BRN C7P-3 BATGND BRN C7B-3 BATGND BRN

A
22
21
C4P-1 C13DEL BL/RD C4B-1 C13DEL BL/RD C8-4 WH-5 BRN-5 C8-2
LS3
C3P-12 C12FTS BL/WH C3B-12 C12FTS BL/WH C8-3 BK-5 RD-5 C8-1
TB12
14
13
C4P-4 C16DE OR/RD C4B-4 C16DE OR/RD

TB16
OR/RD
A2
RD/WH TRAVEL ALARM

ENABLE
DRIVE
+
CR5
B
TS15
R48BRK RD/WH BRAKE RELEASE

Z-30/20N • Z-30/20N RJ
TB48
NC COIL
87
30
CE OPTION:
BRAKE RELEASE
AND ADD
REMOVE
JUMPER
NO COIL
RELAY
PS1 BRAKE RELEASE

PRESSURE SWITCH
TB36
C1P-10 C36SCC BL C1B-10 BL STEER LEFT

RD
TB37
C1P-11 C37SCW BL/BK C1B-11 BL/BK STEER RIGHT

C
R48BRK
GR/WH
10
1
2
3
4
5
6
7
8
9
C31REV WH/BK
C29JSH RD/WH
C32JSL WH/RD
C30FWD WH
DRIVE
P24BAT WH
STEER
LIFT
FWD
REV
L R
DP1
20K
WH/BK HOUR METER

HM
TB19
_
D
C1P-1 C27AUX RD C1B-1

RD-AUX
GR/WH
AUXILIARY
Part No. 106373

PUMP
C27AUX RD
TS1
BCI
C19LPE
AUXILIARY
E
F
LVI/BCI OPTION
April 2007
PUMP
TS51
+
AUXILIARY CONTROL
85
86
RD RD RELAY
5
E
OR/RD
CR3
TB27
BRN
WH/RD
1 2 3 4
5 6 7 8
WH
TB19
C4P-7 C19LPE GR/WH C4B-7

LVI/BCI
C19LPE GR/WH
TB6
C3P-6 C6MFV WH/RD C3B-6 WH/RD PROPORTIONAL

BK
CONTROL VALVE
BK/RD
RD
GR
F
CR19
GR/WH
CONTROL
ROTARY
FLOW
OEM
BP1
WH
7
RIGHT
ROTATE
JIB ROTATE OPTION

TS66
LEFT
JIB
ROTATE
JIB
RIGHT C2P-3 C47JRR OR/BK C2B-3

G
C2P-2 C46JRL OR C2B-2

TS16
LEFT
C2P-5 C46JRL YL
C2P-5 C47JRR RD UP PLATFORM ROTATE RIGHT/
JIB BOOM UP
BOOM

TS58
DOWN JIB BOOM DOWN

JIB
H
LS2
BOOM
JIB
UP C2P-5 C43JU GR C2B-5

13
14
C2P-6 C44JD GR/BK C2B-6

RD-6
BR-6
TS8
DOWN
C47-3 C44JD WH
JIB MANIFOLD
C47-4 C43JU BK
CE RD C11-1
RIGHT
CE OG/BK C11-2
PLATFORM
I
ROTATE
C47-1 C18PRL OR
ALL SOLENOID AND RELAY COILS ARE 24VDC EXCEPT WHERE NOTED.
TS57
LEFT
PLATFORM
SETUP ENABLE: USE TO SET THE BATTERY INDICATOR PROFILES.

C47-2 C17PRR BL
ROTATE
PLATFORM LEVEL
RIGHT C4P-6 C18PRR GR/BK C4B-6 CUT-OUT OPTION
CR10A 86
85
86
85
C4P-5 C17PRL GR C4B-5
CR10B
TS7
LEFT
UP TB14
OR PLATFORM LEVEL
PLATFORM
UP COIL
30
87
OR/BK
LEVEL
PLATFORM LEVEL
TS59
TB15
DOWN DOWN COIL
30
87
J
PLATFORM
LEVEL
UP C4P-2 C14PLU OR C4B-2

C4P-3 C15PLD OR/BK C4B-3
TB7
TS9
DOWN
EXTEND BK BOOM EXTEND
PRIMARY
BK/WH
BOOM
BOOM RETRACT
TS63
TB8
RETRACT
PRIMARY
BOOM
K
EXTEND C3P-7 C7PBE BK C3B-7
4.
5
C3P-8 C8PBR BK/WH C3B-8
TB1
TS13
RETRACT UP RD PRIMARY
ALL LIMIT SWITCHES SHOWN WITH BOOM IN STOWED POSITION EXCEPT AS NOTED.
BOOM UP
PRIMARY
RD/BK PRIMARY
BOOM
TS61
TB2
DOWN BOOM DOWN
SWITCH SHOWN WITH BOOM ROTATED PAST EITHER NON-STEER WHEEL.

PRIMARY
CR19
BOOM
UP C3P-1 C1PBU RD C3B-1

1
5
C3P-2 C2PBD RD/BK C3B-2
TB10
TS11
DOWN
L
SECONDARY
UP BL SECONDARY
BOOM UP
BL/BK SECONDARY
BOOM
TS60
SECONDARY
TB11
DOWN BOOM DOWN
CR19
SWITCH SHOWN WITH BOOM EXTENDED.

BOOM
OR DESCENT ALARM
UP C3P-10 C10SBU BL C3B-10
A3
OPTION
+
6
2
C3P-11 C11SBD BL/BK C3B-11
TS10
DOWN
TB5
RIGHT TURNTABLE
TURNTABLE
WH/BK
ROTATE RIGHT
ROTATE
WH TURNTABLE
M
TS62
TB4
LEFT ROTATE LEFT
TURNTABLE
ROTATE
RD
RIGHT C3P-5 C5TRR WH/BK C3B-5
C3P-4 C4TRL WH C3B-4
NOTES:
TS12
R42BAT OR/RD
LEFT
P24BAT WH
1.
FUNCTION
3
ENABLE
C31REV WH/BK
C29JSH RD/WH
C19LPE GR/WH
C32JSL WH/RD
C12DRE BL/WH
C30FWD WH
REV A
N
TS55
(GND)
CR3
CR5
RD
RD

C29JSH RD/WH
1 C32JSL WH/RD
C31REV WH/BK
C30FWD WH
TB134 FS1
P2 RD-(FS) C9P-3
P26BAT RD
R42BAT OR/RD
C132PLI BL/WH C1P-12 RD

