genie boom 30z 20n

Service Manual

Z-30/20NZ-30/20N RJ

Part No. 106373

Rev C

June 2008

Serial Number Range

from Z30N-5934 to Z30N08-11499

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

June 2008

ii

Introduction

Important

Read, understand and obey the safety rules andoperating instructions in the Genie Z-30/20NOperator's Manual before attempting anymaintenance or repair procedure.

This manual provides detailed scheduledmaintenance information for the machine ownerand user. It also provides troubleshooting faultcodes and repair procedures for qualified serviceprofessionals.

Basic mechanical, hydraulic and electrical skillsare required to perform most procedures.However, several procedures require specializedskills, tools, lifting equipment and a suitableworkshop. In these instances, we stronglyrecommend that maintenance and repair beperformed at an authorized Genie dealer servicecenter.

Technical Publications

Genie Industries has endeavored to deliver thehighest degree of accuracy possible. However,continuous improvement of our products is a Geniepolicy. Therefore, product specifications aresubject to change without notice.

Readers are encouraged to notify Genie of errorsand send in suggestions for improvement. Allcommunications will be carefully considered forfuture printings of this and all other manuals.

Contact Us:

http://www.genieindustries.come-mail: [email protected]

Copyright © 1996 by Genie Industries

106373 Rev C June 2008Second Edition, Third Printing

"Genie" and "Z" are registered trademarks ofGenie Industries in the USA and many othercountries.

Printed on recycled paper

Printed in U.S.A.

Serial Number Information

Genie Industries offers the following ServiceManuals for these models:

Title Part No.

Z-30/20N Service Manual(before serial number 5934) ................................ 35532

Z-30/20N Service Manual(after serial number 11499) ................................139378

Introduction

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

June 2008

Z30N 05 - 12345

Model

Year ofmanufacture

Sequencenumber

PN - 77055

Country of manufacture: USA

This machine complies with:

Genie Industries

18340 NE 76th Street

Redmond, WA 98052

USA

Model: Z-30/20N

Serial number: Z30N05-12345

Electrical schematic number: ESXXXX

Machine unladen weight:

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

Maximum allowable inclination of the chassis:

0 deg

Gradeability: N/A

Maximum allowable side force : XXX lb / XXX N

Maximum number of platfrm occupants: X

Model year: Manufacture date: 04/12/052005

Maximum wind speed : XX mph/ XX m/s

Maximum platform height : XX ft / XX m

Maximum platform reach : XX ft / XX m

Serial numberstamped on chassis

Serial label(located under cover)

Serial Number Legend

INTRODUCTION

iii

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

June 2008

This page intentionally left blank.

iv

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

June 2008

v

DangerFailure to obey the instructions and safety rulesin this manual and the Genie Z-30/20N Operator’sManual will result in death or serious injury.

Many of the hazards identified in theoperator’s manual are also safety hazardswhen maintenance and repair proceduresare performed.

Do Not Perform MaintenanceUnless:

You are trained and qualified to performmaintenance 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, liftingequipment and a suitable workshop.

Safety Rules

Section 1 • Safety Rules

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

June 2008

SAFETY RULES

vi

Personal SafetyAny person working on or around a machine mustbe aware of all known safety hazards. Personalsafety and the continued safe operation of themachine should be your top priority.

Read each procedure thoroughly. Thismanual and the decals on the machine,use signal words to identify the following:

Safety alert symbol—used to alertpersonnel to potential personalinjury hazards. Obey all safetymessages that follow this symbolto avoid possible injury or death.

Indicates an imminently hazardoussituation which, if not avoided, willresult in death or serious injury.

Indicates a potentially hazardoussituation which, if not avoided,could result in death or seriousinjury.

Indicates a potentially hazardoussituation which, if not avoided,may cause minor or moderateinjury.

Indicates a potentially hazardoussituation which, if not avoided,may result in property damage.

Be sure to wear protective eye wear andother protective clothing if the situationwarrants it.

Be aware of potential crushing hazardssuch as moving parts, free swinging orunsecured components when lifting or

placing loads. Always wear approved steel-toedshoes.

Workplace SafetyBe sure to keep sparks, flames andlighted tobacco away from flammable andcombustible materials like battery gases

and engine fuels. Always have an approved fireextinguisher within easy reach.

Be sure that all tools and working areasare properly maintained and ready foruse. Keep work surfaces clean and free of

debris that could get into machine components andcause damage.

Be sure any forklift, overhead crane orother lifting or supporting device is fullycapable of supporting and stabilizing the

weight to be lifted. Use only chains or straps thatare in good condition and of ample capacity.

Be sure that fasteners intended for onetime use (i.e., cotter pins and self-lockingnuts) are not reused. These components

may fail if they are used a second time.

Be sure to properly dispose of old oil orother fluids. Use an approved container.Please be environmentally safe.

Be sure that your workshop or work areais properly ventilated and well lit.