2
RD
+
P22BAT BK
LS18 TILT
L4 ALARM L48
C1B-12
P3 H1
PLATFORM TB22 HORN 5
10 A P1
P182BAT RD KS1
D39 6 D40
CB2
GROUND
C3P-3
C7P-2
C1P-2
C2P-4
C2P-1
C7B-1
C3P-9
C1P-4
C1P-5
C1P-6
C1P-3
1 3
4 5
P22BAT BK
RD
C30FWD WH
C31REV WH/BK
C32JSL WH/RD
C29JSH RD/WH
U33
R42BAT OR/RD
P23BAT WH
C9HRN BK/RD
C133PLA BL/RD
C28TTA RD/BK
C3BAT RD/WH
6 7
5
3 12 8
H6
C7B-2
C2B-1
C3B-9
C1B-2
C3B-3
C2B-4
L45
C1B-4
C1B-5
C1B-6
C1B-3
GR/BK
C48-1 P182BAT RD
RD
C49-4
C49-5
C49-6
C49-3
TB40
CR5
4 P42BAT OR/RD
C12FTS
C19LPE GR/WH
C12DRE BL/WH
C19LPE GR/WH
P42BAT OR/RD
R42BAT OR/RD
RD/WH
OR/RD
WH
WH/RD
OR/RD
WH/BK
OR/RD
F5
C49-8
C49-9
AP2 48V 500 A
86 30
PR1 86 CR2
LED L3
CONTROLLER STATUS
+48 V
C9HRN BK/RD
RD
RD/BK
+
85
PR1
CR5
F2 87
85 30
100 A
OR/RD
BL/WH
CR3 30
86
RD 20
87 CR1
C49-2 C48BRK RD/BK
87a
BK
J2-BK
C52-2 WH-8
C52-1 BK-8
P22LS BK
5
C49-7 C178CSL BK
OFF-LIMT SPD INP
+
LEFT 85 87
DIODE RETURN
BOX
C49-11 C19LPE GR/WH

C182PWR GR
C49-1 R27AUX RD
+
INTERLOCK
+48V INPUT
FORWARD
POT. LOW
REVERSE
POT. HI
LS4 21
(SEC)
+
10
11
14
16
17
20
22
AP2
30
RD/WH
86
U6A
24 V
J1-WH 87 85
F3 30 86
AP1 F1 M- B+ F2 B-
100 A CR20
6 +24 V PR3 PR2
87
85
A C
+
33
C11-3 BK-6
C11-4 WH-6
C10-2 WH-7
C10-1 BK-7
RD
WH
+
R19LPE GR/WH
+ FB
PR3
A2 A2 H2
LEFT F2 F1
+
MOTOR
-
RIGHT
WH
RIGHT
+
+ LS2 LS1
PUMP PUMP CHARGER
(PRI) (EXT) 33
22 14 2
BK
-
BRN
PR2
BK
+
B
-
BRN
BRN
BRN
GROUND
AC POWER
BK 2 GA 10A TB52
C48-3 GND BR
CB3
AP1 P182BAT BK CR3
LS2-PRI. UP/DWN
RELAY
HORN
LIFT PUMP
PRIMARY
CONTACTOR
PR1 DRIVE
CHASSIS GROUND
PUMP PR3
AUXILIARY LIFT
OPTION
FLASHING BEACON
LIFT PUMP
AUXILIARY
RELAY CR5
BRAKE RELEASE
LS1-EXT/RET
CONTACTOR RELAY
PRIMARY LIFT PUMP
BOX GROUND
BASE CONTROL
HORN
PUMP PR2
PRIMARY LIFT
LS4-SEC. UP/DWN
RELAY CR1
48V POWER
RELAY CR2
48V POWER
TILT SENSOR
8 NOTES:
1. ALL LIMIT SWITCHES SHOWN WITH BOOM IN STOWED POSITION EXCEPT AS NOTED. 5 CE & PLATFORM LOAD SENSE OPT.
2 SWITCH SHOWN WITH BOOM EXTENDED. 6 ADD D40 ONLY IF UNIT HAS L4 AND L48.
6 - 21 Z-30/20N • Z-30/20N RJ Part No. 106373

1
8
Section 6 • Schematics

6 - 22
ENABLE
SWITCH
DRIVE
3
LIMIT
TB52
L1
BRN C7P-3 BATGND BRN C7B-3 BATGND BRN

A
22
21
C4P-1 C13DEL BL/RD C4B-1 C13DEL BL/RD C8-4 WH-5 BRN-5 C8-2
LS3
C3P-12 C12FTS BL/WH C3B-12 C12FTS BL/WH C8-3 BK-5 RD-5 C8-1
TB12
14
13
C4P-4 C16DE OR/RD C4B-4 C16DE OR/RD

TB16
OR/RD
A2
RD/WH TRAVEL ALARM

ENABLE
DRIVE
+
CR5
TS15
B
R48BRK RD/WH BRAKE RELEASE

TB48
NC COIL
87
30
Z-30/20N • Z-30/20N RJ
CE OPTION:
BRAKE RELEASE
AND ADD
REMOVE
JUMPER
NO COIL
RELAY
PS1 BRAKE RELEASE

PRESSURE SWITCH
TB36
C1P-10 C36SCC BL C1B-10 BL STEER LEFT

RD
TB37
C1P-11 C37SCW BL/BK C1B-11 BL/BK STEER RIGHT

C
R48BRK
GR/WH
10
1
2
3
4
5
6
7
8
9
C31REV WH/BK
C29JSH RD/WH
C32JSL WH/RD
C30FWD WH
DRIVE
P24BAT WH
STEER
LIFT
FWD
REV
L R
DP1
20K
WH/BK HOUR METER

HM
TB19
_
D
C1P-1 C27AUX RD C1B-1

RD-AUX
GR/WH
AUXILIARY
PUMP
Part No. 106373

C27AUX RD
TS1
BCI
C19LPE
AUXILIARY
E
F
LVI/BCI OPTION
PUMP
TS51
+
April 2007
AUXILIARY CONTROL
85
86
RD RD RELAY
5
OR/RD
E
CR3
TB27
BRN
WH/RD
1 2 3 4
5 6 7 8
WH
TB19
C4P-7 C19LPE GR/WH C4B-7