Table of Contents

vii

Introduction

Important Information ................................................................................................... ii

Serial Number Information............................................................................................ ii

Serial Number Legend ................................................................................................. iii

Section 1 Safety Rules

General Safety Rules .................................................................................................. v

Section 2 Rev Specifications

E Machine Specifications .......................................................................................... 2 - 1

Performance Specifications ................................................................................... 2 - 1

Hydraulic Oil Specifications ................................................................................... 2 - 2

Hydraulic Component Specifications ...................................................................... 2 - 3

Manifold Component Specifications ....................................................................... 2 - 3

Machine Torque Specifications .............................................................................. 2 - 4

Hydraulic Hose and Fitting Torque Specifications .................................................. 2 - 5

SAE and Metric Fasteners Torque Charts .............................................................. 2 - 6

Section 3 Rev Scheduled Maintenance Procedures

Introduction ............................................................................................................ 3 - 1

Pre-Delivery Preparation ........................................................................................ 3 - 3

Maintenance Inspection Report .............................................................................. 3 - 5

D Checklist A Procedures

A-1 Inspect the Manuals and Decals .................................................................. 3 - 6

A-2 Perform Pre-operation Inspection ................................................................ 3 - 7

A-3 Perform Function Tests ............................................................................... 3 - 7

A-4 Perform 30 Day Service ............................................................................... 3 - 8

A-5 Grease the Turntable Rotation Bearing and Worm Drive Gear ...................... 3 - 8

A-6 Replace the Drive Hub Oil ............................................................................ 3 - 9


TABLE OF CONTENTS

viii

Section 3 Rev Scheduled Maintenance Procedures, continued

E Checklist B Procedures

B-1 Check the Batteries.................................................................................... 3 - 10

B-2 Inspect the Electrical Wiring ....................................................................... 3 - 11

B-3 Test the Key Switch ................................................................................... 3 - 12

B-4 Check the Tires, Wheels and Lug Nut Torque ............................................ 3 - 13

B-5 Confirm the Proper Brake Configuration...................................................... 3 - 13

B-6 Check the Oil Level in the Drive Hubs and Mounting Bolt Torque ............... 3 - 14

B-7 Test the Ground Control Override ............................................................... 3 - 14

B-8 Test the Platform Self-leveling ................................................................... 3 - 15

B-9 Test the Drive Brakes ................................................................................ 3 - 15

B-10 Test the Drive Speed - Stowed Position ..................................................... 3 - 16

B-11 Test the Drive Speed - Raised or Extended Position .................................. 3 - 16

B-12 Test the Alarm Package (if equipped) ........................................................ 3 - 17

B-13 Test the Turntable Rotation Stop ................................................................ 3 - 18

B-14 Check the Electrical Contactors ................................................................. 3 - 18

B-15 Perform Hydraulic Oil Analysis ................................................................... 3 - 19

D Checklist C Procedures

C-1 Grease the Platform Overload Mechanism (if equipped) ............................. 3 - 20

C-2 Test the Platform Overload System (if equipped) ....................................... 3 - 20

Section 3 Rev Scheduled Maintenance Procedures, continued

D Checklist D Procedures

D-1 Check the Primary Boom Wear Pads ......................................................... 3 - 23

D-2 Check the Free-wheel Configuration ........................................................... 3 - 24

D-3 Check the Turntable Rotation Bearing Bolts ............................................... 3 - 25

D-4 Replace the Drive Hub Oil .......................................................................... 3 - 26

D-5 Replace the Hydraulic Tank Return Filter Element ..................................... 3 - 26

D-6 Inspect for Turntable Bearing Wear ............................................................ 3 - 27

C Checklist E Procedures

E-1 Test or Replace the Hydraulic Oil ............................................................... 3 - 29

E-2 Grease the Steer Axle Wheel Bearings ...................................................... 3 - 31

Section 4 Rev Repair Procedures

Introduction ............................................................................................................ 4 - 1

B Platform Controls

1-1 Controllers .................................................................................................... 4 - 2

C Platform Components

2-1 Platform Leveling Slave Cylinder .................................................................. 4 - 4

2-2 Platform Rotator ........................................................................................... 4 - 5

2-3 Platform Overload System ........................................................................... 4 - 7

B Jib Boom Components

3-1 Jib Boom...................................................................................................... 4 - 9

3-2 Jib Boom Bell Crank (models without rotating jib boom) ............................. 4 - 10

3-3 Jib Boom Rotator (models with rotating jib boom) ....................................... 4 - 11

3-4 Jib Boom Lift Cylinder ................................................................................ 4 - 13

TABLE OF CONTENTS

ix

x

Section 4 Rev Repair Procedures, continued

B Primary Boom Components

4-1 Cable Track ................................................................................................ 4 - 14

4-2 Primary Boom ............................................................................................ 4 - 14

4-3 Primary Boom Lift Cylinder ......................................................................... 4 - 18

4-4 Extension Cylinder ..................................................................................... 4 - 19

4-5 Platform Leveling Master Cylinder .............................................................. 4 - 20

B Secondary Boom Components

5-1 Secondary Boom........................................................................................ 4 - 23

5-2 Secondary Boom Lift Cylinder .................................................................... 4 - 28

A Hydraulic Pump

6-1 Auxiliary and Function Pump...................................................................... 4 - 30

D Manifolds

7-1 Function Manifold Components .................................................................. 4 - 32

7-2 Valve Adjustments - Function Manifold ...................................................... 4 - 36

7-3 Jib Boom and Platform / Jib Boom Rotate Manifold Components ............... 4 - 39

7-4 Valve Coils ................................................................................................. 4 - 40

B Turntable Rotation Components

8-1 Turntable Rotation Hydraulic Motor ............................................................. 4 - 42

C Steer Axle Components

9-1 Hub and Bearings ....................................................................................... 4 - 43

B Motor Controller

10-1 Motor Controller .......................................................................................... 4 - 44

Section 5 Rev Fault Codes

Introduction ............................................................................................................ 5 - 1

A Fault Code Chart .................................................................................................... 5 - 3

TABLE OF CONTENTS

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

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

Section 2 • SpecificationsJune 2008

REV E Specifications

Machine Specifications

Tires and wheels

Tire size (solid rubber) 22 x 7 x 18.4 in56 x 18 x 47 cm

Load range 7600 lbs3447 kg

Overall tire diameter 22 in56 cm

Wheel diameter 18.4 in47 cm

Wheel width 7 in18 cm

Wheel lugs

Front 8 @ 5/8 -18Rear 9 @ 5/8 -18

Lug nut torque, dry 125 ft-lbs169.5 Nm

Lug nut torque, lubricated 94 ft-lbs127.4 Nm

Fluid Capacities

Hydraulic tank capacity 4 gallons15.1 liters

Hydraulic system capacity 6 gallons(including tank) 22.7 liters

Drive hubs61:1 23 ounces 0.68 liter62.5:1 25.6 ounces 0.76 liter

Drive hub oil type:SAE 90 multipurpose hypoid gear oil API serviceclassification GL5

Continuous improvement of our products is aGenie policy. Product specifications aresubject to change without notice.

Performance Specifications

Drive speed, maximum

Stowed position 3.3 mph5.3 km/h

40 ft / 8.2 sec12.2 m / 8.2 sec

Boom raised or extended 0.6 mph1 km/h

40 ft / 44 sec12.2 m / 44 sec

Braking distance, maximum

High range on paved surface 2 to 4 ft0.6 to 1.2m

Gradeability See Operator's Manual

Boom function speeds, maximum from platformcontrols (with rated load secured to platform)

Jib boom up 26 to 32 seconds

Jib boom down 23 to 29 seconds

Jib boom rotate, 200°(before serial number 8333) 12 to 18 seconds

Jib boom rotate, 180°(after serial number 8332) 12 to 18 seconds

Primary boom up 14 to 22 seconds

Primary boom down 12 to 20 seconds

Primary boom extend(models with rotating jib boom) 14 to 24 seconds(models without rotating jib boom) 9 to 15 seconds

Primary boom retract 12 to 18 seconds

Secondary boom up 11 to 18 seconds

Secondary boom down 7 to 15 seconds

Turntable rotate, 355° 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

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

Section 2 • Specifications June 2008

REV ESPECIFICATIONS

Hydraulic Oil Specifications

Hydraulic Oil Specifications

Hydraulic oil type Chevron Rykon MV equivalentViscosity grade Multi-viscosityViscosity index 200

Cleanliness level, minimum 15/13

Water content, maximum 200 ppm

Chevron Rykon MV oil is fully compatible andmixable with Shell Donax TG (Dexron III) oils.Genie specifications require hydraulic oils which aredesigned to give maximum protection to hydraulicsystems, have the ability to perform over a widetemperature range, and the viscosity index shouldexceed 140. They should provide excellent antiwear,oxidation, corrosion inhibition, seal conditioning, andfoam and aeration suppression properties.

Optional fluids

Biodegradable Petro Canada Environ MV46Statoil Hydra Way Bio Pa 32

BP Biohyd SE-S

Fire resistant UCON Hydrolube HP-5046Quintolubric 822

Mineral based Shell Tellus T32Shell Tellus T46

Chevron Aviation A

Continued use of ChevronAviation A hydraulic fluid whenambient temperatures areconsistently above 32°F / 0°C mayresult in component damage.

Note: Use Chevron Aviation A hydraulic fluid whenambient temperatures are consistently below0°F / -18°C.

Note:Use Shell Tellus T46 hydraulic oil when oiltemperatures consistently exceed 205°F / 96°C.

Note:Genie specifications require additionalequipment and special installation instructions forthe approved optional fluids. Consult the GenieIndustries Service Department before use.


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


REV E SPECIFICATIONS

Hydraulic ComponentSpecifications

Function pump

Type: Fixed displacement gear pump

Displacement 0.183 cu in3 cc

Flow rate @ 2.1 gpm2800 psi / 172 bar 7.9 L/min

Hydraulic tank 10 micron withreturn filter 25 psi / 1.7 bar bypass

Function manifold

System relief valve pressure 2800 psi193 bar

Primary boom down relief pressure 1600 psi110 bar

Secondary boom down relief pressure 1600 psi110 bar

Primary boom extend relief pressure 1800 psiModels with rotating jib 124 bar

Turntable rotate relief pressure 1100 psi76 bar

Auxiliary pump

Type: Fixed displacement gear pump

Displacement 0.3 gpm1.14 L/min


Manifold ComponentSpecifications

Plug torque

SAE No. 2 36 in-lbs / 4 Nm

SAE No. 4 10 ft-lbs / 13 Nm





Valve Coil Resistance

Note: The following coil resistance specifications are atan ambient temperature of 68°F / 20°C. As valve coilresistance is sensitive to changes in air temperature,the coil resistance will typically increase or decrease by4% for each 18°F / 10°C that your air temperatureincreases or decreases from 68°F / 20°C.

Valve Coil Resistance Specification

Description Specification

Solenoid valve, 3 position 4 way, 20V DC 22 Ω(schematic items A, J, K, U, V, Y, AA, BB and CC)

Proportional solenoid valve, 24V DC 19.5 Ω(schematic item H)

Solenoid valve, N.C. poppet, 20V DC 23.5 Ω(schematic item M)

Solenoid valve, N.O. poppet, 20V DC 23.5 Ω(schematic item P)

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


REV ESPECIFICATIONS

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-lbs379 Nm

3/8 -16 bolts, GR 5, lubricated 23 ft-lbs31 Nm

Turntable rotate bearing

Rotate bearing mounting bolts, lubricated 180 ft-lbs244 Nm

Drive hubs, brakes and motors

Drive hub mounting bolts, lubricated 180 ft-lbs244 Nm

Brake mounting bolts, lubricated 93 ft-lbs126 Nm

Drive motor mounting bolts 31 ft-lbs42 Nm


Part No. 106373 Z-30/20N • Z-30/20N RJ 2 - 5


REV E SPECIFICATIONS

Hydraulic Hose and FittingTorque SpecificationsYour machine is equipped with Parker Seal-Lok®

fittings and hose ends. Genie specifications requirethat fittings and hose ends be torqued tospecification when they are removed and installedor when new hoses or fittings are installed.