LVI/BCI
C19LPE GR/WH
TB6
C3P-6 C6MFV WH/RD C3B-6 WH/RD PROPORTIONAL

BK
CONTROL VALVE
BK/RD
RD
GR
CR19
GR/WH
CONTROL
F
ROTARY
FLOW
OEM
BP1
WH
7
RIGHT
ROTATE
JIB ROTATE OPTION

TS66
LEFT
JIB
ROTATE
JIB
RIGHT C2P-3 C47JRR OR/BK C2B-3

G
C2P-2 C46JRL OR C2B-2

TS16
LEFT
C2P-5 C46JRL YL
C2P-5 C47JRR RD UP PLATFORM ROTATE RIGHT/
JIB BOOM UP
BOOM

TS58
DOWN JIB BOOM DOWN

JIB
H
LS2
BOOM
JIB
UP C2P-5 C43JU GR C2B-5

13
14
C2P-6 C44JD GR/BK C2B-6

RD-6
BR-6
TS8
DOWN
C47-3 C44JD WH
JIB MANIFOLD
C47-4 C43JU BK
CE RD C11-1
RIGHT
CE OG/BK C11-2
PLATFORM
I
ROTATE
C47-1 C18PRL OR
ALL SOLENOID AND RELAY COILS ARE 24VDC EXCEPT WHERE NOTED.
TS57
LEFT
PLATFORM
SETUP ENABLE: USE TO SET THE BATTERY INDICATOR PROFILES.

C47-2 C17PRR BL
ROTATE
PLATFORM LEVEL
RIGHT C4P-6 C18PRR GR/BK C4B-6 CUT-OUT OPTION
CR10A 86
85
86
85
C4P-5 C17PRL GR C4B-5
CR10B
TS7
LEFT
UP TB14 OR PLATFORM LEVEL
PLATFORM
UP COIL
30
87
OR/BK
LEVEL
PLATFORM LEVEL
TS59
TB15
DOWN DOWN COIL
30
87
J
PLATFORM
LEVEL
UP C4P-2 C14PLU OR C4B-2

C4P-3 C15PLD OR/BK C4B-3
TB7
TS9
DOWN
EXTEND BK BOOM EXTEND
PRIMARY
BK/WH
BOOM
BOOM RETRACT
TS63
TB8
RETRACT
PRIMARY
BOOM
K
EXTEND C3P-7 C7PBE BK C3B-7
4.
5
C3P-8 C8PBR BK/WH C3B-8
TB1
TS13
RETRACT UP RD PRIMARY
ALL LIMIT SWITCHES SHOWN WITH BOOM IN STOWED POSITION EXCEPT AS NOTED.
BOOM UP
PRIMARY
RD/BK PRIMARY
BOOM
TS61
TB2
DOWN BOOM DOWN
SWITCH SHOWN WITH BOOM ROTATED PAST EITHER NON-STEER WHEEL.

PRIMARY
CR19
BOOM
UP C3P-1 C1PBU RD C3B-1

1
5
C3P-2 C2PBD RD/BK C3B-2
TB10
TS11
DOWN
L
SECONDARY
UP BL SECONDARY
BOOM UP
BL/BK SECONDARY
BOOM
TS60
SECONDARY
TB11
DOWN BOOM DOWN
CR19
SWITCH SHOWN WITH BOOM EXTENDED.

BOOM
OR DESCENT ALARM
UP C3P-10 C10SBU BL C3B-10
A3
OPTION
+
6
2
C3P-11 C11SBD BL/BK C3B-11
TS10
DOWN
TB5
RIGHT TURNTABLE
TURNTABLE
WH/BK
ROTATE RIGHT
ROTATE
WH TURNTABLE
M
TS62
TB4
LEFT ROTATE LEFT
TURNTABLE
ROTATE
RD
RIGHT C3P-5 C5TRR WH/BK C3B-5
C3P-4 C4TRL WH C3B-4
NOTES:
TS12
R42BAT OR/RD
LEFT
P24BAT WH
1.
FUNCTION
3
ENABLE
C31REV WH/BK
C29JSH RD/WH
C19LPE GR/WH
C32JSL WH/RD
C12DRE BL/WH
C30FWD WH
REV A
N
TS55
(GND)
CR3
CR5
RD
RD

Ground Control Panel Wiring Diagram


GRN/WHT-19C
1 BRN-CB2 BLK [OPTION 2] 52 BRN-CH BRN-CR4 GROUND ORG/RED-CH RED-27D
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
2 GRN-1 43 GRN-SP JIB BOOM UP 5 10A 10B
RED/BLK-CH RED-6
ORG/RED-CR1 ORG/RED-1 42 ORG/RED-CH ORG/RED-L3 SWITCHED 48V DC
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
30 DRIVE FORWARD
3 WHT-1 WHT-CH ORG/BLK-3 15 ORG/BLK-CR10B ORG/BLK-SP PLAT. LEVEL DOWN
P1
RED/WHT-1 29 RED/WHT-CH 2-WIRE POT. ORG-3 14 ORG-CR10A ORG-SP PLAT. LEVEL UP
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 CB1
4 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
BLK-5 BLU/WHT-3 12 BLU/WHT-CH FOOTSWITCH WHT-23A
5 L3 BLK-22A
RED
BLU/BLK-3 11 BLU/BLK-MH BLU/BLK-SP SECONDARY BOOM DOWN CB2
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
WHT/BLK-3 5 WHT/BLK-MH WHT/BLK-SP TURNTABLE ROTATE RIGHT ORG-46A
(OPTION)
6 WHT-3 4 WHT-MH WHT-SP TURNTABLE ROTATE LEFT TS66 L R R E
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
1 RED-MH PRIMARY BOOM UP GRN/BLK-18A
RED-3 RED-SP KS1 KEY SWITCH
GRN/WHT-19A TS61 TS57
D C B A TS55 FUNCTION ENABLE TOGGLE SWITCH GRN/BLK-44A D D
TS58 L R
TS58 JIB BOOM UP/DOWN TOGGLE SWITCH GRN-43A
7 TS59 PLATFORM LEVEL TOGGLE SWITCH RED/BLK-2A
U U
TS60 SECONDARY BOOM UP/DOWN TOGGLE SWITCH RED-1A
TS61 PRIMARY BOOM UP/DOWN TOGGLE SWITCH GRN-17A
[* SEE OPTIONAL WIRING] TS63 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
U
J1 BRAKE RELEASE JACK BLU/BLK-11A
8 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
6 - 23 Z-30/20N • Z-30/20N RJ Part No. 106373