Seal-Lok® fittings

1 Replace the O-ring. The O-ring must bereplaced anytime the seal has been broken.The O-ring cannot be re-used if the fitting orhose end has been tightened beyond fingertight.

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 areavailable in the O-ring field service kit (Genie partnumber 49612).

2 Lubricate the O-ring before installation.

3 Be sure that the face seal O-ring is seated andretained properly.

4 Position the tube and nut squarely on the faceseal end of the fitting and tighten the nut fingertight.

5 Tighten the nut or fitting to the appropriatetorque per given size as shown in the table.

6 Operate all machine functions and inspect thehoses and fittings and related components toconfirm that there are no leaks.

SAE O-ring Boss Port(tube fitting - installed into Aluminum)

SAE Dash size Torque

-4 11 ft-lbs / 14.9 Nm

-6 23 ft-lbs / 31.2 Nm

-8 40 ft-lbs / 54.2 Nm

-10 69 ft-lbs / 93.6 Nm

-12 93 ft-lbs / 126.1 Nm

-16 139 ft-lbs / 188.5 Nm

-20 172 ft-lbs / 233.2 Nm

-24 208 ft-lbs / 282 Nm

SAE O-ring Boss Port(tube fitting - installed into Steel)


-4 16 ft-lbs / 21.7 Nm

-6 35 ft-lbs / 47.5 Nm

-8 60 ft-lbs / 81.3 Nm

-10 105 ft-lbs / 142.4 Nm

-12 140 ft-lbs / 190 Nm

-16 210 ft-lbs / 284.7 Nm

-20 260 ft-lbs / 352.5 Nm

-24 315 ft-lbs / 427.1 Nm

Seal-Lok® Fittings(hose end)


-4 18 ft-lbs / 24.4 Nm

-6 27 ft-lbs / 36.6 Nm

-8 40 ft-lbs / 54.2 Nm

-10 63 ft-lbs / 85.4 Nm

-12 90 ft-lbs / 122 Nm

-16 120 ft-lbs / 162.7 Nm

-20 140 ft-lbs / 190 Nm

-24 165 ft-lbs / 223.7 Nm

2 - 6 Z-30/20N • Z-30/20N RJ Part No. 106373


REV E

SIZE THREAD

in-lbs N m in- lbs N m in- lbs N m in- lbs N m in- lbs N m20 80 9 100 11.3 110 12.4 140 15.8 130 14.728 90 10.1 120 13.5 120 13.5 160 18 140 15.8

f t - lbs N m ft- lbs N m ft- lbs N m ft- lbs N m ft- lbs N m18 13 17.6 17 23 18 24 25 33.9 21 28.424 14 19 19 25.7 20 27.1 27 36.6 24 32.516 23 31.2 31 42 33 44.7 44 59.6 38 51.524 26 35.2 35 47.4 37 50.1 49 66.4 43 58.314 37 50.1 49 66.4 50 67.8 70 94.7 61 82.720 41 55.5 55 74.5 60 81.3 80 108.4 68 92.113 57 77.3 75 101.6 80 108.4 110 149 93 12620 64 86.7 85 115 90 122 120 162 105 14212 80 108.4 110 149 120 162 150 203 130 17618 90 122 120 162 130 176 170 230 140 18911 110 149 150 203 160 217 210 284 180 24418 130 176 170 230 180 244 240 325 200 27110 200 271 270 366 280 379 380 515 320 43316 220 298 300 406 310 420 420 569 350 4749 320 433 430 583 450 610 610 827 510 69114 350 474 470 637 500 678 670 908 560 7598 480 650 640 867 680 922 910 1233 770 104412 530 718 710 962 750 1016 990 1342 840 11397 590 800 790 1071 970 1315 1290 1749 1090 147712 670 908 890 1206 1080 1464 1440 1952 1220 16547 840 1138 1120 1518 1360 1844 1820 2467 1530 207412 930 1260 1240 1681 1510 2047 2010 2725 1700 23046 1460 1979 1950 2643 2370 3213 3160 4284 2670 362012 1640 2223 2190 2969 2670 3620 3560 4826 3000 4067

5/16

3/8

7/16

1/2

1 1/2

9/16

5/8

3/4

7/8

1

1 1/8

1 1/4

LUBED

1/4

LUBED DRY LUBED DRY

LUBEDDRYLUBED

SAE FASTENER TORQUE CHART

Grade 5DRYLUBED

• This chart is to be used as a guide only unless noted elsewhere in this manual •A574 High Strength Black Oxide BoltsGrade 8

Size(mm)

in- lbs N m in-lbs N m in- lbs N m in- lbs N m in- lbs N m in- lbs N m in- lbs N m in- lbs N m5 16 1.8 21 2.4 41 4.63 54 6.18 58 6.63 78 8.84 68 7.75 91 10.36 19 3.05 36 4.07 69 7.87 93 10.5 100 11.3 132 15 116 13.2 155 17.67 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

f t - lbs N m ft-lbs N m ft- lbs N m ft- lbs N m ft- lbs N m ft- lbs N m ft- lbs N m ft- lbs N m8 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 42.610 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 84.412 18.9 25.6 25.1 34.1 48.6 66 64.9 88 69.7 94.5 92.2 125 81 110 108 14714 30.1 40.8 40 54.3 77.4 105 103 140 110 150 147 200 129 175 172 23416 46.9 63.6 62.5 84.8 125 170 166 226 173 235 230 313 202 274 269 36518 64.5 87.5 86.2 117 171 233 229 311 238 323 317 430 278 377 371 50320 91 124 121 165 243 330 325 441 337 458 450 610 394 535 525 71322 124 169 166 225 331 450 442 600 458 622 612 830 536 727 715 97024 157 214 210 285 420 570 562 762 583 791 778 1055 682 925 909 1233

LUBED DRY LUBED DRYLUBED DRY LUBED DRY

LUBEDDRYLUBED

Class 12.9Class 4.6DRYLUBED

METRIC FASTENER TORQUE CHART• This chart is to be used as a guide only unless noted elsewhere in this manual •

LUBED DRY

Class 10.9Class 8.8DRY

10.9 12.98.84.6

SPECIFICATIONS

Part No. 106373 Z-30/20N • Z-30/20N RJ 3 - 1

Section 3 • Scheduled Maintenance ProceduresJune 2008

Scheduled Maintenance Procedures

About This Section

This section contains detailed procedures for eachscheduled maintenance inspection.

Each procedure includes a description, safetywarnings and step-by-step instructions.

Symbols Legend






Indicates that a specific result is expected afterperforming a series of steps.

Indicates that an incorrect result has occurredafter performing a series of steps.

Observe and Obey:

Maintenance inspections shall be completed bya person trained and qualified on themaintenance of this machine.

Scheduled maintenance inspections shall becompleted daily, quarterly, six months, annuallyand every 2 years as specified on theMaintenance Inspection Report.

Failure to properly complete eachinspection when required couldresult in death, serious injury orsubstantial machine damage.

Immediately tag and remove from service adamaged or malfunctioning machine.

Repair any machine damage or malfunctionbefore operating machine.

Use only Genie approved replacement parts.

Unless otherwise specified, perform eachprocedure with the machine in the followingconfiguration:

• Machine parked on a firm, level surface

• Boom in the stowed position

• Turntable rotated with the boom between thenon-steer wheels

• Key switch in the off position with thekey removed

• Wheels chocked

• All external AC power supply disconnectedfrom the machine

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

Section 3 • Scheduled Maintenance Procedures June 2008

Maintenance Symbols Legend

The following symbols have been used in thismanual to help communicate the intent of theinstructions. When one or more of the symbolsappear at the beginning of a maintenanceprocedure, it conveys the meaning below.

Indicates that tools will be required toperform this procedure.

Indicates that new parts will be requiredto perform this procedure.

Indicates that a cold motor or pump willbe required to perform this procedure.

Indicates that dealer service will berequired to perform this procedure.

Maintenance Schedule

There are five types of maintenance inspectionsthat must be performed according to a schedule—daily, quarterly, six months, annual, and two year.The Scheduled Maintenance Procedures Sectionand the Maintenance Inspection Report have beendivided into five subsections—A, B, C, D and E.Use the following chart to determine whichgroup(s) of procedures are required to perform ascheduled inspection.

Inspection Checklist

Daily or every 8 hours A

Quarterly or every 250 hours A + B

Six months or every 500 hours A + B + C

Annual or every 1000 hours A + B + C + D

Two year or every 2000 hours A + B + C + D + E

Maintenance Inspection Report

The maintenance inspection report containschecklists for each type of scheduled inspection.

Make copies of the Maintenance Inspection Reportto use for each inspection. Maintain completedforms for a minimum of 4 years or in compliancewith employer, jobsite and govermental regulationsand requirements.

SCHEDULED MAINTENANCE PROCEDURES

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


Genie Industries USA18340 NE 76th StreetPO Box 97030Redmond, WA 98073-9730(425) 881-1800

Copyright © 2002 by Genie Industries. Genie® is a registered trademark of Genie Industries.Rev B

Genie UKThe Maltings, Wharf Road

Grantham, LincolnshireNG31- 6BH England

(44) 1476-584333

Pre-DeliverPre-DeliverPre-DeliverPre-DeliverPre-Delivery Preparationy Preparationy Preparationy Preparationy Preparation

Pre-Delivery Preparation Y N R

Pre-operation inspection completed

Maintenance items completed

Function tests completed

Model

Serial number

Date

Machine owner

Inspected by (print)

Inspector signature

Inspector title

Inspector company

Instructions

Use the operator’s manual on your machine.

The Pre-delivery Preparation consists of completing thePre-operation Inspection, the Maintenance items and theFunction Tests.

Use this form to record the results. Place a check in theappropriate box after each part is completed. Follow theinstructions in the operator’s manual.

If any inspection receives an N, remove the machine fromservice, repair and re-inspect it. After repair, place a checkin the R box.

LegendY = yes, completedN = no, unable to completeR = repaired

Comments

Fundamentals

It is the responsibility of the dealer to perform thePre-delivery Preparation.

The Pre-delivery Preparation is performed prior to eachdelivery. The inspection is designed to discover if anythingis apparently wrong with a machine before it is put intoservice.

A damaged or modified machine must never be used. Ifdamage or any variation from factory delivered condition isdiscovered, the machine must be tagged and removedfrom service.

Repairs to the machine may only be made by a qualifiedservice technician, according to the manufacturer'sspecifications.

Scheduled maintenance inspections shall be performed byqualified service technicians, according to themanufacturer's specifications and the requirements listedin the responsibilities manual.