RED 134B
BRN
[OPTION 2]
WHT-2
134A
RED-A6 RED-KSI
KEYSWITCH POWER
KEYSWITCH POWER
1
RED/WHT-TILT 134 RED C23-1
BRN-CB2 BLK [OPTION 2] 52 BRN-CH BRN-CR4 GROUND
A3 A2 A2 A6
BRN-5 BRN-2 52 BRN-MH BRN-SP GROUND
WHT-6 WHT-8 50 LS2-LS4 JUNCTION BLU/RED-1
BLK-7 BLK-6 49 LS1-LS2 JUNCTION
BRN RED/WHT-48A BRN
WHT/BLK-SP RED/WHT-CR5 48 RED/WHT-MH RED/WHT-SP BRAKE RELEASE
ORG/BLK-1 47 ORG/BLK-SP ** JIB RIGHT
ORG-1 46 ORG-SP ** JIB LEFT
GRN/BLK-1 44 GRN/BLK-SP JIB DOWN
ORG
GRN-1 43 GRN-SP JIB UP

ORG/RED-CR1 ORG/RED-1 42 ORG/RED-CH ORG/RED-L3 SWITCHED 48V 2
BLK-8 40 ORG-CH OFF-LIMIT SPEED
BLU/BLK-19D BLU/BLK-1 37 BLU/BLK-MH STEER RIGHT GRN/BLK
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 REVERSE
WHT-1 30 WHT-CH FORWARD WHT/BLK-19D/48D
HM 29 2-WIRE POT. BRN-52A HM
RED/WHT-1 RED/WHT-CH
P1 RED/BLK-TILT RED/BLK-1 28 TILT ALARM P1
RED-CR3 RED-1 27 RED-SP AUXILIARY PUMP SELECT
NC
NC 26 LIFT LOCKOUT 3
25 BATTERY LIGHT
NC NC
24 TRACTION CONTROL
23
WHT-7 BLK-C23-4 22 BLK-CR4 BLK-SP +24V TO PLATFORM
CB1 TB36/TB37 GRN/WHT-CR3 19 GRN/WHT-MH LIFT PUMP CB1
WHT/BLK-SP 19 GRN/WHT-SP LIFT PUMP RED-CH KS1
GRN/WHT-3
TS51 18 TS51
SWITCH PANEL
GRN/BLK-3 GRN/BLK-SP PLAT. ROTATE RIGHT
KS1 GRN-3 17 GRN-SP PLAT. ROTATE LEFT
RED-5 ORG/RED-3 16 ORG/RED-CR5 DRIVE ENABLE
J1 NO NO *
*
ORG/BLK-3
ORG-3
15 ORG/BLK-MH *
14 ORG-MH *
ORG/BLK-SP
ORG-SP
PLAT. LEVEL DOWN
PLAT. LEVEL UP
L45 4
WHT-5 BLU/RED-3 13 DRIVE ENABLE LIGHT RED/134A
RED-C23-6
BLK-5 BLU/WHT-3 12 BLU/WHT-CH FOOTSWITCH
BLK-22A
BLU/BLK-3 11 BLU/BLK-MH BLU/BLK-SP SEC. BOOM DOWN RED-27A
BLU-3 10 BLU-MH BLU-SP SEC. BOOM UP ORG/BLK-15A
BLK/RED-CR4 BLK/RED-3 9 HORN BLK-7A
BLK/WHT-3 8 BLK/WHT-MH BLK/WHT-SP BOOM RETRACT BLK/WHT-8A
WHT/RED-6A
BLK-3 7 BLK-MH BLK-SP BOOM EXTEND TS59
TS66 TS63 TS59 TS63
WHT/RED-3 6 WHT/RED-MH WHT/RED-SP BOOM FUNCTION F.C. ORG/BLK-47A
JIB ROTATE ORG-46A D
WHT/BLK-3 5 WHT/BLK-MH WHT/BLK-SP TURN. ROTATE RIGHT
(OPTION)
WHT-3 4 WHT-MH WHT-SP TURN. ROTATE LEFT TS66 L R R E 5
RED/WHT-CR1 RED/WHT-3 3 48V RELAY COIL PWR. U
RED/BLK-3 2 RED/BLK-MH RED/BLK-SP PRIMARY BOOM DOWN ORG-14A
ORG
RED-3 1 RED-MH RED-SP PRIMARY BOOM UP GRN/BLK-18A
TS61 GRN/WHT-19A TS61
TS58 TS57 TS57
ORG D C B A GRN/BLK-44A D D
[* SEE OPTIONAL WIRING]
TS58 L R
[** JIB ROTATE OPTION] GRN-43A
U U
RED/BLK-2A
RED-1A
ORG
GRN-17A
6
RED A6
BLU/WHT-1
BLK 22C
BLK-2
GRN/BLK H6
BRN/GND
WHT/BLK-5A TS62
TS60 TS62 WHT-4A
TS55 D TS60
TS55 L R
U
BLU/BLK-11A
GRN/WHT-19C
ORG/RED-CH RED-27D RED-C23-7
GRN/WHT-CH BLK-22B LABEL DESCRIPTION
BLU-10A A2 BRAKE RELEASE/TRAVEL ALARM
1 2 3 4
A3 DESCENT ALARM (OPTION)
BRN-52A 1 3 4 5 6 7 8 12 A6 PLATFORM OVERLOAD ALARM (CE MODELS)
RED/WHT-TB3D
CB1 CIRCUIT BREAKER, CONTROLS, 10A
BLK/RED-HORN
C23
CB2 CIRCUIT BREAKER, CONTROLS RETURN, 10A 7
CH CHASSIS HARNESS
ORG/RED-42D RED-CH BLK/RED-9D CR CONTROL RELAY
DESCENT ALARM WIRING (OPTION) HM HOURMETER
J1 BRAKE RELEASE JACK
RED/WHT-48C ORG-MH ORG/BLK-MH U33 KS1 KEY SWITCH
CONTROL RELAY I.D. SPARE WIRE LIST L3 CONTROLLER STATUS LED
BLK-1 5 10A 10B L45 PLATFORM OVERLOAD LED (CE MODELS)
CR1 - SECONDARY 48V DC POWER
CR2 - PRIMARY 48V DC POWER
BLK/WHT-1 RED/BLK-CH RED-6 MH MANIFOLD HARNESS
BLK/RED-1
CR3 - AUXILIARY PUMP
GRN/WHT-1 TILT SENSOR RED A RED/WHT-134D
CR4 - HORN ORG/RED-16A
SP SWITCH PANEL
CR5 - BRAKE RELEASE C RED/BLK-28D
WHT TS51 AUXILIARY TOGGLE SWITCH
CR10A - PLATFORM LEVEL CUTOUT (CE ONLY)
CR10B - PLATFORM LEVEL CUTOUT (CE ONLY)
ORG-14B ORG/BLK-15B BLK B BRN-CB2
TS55 FUNCTION ENABLE TOGGLE SWITCH 8
OPTION NUMBERS TS58 JIB BOOM UP/DOWN TOGGLE SWITCH
1 - PLATFORM LEVEL CUTOUT TS59 PLATFORM LEVEL TOGGLE SWITCH
2 - FLASHING BEACON ORG-6 TS60 SECONDARY BOOM UP/DOWN TOGGLE SWITCH
3 - DESCENT ALARM CB2 L3 TS61 PRIMARY BOOM UP/DOWN TOGGLE SWITCH
ORG/BLK-3 15 ORG/BLK-CR10B ORG/BLK-SP PLAT. LEVEL DOWN
ORG-3 14 ORG-CR10A ORG-SP PLAT. LEVEL UP BRN-52D BLK-CH
TS63 BOOM EXTEND/RETRACT TOGGLE SWITCH
TS66 JIB BOOM ROTATE TOGGLE SWITCH (OPTION)
PLATFORM LEVEL CUTOUT (CE MODELS ONLY) BRN-CH ORG/RED-42A U33 PLATFORM OVERLOAD MODULE (CE MODELS)
Part No. 106373 Z-30/20N • Z-30/20N RJ 6 - 24