3 - 4 Z-30/20N • Z-30/20N RJ Part No. 106373



Checklist A - Rev D Y N R

A-1 Manuals and decals

A-2 Pre-operationinspection

A-3 Function tests

Perform after 40 hours:

A-4 30 Day Service

Perform every 100 hours:

A-5 Grease rotationbearing

Perform after 150 hours:

A-6 Replace drive hub oil

Checklist B - Rev E Y N R

B-1 Batteries

B-2 Electrical wiring

B-3 Key switch

B-4 Tires and Wheels

B-5 Brake configuration

B-6 Drive hub oil level

B-7 Ground controloverride

B-8 Platform leveling

B-9 Drive brakes

B-10 Drive speed-stowed

B-11 Drive speed-raised

B-12 Alarm package(if equipped)

B-13 Turntable rotation stop

B-14 Electrical contactors

B-15 Hydraulic oil analysis

Checklist C - Rev D Y N R

C-1 Grease platformoverload (if equipped)

C-2 Test platformoverload (if equipped)

Checklist D - Rev D Y N R

D-1 Boom wear pads

D-2 Free-wheelconfiguration

D-3 Turntable bearing bolts

D-4 Drive hub oil

D-5 Hydraulic return filter

D-6 Turntable bearingwear

Checklist E - Rev D Y N R

E-1 Hydraulic oil

E-2 Wheel bearings

Instructions• Make copies of this page to use for

each inspection.

• Select the appropriate checklist(s) forthe type of inspection to beperformed.

Daily or 8 hourInspection: A

Quarterly or 250 hourInspection: A+B

Six Month or 500 hourInspection: A+B+C

Annual or 1000 hoursInspection: A+B+C+D

2 Year or 2000 hourInspection: A+B+C+D+E

• Place a check in the appropriate boxafter each inspection procedure iscompleted.

• Use the step-by-step procedures inthis section to learn how to performthese inspections.

• If any inspection receives an “N”, tagand remove the machine fromservice, repair and re-inspect it. Afterrepair, place a check in the “R” box.

LegendY = yes, acceptableN = no, remove from serviceR = repaired

Maintenance Inspection Report

Model

Serial number

Date

Hour meter

Machine owner

Inspected by (print)

Inspector signature

Inspector title

Inspector company

Comments

3 - 6 Z-30/20N • Z-30/20N RJ Part No. 106373


REV DChecklist A Procedures

A-1Inspect the Manuals and DecalsNote: Genie specifications require that thisprocedure be performed daily or every 8 hours,whichever comes first.

Maintaining the operator’s and safety manuals ingood condition is essential to safe machineoperation. Manuals are included with eachmachine and should be stored in the containerprovided in the platform. An illegible or missingmanual will not provide safety and operationalinformation necessary for a safe operatingcondition.

In addition, maintaining all of the safety andinstructional decals in good condition is mandatoryfor safe machine operation. Decals alert operatorsand personnel to the many possible hazardsassociated with using this machine. They alsoprovide users with operation and maintenanceinformation. An illegible decal will fail to alertpersonnel of a procedure or hazard and couldresult in unsafe operating conditions.

1 Check to make sure that the operator's andsafety manuals are present and complete in thestorage container on the platform.

2 Examine the pages of each manual to be surethat they are legible and in good condition.

Result: The operator's manual is appropriate forthe machine and all manuals are legible and ingood condition.

Result: The operator's manual is notappropriate for the machine or all manuals arenot in good condition or are illegible. Removethe machine from service until the manual isreplaced.

3 Open the operator's manual to the decalsinspection section. Carefully and thoroughlyinspect all decals on the machine for legibilityand damage.

Result: The machine is equipped with allrequired decals, and all decals are legible andin good condition.

Result: The machine is not equipped with allrequired decals, or one or more decals areillegible or in poor condition. Remove themachine from service until the decals arereplaced.

4 Always return the manuals to the storagecontainer after use.

Note: Contact your authorized Genie distributor orGenie Industries if replacement manuals or decalsare needed.

Part No. 106373 Z-30/20N • Z-30/20N RJ 3 - 7


REV D

A-2Perform Pre-operationInspectionNote: Genie specifications require that thisprocedure be performed daily or every 8 hours,whichever comes first.

Completing a pre-operation inspection is essentialto safe machine operation. The pre-operationinspection is a visual inspection performed by theoperator prior to each work shift. The inspection isdesigned to discover if anything is apparentlywrong with a machine before the operator performsthe function tests. The pre-operation inspectionalso serves to determine if routine maintenanceprocedures are required.

Complete information to perform this procedure isavailable in the appropriate Genie Z-30/20NOperator's Manual. Refer to the Operator's Manualon your machine.

CHECKLIST A PROCEDURES

A-3Perform Function TestsNote: Genie specifications require that thisprocedure be performed daily or every 8 hours,whichever comes first.

Completing the function tests is essential to safemachine operation. Function tests are designed todiscover any malfunctions before the machine isput into service. A malfunctioning machine mustnever be used. If malfunctions are discovered, themachine must be tagged and removed fromservice.

Complete information to perform this procedure isavailable in the appropriate Genie Z-30/20NOperator's Manual. Refer to the Operator's Manualon your machine.

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


REV D

A-4Perform 30 Day Service

The 30 day maintenance procedure is a one-timesequence of procedures to be performed after thefirst 30 days or 40 hours of usage. After thisinterval, refer to the maintenance checklists forcontinued scheduled maintenance.

1 Perform the following maintenance procedures:

• A-5 Grease the Turntable RotationBearing and Worm Drive Gear

• B-4 Check the Tires, Wheels and Lug NutTorque

• D-3 Check the Turnable RotationBearing Bolts

• D-5 Replace the Hydraulic TankReturn Filter Element

A-5Grease the Turntable RotationBearing and Worm Drive Gear

Note: Genie specifications require that thisprocedure be performed every 100 hours.

Frequent application of lubrication to the turntablebearing and worm drive gear is essential to goodmachine performance and service life. Continueduse of an insufficently greased gear will result incomponent damage.