SWITCH PANEL
1
RD C23-1
RD/WH-48A
A2 A6
TILT SENSOR A
RD RD/WH-134D
2 WH C RD/BK-C1B-2
BR-52A
B
BK BR-CB2
BR-52A
A3 A2
RD 134B
L3
BL/RD C2B-1
BR-52D BK-C49-7
CB2
GN/BK
BR-C48-3 OR/RD-42A WH/BK-19D/48D

BR-52A
3 BR C32-12
NC
P1
NC HM
HM TO TERMINAL BASE
AND CONNECTORS
P1
NC
RD-C48-1
4 NC
CB1
TS51
CB1 KS1
RD/134A L45
TS51
KS1 BK-22A
RD-C23-6
RD-27A
NO NO
5 J1 OR/BK-15A
BK-7A
BK/WH-8A
LABEL DESCRIPTION WH/RD-6A
TS63 TS59
P1 EMERGENCY STOP BUTTON JIB ROTATE OR/BK-C2-3
(OPTION) OR-C2-2 D
KS1 KEY SWITCH
TS66 L R R E
TS51 AUXILIARY SWITCH
U
TS55 FUNCTION ENABLE SWITCH
TS66 TS63 TS59
OR-14A
TS57 PLATFORM ROTATE SWITCH GN/BK-18A
6 TS58 JIB UP/DOWN SWITCH GN/WH-19A TS61 TS57
TS59 PLATFORM LEVEL SWITCH GN/BK-44A
D D
TS60 SECONDARY BOOM UP/DOWN SWITCH BL/WH C1-12
OR TS58 L R
TS61 PRIMARY BOOM UP/DOWN SWITCH BK 22C GN-43A
BK C7-1 U U
TS58 TS61 TS62 TURNTABLE ROTATE SWITCH RD/BK-2A
TS57
OR RD-1A
TS63 BOOM EXTEND/RETRACT SWITCH BR HM(-)
GN-17A
TS66 JIB ROTATE SWITCH (OPTION) WH/BK-5A
RD-C23-6
RD A6
BL/WH C132PLI
BK 22C
BK P22BAT
BR/GND
GN/BK A6 TS62
WH-4A
CB1 CIRCUIT BREAKER, CONTROLS, 10A
D
7 OR CB2 CIRCUIT BRKR., CONTROLS RETURN, 10A
TS55
TS60
L R
J1 BRAKE RELEASE JACK U
TS60 TS62 BL/BK-11A
HM HOURMETER
TS55 RD-C32-7
CH CHASSIS HARNESS
MH MANIFOLD HARNESS BL-10A
SP SWITCH PANEL
1 3 4 5 6 7 8 12
CR CONTROL RELAY
A2 TRAVEL ALARM C32
8 A3 DESCENT ALARM (OPTION)
A6 PLATFORM OVERLOAD (CE OPTION)
DESCENT ALARM WIRING (OPTION)
L3 CONTROLLER STATUS LED U33
PLATFORM OVERLOAD
L45 PLATFORM OVERLOAD LED
(OPTION)
6 - 25 Z-30/20N • Z-30/20N RJ Part No. 106373

Ground Control Panel Terminal Strip Wiring Diagram

REV A (after serial number 8354)
C52 TERMINAL BASE (TB) WIRES FROM CONNECTOR TO CONNECTOR 1

DESCRIPTION CIRCUIT #
LS4-SECONDARY RD/WH (FLASH. BEACON OPT.) 134 RD-C32-1 KEYSWITCH POWER C134PWR
CIRCUIT#
WIRES FROM TO DESC.
UP/DOWN RD/WH-TILT WH C7B-2 134 RD-A6 (CE OPTION) RD-KSI-4 KEYSWITCH POWER C134PWR
WH J2 C11-4 C10-2 LS2-LS4 JUNCTION
BR-CB2 BK (FLASH. BEACON OPT.) 52 BR- MH BR-CR4 GROUND BATGND
C8 BK J1 C11-3 C52-1 LS1-LS2 JUNCTION
BR C8-2 BR C7B-3 52 BR BR-SP GROUND BATGND
OR/BK C47JRR C2B-3 SP JIB ROTATE RIGHT (OPTION)
LS3-DRIVE ENABLE RD/WH-CR5 WH/BK-SP 48 RD/WH-MH RD/WH-SP BRAKE RELEASE C48BRK
OR C46JRL C2B-2 SP JIB ROTATE LEFT (OPTION)
OR/RD-CR1 OR/RD C2B-4 42 OR/RD C49-10 OR/RD-L3 SWITCHED 48V R42BAT
GR/BK C44JD C2B-6 SP JIB DOWN
C11 BL/BK-19D BL/BK C1B-11 37 BL/BK-MH STEER RIGHT C37SCW
GR C43JU C2B-5 SP JIB UP
LS2-PRIMARY
BL-19D BL C1B-10 36 BL-MH STEER LEFT C36SCC
OR C40LS C52-2 CH OFF-LIMIT SPEED 2
RD-CR3 RD C1B-1 27 RD-SP AUXILIARY PUMP SELECT C27AUX
UP/DOWN WH/RD C32JSL C1B-6 CH JOYSTICK POT. LOW
WH C10-2 BK-C23-4 22 BK-SP BK-CR4 +24V TO PLATFORM P22BAT
WH/BK C31REV C1B-5 CH REVERSE
C10 TB36/TB37 GR/WH-CR3 19 GR/WH-MH LIFT PUMP C19LPE
WH C30FWD C1B-4 CH FORWARD
LS1-PRIMARY WH/BK-SP GR/WH C4B-7 19 GR/WH-SP LIFT PUMP C19LPE
RD/WH C29JSH C1B-3 CH 2-WIRE POT.
EXTEND/RETRACT OR/RD C8-1 OR/RD C4B-4 16 OR/RD-CR5 DRIVE ENABLE C16DE
RD/BK C28TTA TILT-C C1B-2 TILT ALARM
(CE OPTION) OR/BK C4B-3 15 OR/BK-MH OR/BK-SP PLAT. LEVEL DOWN C15PLD
26 LIFT LOCK-OUT
(CE OPTION) OR C4B-2 14 OR-MH OR-SP PLAT. LEVEL UP C14PLU
25 BATTERY LIGHT
BK C8-3 BL/WH C3B-12 12 BL/WH-CH FOOTSWITCH C12FTS
BL/BK C3B-11 11 BL/BK-MH BL/BK-SP SEC. BOOM DOWN C11SBD

24 TRACTION CONTROL 3
GR/BK C18PRR C4B-6 SP PLAT. ROTATE RIGHT
BL C3B-10 10 BL-MH BL-SP SEC. BOOM UP C10SBU
GR C17PRL C4B-5 SP PLAT. ROTATE LEFT
BK/WH C3B-8 8 BK/WH-MH BK/WH-SP BOOM RETRACT C8PBR
BL/RD C13DEL C8-4 C4B-1 DRIVE ENABLE LIGHT
BK C3B-7 7 BK-MH BK-SP BOOM EXTEND C7PBE
BK/RD C9HRN CR4 C3B-9 HORN
WH/RD C3B-6 6 WH/RD-MH WH/RD-SP BOOM FUNCTION F.C. C6MFV
CABLE#2 RD/WH C3BAT CR1 C3B-3 48V RELAY COIL PWR.
C7B WH/BK C3B-5 5 WH/BK-MH WH/BK-SP TURN. ROTATE RIGHT C5TRR
BL/WH C132PLI C1B-12 C32-3 PLAT OVERLOAD INPUT
WH C3B-4 4 WH-MH WH-SP TURN. ROTATE LEFT C4TRL
BL/RD C133PLA C2B-1 A6(-) PLAT OVERLOAD ALARM
RD/BK C3B-2 2 RD/BK-MH RD/BK-SP PRIMARY BOOM DOWN C2PBD
RD C3B-1 1 RD-MH RD-SP PRIMARY BOOM UP C1PBU 4
D C B A
C4B
CABLE#3
C3B
TO TERMINAL BASE
RD-27D 5
GR/WH-19C
OR/RD-C48-2
GR/WH-C49-11 BK-22A
OR RELAY BLOCK CONTROL RELAY I.D.
C2B CR1 - SECONDARY 48V POWER
CR1 CR2 CR3 CR4
CR2 - PRIMARY 48V POWER
CABLE#1 CR3 - AUXILIARY PUMP
BR-52A
RD/WH-C3B-3 CR4 - HORN
C1B CR5 - BRAKE RELEASE
BK/RD-MH-HORN CR9 - PLAT. LEVEL CUTOUT (CE ONLY)
CR10 - PLAT. LEVEL CUTOUT (CE ONLY) 6
OR/RD-42D BK/RD-C3B-9
RD-C49-1
RD/WH-48D OR-MH OR/BK-MH REF.
30
CR5 CR10A CR10B
RD/BK-C49-2 RD-C11-1 86 85 7
87A
OR/RD-16A
87
BR-52D
MANIFOLD
HARNESS OR-14A OR/BK-15A
(MH)
C48 8
OR/BK C11-2
CHASSIS
HARNESS OR/BK C4B-3 15 OR/BK-CR10 OR/BK-SP PLAT. LEVEL DOWN
(CH) C49
OR C4B-2 14 OR-CR9 OR-SP PLAT. LEVEL UP
PLATFORM LEVEL CUTOUT (CE VERSION ONLY)
Part No. 106373 Z-30/20N • Z-30/20N RJ 6 - 26

Ground Control Panel Terminal Strip Wiring Diagram

Platform Control Box Wiring Diagram


WHT
2 WHT
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
P3 TS7
WHT
3 HORN NO TS9
A1
RED
RED
TS11
CABLE LOAD SENSE
#3 (ACCESSORY)
P2
EMERGENCY NC
STOP BUTTON TS13 TS10
NC
4
ORG/RED
CABLE
#2
F.S.
TS16
TS8
BCI CABLE JIB
(OPTION) #1
BRN
LABEL DESCRIPTION
5 P2 EMERGENCY STOP BUTTON
GRN
RED
BLK/RED
BP1 P3 HORN BUTTON
BOOM DP1 DRIVE CONTROLLER
FUNCTION BP1 BOOM FUNCTION SPEED CONTROLLER
TS1 AUXILIARY POWER TOGGLE SWITCH
SPEED
CONTROL
BRN-JIB
TS10 SECONDARY BOOM UP/DOWN TOGGLE SWITCH
BRN
TS11 PRIMARY BOOM UP/DOWN TOGGLE SWITCH
TS13 BOOM EXTEND/RETRACT TOGGLE SWITCH
6 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
7
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
6 - 27 Z-30/20N • Z-30/20N RJ Part No. 106373


WHT WHT
2
SPARE WIRES
BLK-1
TS15
TS1
L1
BLK/WHT-1
BLK/RED-1
TS12
TS7
R
WHT
P3
3
A1
TS9
D
LS18
NO
RED
CABLE
TS11
#3
TS13
U
E
NC NC
RED
P2
TS10
RED
4
ORG/RED
F.S.
#2
R
U
L
TS8
(OPTION)
CABLE
TS16
BCI
JIB
#1
BRN
GRN
RED
BLK/RED
BP1
BRN-JIB
L4
BRN
RED/BLK
RED
6
BRN-2
R
L
DP1
1 2 3 4 5 6 7 8 9 10
L48
GRN/BLK
6
7
LABEL DESCRIPTION
A1 TILT ALARM
BCI BATTERY CHARGE INDICATOR (OPTION)
BP1 BOOM FUNCTION SPEED CONTROLLER
L1 DRIVE ENABLE LIGHT
L4 TILT ALARM LED
L48 PLATFORM OVERLOAD LED
P3 HORN BUTTON
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
WHT-2
RED/BLK-1
BLU/RED-1
BLU/WHT-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
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