1 Locate the grease fitting on the tank sideturntable cover bulkhead.

2 Pump grease into the turntable rotation bearing.Rotate the turntable in increments of 4 to 5inches / 10 to 13 cm at a time and repeat thisstep until the entire bearing has been greased.

3 Locate the 2 grease fittings on top of the wormdrive housing.

a grease fittings

4 Pump grease into the gear until you see itcoming out of the side of the gear housing.

5 Grease each tooth on the outside of theturntable rotation bearing.

Grease Specification

Chevron Ultra-duty grease, EP NLGI 2 (lithium based)or equivalent

a


Part No. 106373 Z-30/20N • Z-30/20N RJ 3 - 9


REV D

A-6Replace the Drive Hub Oil

Note: Manufacturer drive hub specifications requirethat this one-time procedure be performed after thefirst 150 hours.

Replacing the drive hub oil is essential for goodmachine performance and service life. Failure toreplace the drive hub oil after the first 150 hours ofuse may cause the machine to perform poorly andcontinued use may cause component damage.

1 Select the drive hub to be serviced. Drive themachine until one of the two plugs is at thelowest point.

2 Remove both plugs and drain the oil into asuitable container.

3 Drive the machine until one plug is at the topand the other is at 90 degrees.

a drive hub plugs

4 Fill the hub with oil from the top hole until the oillevel is even with the bottom of the side plughole. Refer to Section 2, Specifications.

5 Install the plugs into the drive hub.

6 Repeat this procedure for the other drive hub.

a


3 - 10 Z-30/20N • Z-30/20N RJ Part No. 106373


REV EChecklist B Procedures

B-1Check the Batteries

Note: Genie specifications require that thisprocedure be performed every 250 hours orquarterly, whichever comes first.

Proper battery condition is essential to goodmachine performance and operational safety.Improper fluid levels or damaged cables andconnections can result in component damage andhazardous conditions.

Electrocution/burn hazard. Contactwith hot or live circuits could resultin death or serious injury. Removeall rings, watches and otherjewelry.

Bodily injury hazard. Batteriescontain acid. Avoid spilling orcontacting battery acid. Neutralizebattery acid spills with baking sodaand water.

1 Disconnect each battery pack from themachine.

2 Release the battery pack latches and rotateeach battery pack out and away from thechassis.

3 Remove the cover from each battery box.

4 Be sure that the battery cable connections arefree of corrosion.

Note: Adding terminal protectors and a corrosionpreventative sealant will help eliminate corrosionon the battery terminals and cables.

5 Be sure that the battery retainers and cableconnections are tight.

6 Fully charge the batteries. Allow the batteries torest 24 hours before continuing this procedureto allow the battery cells to equalize.

7 Put on protective clothing and eye wear.

8 Remove the battery vent caps and check thespecific gravity of each battery cell with ahydrometer. Note the results.

9 Check the ambient air temperature and adjustthe specific gravity reading for each cell asfollows:

• Add 0.004 to the reading of each cell forevery 10° / 5.5° C above 80° F / 26.7° C.

• Subtract 0.004 from the reading of each cell forevery 10° / 5.5° C below 80° F / 26.7° C.

Result: All battery cells display an adjustedspecific gravity of 1.277 or higher. The batteryis fully charged. Proceed to step 13.

Result: One or more battery cells display aspecific gravity of 1.217 or below. Proceed tostep 10.

10 Perform an equalizing charge OR fully chargethe batteries and allow the batteries to rest atleast 6 hours.

11 Remove the battery vent caps and check thespecific gravity of each battery cell with ahydrometer. Note the results.

Part No. 106373 Z-30/20N • Z-30/20N RJ 3 - 11


REV E CHECKLIST B PROCEDURES

12 Check the ambient air temperature and adjustthe specific gravity reading for each cell asfollows:

• Add 0.004 to the reading of each cell forevery 10° / 5.5° C above 80° F / 26.7° C.

• Subtract 0.004 from the reading of each cell forevery 10° / 5.5° C below 80° F / 26.7° C.

Result: All battery cells display a specific gravityof 1.277 or greater. The battery is fully charged.Proceed to step 13.

Result: The difference in specific gravityreadings between cells is greater than 0.1 ORthe specific gravity of one or more cells is lessthan 1.217. Replace the battery.

13 Check the battery acid level. If needed,replenish with distilled water to 1/8 inch / 3 mmbelow the bottom of the battery fill tube. Do notoverfill.

14 Install the vent caps and neutralize anyelectrolyte that may have spilled.

B-2Inspect the Electrical Wiring


Maintaining electrical wiring in good condition isessential to safe operation and good machineperformance. Failure to find and replace burnt,chafed, corroded or pinched wires could result inunsafe operating conditions and may causecomponent damage.


1 Remove the drive chassis cover from thenon-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

3 - 12 Z-30/20N • Z-30/20N RJ Part No. 106373


REV ECHECKLIST B PROCEDURES

3 Turn the key switch to ground controls and pullout the red Emergency Stop button to the onposition at both the ground and platformcontrols.

4 Raise the secondary boom until the mid-pivot isapproximately 10 feet / 3 m off the ground.

5 Inspect the turntable center area for burnt,chafed and pinched cables.

6 Lower the boom to the stowed position and turnthe machine off.

7 Inspect the following areas for burnt, chafed,corroded, pinched and loose wires:

• Cable track on the primary boom

• Primary boom to platform cable harness

• Inside of the platform control box

8 Inspect for a liberal coating of dielectric greaseat the following location:

• All wire harness connectors to the platformcontrol box

• All wire harness connectors located under theground control side turntable cover

• Harness connector to the drive motorcontroller located in the non-steer end of thedrive chassis

B-3Test the Key SwitchNote: Genie specifications require that thisprocedure be performed every 250 hours orquarterly, whichever comes first.