TS7 PLATFORM ROTATE TOGGLE SWITCH 8
TS10 SECONDARY BOOM UP/DOWN TOGGLE SWITCH
TS11 PRIMARY BOOM UP/DOWN TOGGLE SWITCH
TS13 EXTEND/RETRACT TOGGLE SWITCH
TS16 JIB ROTATE TOGGLE SWITCH (OPTION)
NOTE: JIB ROTATE
6 REMOVE JUMPER JP1 FOR CE VERSION.
OPTION
Part No. 106373 Z-30/20N • Z-30/20N RJ 6 - 28




Y
Y
2 WH
TS15 C9 F.S.
TS1
L1 A1
3
TS12 C7B
TS9
TS7
PBOX
R R
3 P3
RD
D U
NO
L L
C47 JIB
TS11
C1P
E R D U D U
NC
P2
TS13 TS10 C2P
4 NC
LS18
R CE OPT.
ORG/RD
RD
RD
D U C3P
L
TS16 TS8
C4P OPT.
BCI
BRN
GRN
RD
BK/RD
BRN-JIB
LABEL DESCRIPTION
BP1
P3 HORN BUTTON
2 BP1 BOOM FUNCTION SPEED CONTROLLER
TS1 AUXILIARY SWITCH
L48 TS7 PLATFORM ROTATE SWITCH
TS8 JIB UP/DOWN SWITCH
BRN-2
TS9 PLATFORM LEVEL SWITCH
6 RD/BK TS10
TS11
SECONDARY BOOM UP/DOWN SWITCH
PRIMARY BOOM UP/DOWN SWITCH
TS12 TURNTABLE ROTATE SWITCH
TS13 EXTEND/RETRACT SWITCH
DP1 TS15 DRIVE ENABLE SWITCH
TS16 JIB ROTATE SWITCH (OPTION)
A1 TILT ALARM
1 2 3 4 5 6 7 8 9 10 4 BCI BATTERY CHARGE INDICATOR (OPTION)
L1 DRIVE ENABLE LED
L4 L4 TURNTABLE TILT ALARM LED (CSA OPTION)
L48 PLATFORM OVERLOAD LED (CE OPTION)
1
7
C47JRR RD C47-6
C46JRL YL C47-5
C43JU BK C47-4
C44JD WH C47-3
C18PRL OR C47-1
C17PRR BL C47-2
C27AUX RD C1P-1
C9HRN BK/RD C3P-9
P22BAT BK C7P-1
P26BAT BK C9P-1
R42BAT OR/RD C2P-4
C3BAT RD/WH C3P-3
C29JSH RD/WH C1P-3

C32JSL WH/RD C1P-6
C31REV WH/BK C1P-5
C30FWD WH C1P-4
P24BAT WH C9P-2
C36SCC BL C1P-10
C37SCW BL/BK C1P-11
C13DEL BL/RD C4P-1
C7PBE BK C3P-7
C8PBR BK/WH C3P-8

C15PLD OR/BK C4P-3
C46JRL OR C2P-2
C47JRR OR/BK C2P-3
C14PLU OR C4P-2
C1PBU RD C3P-1
C2PBD RD/BK C3P-2
C44JD GR/BK C2P-6
C19LPE GR/WH C4P-7
C43JU GR C2P-5
C17PRL GR C4P-5
C18PRR GR/BK C4P-6
C6MFV WH/RD C3P-6
C10SBU BL C3P-10
C11SBD BL/BK C3P-11
C4TRL WH C3P-4
C5TRR WH/BK C3P-5
C16DRE OR/RD C4P-4
C12FTS BL/WH C3P-12
P23BAT WH C7P-2
C28TTA RD/BK C1P-2
C133PLA BL/RD C2P-1
C132PLI BL/WH C1P-12

NOTES:
1 REMOVE JUMPER JP1 FOR CE VERSION.
8 2 TURNTABLE TILT ALARM LED (CSA OPTION).
3 ADD D40 ONLY IF UNIT HAS L4 AND L48.
4 PLATFORM OVERLOAD LED (CE OPTION).
JIB ROTATE
OPTION
6 - 29 Z-30/20N • Z-30/20N RJ Part No. 106373

LVI / BCI Option Wiring Diagram

TS1 L1 TS15
C9 F.S.
C7B
P3
TS9 TS7 TS12
NO
3
OR/BK
OR/RD
OR
OR/RD
OR/BK
OR
C47 JIB
TS13 TS11 TS10 C1P
NC
P2
NC
4
C2P
8 7 6 5 4 3 2 1
TS8 LS18 RESET DISCHARGE

C3P L.V.I.
3
SET TO "B" SET TO "N" 5
BCI
5
C4P OPT.
4
BP1
BK
6
BK/RD
WH
RD
RD
GR
BL
GND BRN
7 8
TS2 5 6
7
1 2 3 4 5 6 7 8 9 10
7 8
DP1 5 6
3 4
1 2
TS6 TS4 3 4
8
1 2
C2P-4 R42BAT OR/RD

C3P-1 C1PBU RD
C3P-10 C10SBU BL
CR19
LIFT LOCKOUT
RELAY
Part No. 106373 Z-30/20N • Z-30/20N RJ 6 - 30



TS1 L1 TS15
C9 F.S.
C7B
P3
TS9 TS7 TS12
NO
3
R42BAT OR/RD
GND BRN
CR19LVI BK
P24BAT WH
P24BAT WH
CR19LVI BK
GND BRN
C2P-4 R42BAT OR/RD

C47 JIB
TS13 TS11 TS10 C1P
NC
P2
NC 4
C2P
TS8 LS18
C3P
5
5
WH/RD
LVI/BCI
C4P OPT.
8
BP1
BRN
BK 6
BK/RD
WH
RD
RD
GR
BL
7 8
TS2 5 6
1 2 3 4 5 6 7 8 9 10
7
7 8
DP1 5 6
3 4
1 2
TS6 TS4 3 4
8
1 2
C3P-1 C1PBU RD
C3P-10 C10SBU BL
1
CR19
SETUP ENABLE (+) WIRE
LIFT LOCKOUT
ENABLE WHEN IT IS TEMPORARILY CONNECTED TO 24VDC RELAY
Part No. 106373 Z-30/20N • Z-30/20N RJ 6 - 31


January 2008 Section 6 • Schematics
Hydraulic Schematic
REV C
JIB BOOM
JIB BOOM ROTATE
OPTION PLATFORM ROTATE
JR1 JR2 PR1 PR2
ROTATE MANIFOLD 3300 psi 3000 psi 3300 psi ROTATE MANIFOLD
(JIB BOOM)
227.5 bar
3:1
207 bar
1.5:1
227.5 bar
3:1 (PLATFORM) 3
JR1 JR2 J1 J2 PR1 PR2
CC AA BB
EE
0.025 inch
P 0.635 mm
PLATFORM LEVELING DD 0.3 gpm
SLAVE
1.14 L/min 4
T
EXTENSION CYLINDER EXTENSION CYLINDER

JIB BOOM MANIFOLD (MODELS WITHOUT (MODELS WITH
ROTATING JIB BOOM) ROTATING JIB BOOM)
PRIMARY BOOM
SECONDARY BOOM
CYLINDER
CYLINDER
STEER 0.032 inch
0.81 mm
5
BRAKES CYLINDER
M M
TURNTABLE ROTATE
MOTOR
0.090 inch /
3000 psi 2.29 mm
207 bar 5.9 cu in/rev
4.5:1 96.7 cc/rev
(before serial
MASTER number 10808)
7.6 cu in/rev 6
124.5 cc/rev
(after serial 2500 psi
3000 psi 3200 psi 2500 psi 172 bar
number 10807)
L 207 bar 221 bar 172 bar 3:1
3000 psi 3:1 3:1
3:1
N.O. 207 bar (before serial (after serial
T COM 1.5:1 number 6462)
N.C. number 6461)
S1
BRAKE PS SC1 SC2

S2
AUXILIARY PRIMARY P1 G1 P2 L1 L2 TR1 TR2 PC1 PC2 EXT RET

N D
PUMP PUMP G
0.5 gpm 2.1 gpm 2800 psi
1.89 L/min 7.95 L/min 193 bar 0.045 inch 1800 psi
M M
1.14 mm M E F 124 bar 7
1600 psi 1600 psi
R 110 bar 110 bar
3000 psi 1100 psi
P I J C 207 bar B 75.8 bar
Q O 3:1
0.045 inch
1.14 mm
10 MICRON 1.5 gpm
100 MESH A Y U V K
0.8 gpm 5.7 L/min
X
H
3 L/min (before serial
number 10808) 8
HYDRAULIC RESERVOIR
1.8 gpm
6.8 L/min W
(after serial S
number 10807) T2
T1
Note:
FUNCTION MANIFOLD 0.035 inch
0.89 mm Orifice added after serial number 5396
Part No. 106373 Z-30/20N • Z-30/20N RJ 6 - 32

January 2008 Section 6 • Schematics
Hydraulic Schematic
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 Scandinavia
Phone +46 31 575100 Genie China
Fax +46 31 579020 Phone +86 21 53852570
Fax +86 21 53852569
Genie France
Phone +33 (0)2 37 26 09 99 Genie Malaysia
Fax +33 (0)2 37 26 09 98 Phone +65 98 480 775
Fax +65 67 533 544
Genie Iberica
Phone +34 93 579 5042 Genie Japan
Fax +34 93 579 5059 Phone +81 3 3453 6082
Fax +81 3 3453 6083
Genie Germany
Phone 0800 180 9017 Genie Korea
Phone +49 422 149 1818 Phone +82 25 587 267
Fax +49 422 149 1820 Fax +82 25 583 910
Genie U.K. Genie Brasil

Phone +44 (0)1476 584333 Phone +55 11 41 665 755
Fax +44 (0)1476 584334 Fax +55 11 41 665 754
Genie Mexico City Genie Holland

Phone +52 55 5666 5242 Phone +31 183 581 102
Fax +52 55 5666 3241 Fax +31 183 581 566

Service Manual: Z-30/20N Z-30/20N RJ

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Serial Number Range

Part No. 106373

Important Serial Number Information

Basic mechanical, hydraulic and electrical skills

Contact Us: Copyright © 1996 by Genie Industries

106373 Rev C June 2008

Printed on recycled paper

ii Z-30/20N • Z-30/20N RJ Part No. 106373

Serial Number Legend

Rated work load (including occupants): XXX lb / XXX kg

Part No. 106373 Z-30/20N • Z-30/20N RJ iii

This page intentionally left blank.

iv Z-30/20N • Z-30/20N RJ Part No. 106373

Do Not Perform Maintenance

Part No. 106373 Z-30/20N • Z-30/20N RJ v

Personal Safety Workplace Safety

Be sure that all tools and working areas

Indicates a potentially hazardous

Be sure to wear protective eye wear and

Be aware of potential crushing hazards

vi Z-30/20N • Z-30/20N RJ Part No. 106373

Section 1 Safety Rules

Section 2 Rev Specifications

Section 3 Rev Scheduled Maintenance Procedures

Section 3 Rev Scheduled Maintenance Procedures, continued

Section 3 Rev Scheduled Maintenance Procedures, continued

Section 4 Rev Repair Procedures

Section 4 Rev Repair Procedures, continued

Section 5 Rev Fault Codes

Section 6 Rev Schematics

Tire size (solid rubber) 22 x 7 x 18.4 in Stowed position 3.3 mph

Fluid Capacities Jib boom rotate, 200°

Drive hubs Primary boom down 12 to 20 seconds

Continuous improvement of our products is a Secondary boom down 7 to 15 seconds

Platform rotate, 160° 5 to 11 seconds

Platform level up 14 to 19 seconds

Platform level down 13 to 18 seconds

Part No. 106373 Z-30/20N • Z-30/20N RJ 2-1

Hydraulic Oil Specifications

Hydraulic oil type Chevron Rykon MV equivalent

Cleanliness level, minimum 15/13

Water content, maximum 200 ppm

Chevron Rykon MV oil is fully compatible and

Biodegradable Petro Canada Environ MV46

Fire resistant UCON Hydrolube HP-5046

Mineral based Shell Tellus T32

Continued use of Chevron

Note:Use Shell Tellus T46 hydraulic oil when oil

2-2 Z-30/20N • Z-30/20N RJ Part No. 106373

Hydraulic Component Manifold Component

Type: Fixed displacement gear pump SAE No. 2 36 in-lbs / 4 Nm

Displacement 0.183 cu in SAE No. 4 10 ft-lbs / 13 Nm

Hydraulic tank 10 micron with SAE No. 10 41 ft-lbs / 55 Nm

Auxiliary pump Proportional solenoid valve, 24V DC 19.5 Ω

Part No. 106373 Z-30/20N • Z-30/20N RJ 2-3

Machine Torque Specifications

1-8 center bolt, GR 5, lubricated 480 ft-lbs

Platform rotator (Z-30/20N)

Turntable rotate bearing

Rotate bearing mounting bolts, lubricated 180 ft-lbs

Drive hubs, brakes and motors

Drive hub mounting bolts, lubricated 180 ft-lbs