Proper key switch action and response is essentialto safe machine operation. The machine can beoperated from the ground or platform controls andthe activation of one or the other is accomplishedwith the key switch. Failure of the key switch toactivate the appropriate control panel could resultin a hazardous operating situation.

1 Pull out the red Emergency Stop button to theon position at both the ground and platformcontrols.

2 Turn the key switch to platform controls.

3 Check the machine functions from the groundcontrols.

Result: The machine functions should notoperate.

4 Turn the key switch to ground controls.

5 Check the machine functions from the platformcontrols.

Result: The machine functions should notoperate.

6 Turn the key switch to the off position.

Result: No function should operate.

Part No. 106373 Z-30/20N • Z-30/20N RJ 3 - 13


REV E

disengaged position

engaged position

B-4Check the Tires, Wheels andLug Nut Torque


Maintaining the tires and wheels, including properwheel fastener torque, is essential to safeoperation and good performance. Tire and/orwheel failure could result in a machine tip-over.Component damage may also result if problemsare not discovered and repaired in a timely fashion.

1 Check the tire surface and sidewalls for cuts,cracks and unusual wear.

2 Check each wheel for damage, bends andcracks.

3 Check each lug nut for proper torque. Refer toSection 2, Specifications.

B-5Confirm the ProperBrake Configuration


Proper brake configuration is essential to safeoperation and good machine performance.Hydraulically-released, spring-applied individualwheel brakes can appear to operate normally whenthey are actually not fully operational.

1 Check each drive hub disconnect cap to besure it is in the engaged position.

CHECKLIST B PROCEDURES

3 - 14 Z-30/20N • Z-30/20N RJ Part No. 106373


REV E

B-6Check the Oil Level in the DriveHubs and Mounting Bolt Torque


Failure to maintain proper drive hub oil levels,including proper drive hub fastener torque, maycause the machine to perform poorly andcontinued use may cause component damage.

1 Drive the machine to rotate the hub until one ofthe plugs is located on top and the other is at90 degrees.

a drive hub plugs

2 Remove the plug located at 90 degrees andcheck the oil level.

Result: The oil level should be even with thebottom of the side plug hole.

3 If necessary, remove the top plug and add oiluntil the oil level is even with the bottom of theside 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.

B-7Test the Ground ControlOverrideNote: Genie specifications require that thisprocedure be performed every 250 hours orquarterly, whichever comes first.

A properly functioning ground control override isessential to safe machine operation. The groundcontrol override function is intended to allowground personnel to operate the machine from theground controls whether the red Emergency Stopbutton on the platform controls is in the on or offposition. This function is particularly useful if theoperator at the platform controls cannot return theboom to the stowed position.

1 Push in the red Emergency Stop button at theplatform controls to the off position.

2 Turn the key switch to ground controls and pullout the red Emergency Stop button to the onposition.

3 Operate each boom function through apartial cycle at the ground controls.

Result: All boom functions should operate.

CHECKLIST B PROCEDURES

a

Part No. 106373 Z-30/20N • Z-30/20N RJ 3 - 15



B-8Test the Platform Self-leveling


Automatic platform self-leveling throughoutthe full cycle of boom raising and lowering isessential for safe machine operation. Theplatform is maintained level by the platform levelingslave cylinder which is controlled by the platformleveling master cylinder located at the base of theprimary boom. A platform self-leveling failurecreates an unsafe working condition for platformand ground personnel.

1 Turn the key switch to ground controls and pullout the red Emergency Stop button to the onposition at both the ground and platformcontrols.

2 Lower the boom to the stowed position.

3 Adjust the platform to a level position using theplatform leveling toggle switch.

4 Raise and lower the primary boom througha full cycle.

Result: The platform should remain level atall times to within ±5 degrees.

B-9Test the Drive Brakes


Proper brake action is essential to safe machineoperation. The drive brake function should operatesmoothly, free of hesitation, jerking and unusualnoise. Hydraulically-released individual wheelbrakes can appear to operate normally when theyare actually not fully operational.

Collision hazard. Be sure that themachine is not in free-wheel orpartial free-wheel configuration.Refer to B-5, Confirm the ProperBrake Configuration.

1 Select a test area that is firm, level and free ofobstructions.

2 Mark a test line on the ground for reference.

3 Lower the boom to the stowed position.


5 Choose a reference point on the machine; i.e.,contact patch of a tire, as a visual reference foruse when crossing the test line.

6 Bring the machine to top drive speed beforereaching the test line. Release the drive joystickwhen your reference point on the machinecrosses the test line.

7 Measure the distance between the test line andyour machine reference point. Refer toSection 2, Specifications.

Note: The brakes must be able to hold the machineon any slope it is able to climb.

3 - 16 Z-30/20N • Z-30/20N RJ Part No. 106373



B-10Test the Drive Speed -Stowed Position


Proper drive function movement is essential tosafe machine operation. The drive function shouldrespond quickly and smoothly to operator control.Drive performance should also be free ofhesitation, jerking and unusual noise over theentire proportionally controlled speed range.


2 Create start and finish lines by marking twolines on the ground 40 feet / 12.2 m apart.

3 Turn the key switch to platform control and pullout the red Emergency Stop button to the onposition at both the ground and platformcontrols.

4 Choose a reference point on the machine; i.e.,contact patch of a tire, as a visual reference foruse when crossing the start and finish lines.

5 Bring the machine to maximum drive speedbefore reaching the start line. Begin timingwhen your reference point on the machinecrosses the start line.

6 Continue at full speed and note the time whenyour machine reference point passes over thefinish line. Refer to Section 2, Specifications.

B-11Test the Drive Speed -Raised or Extended Position


Proper drive function movement is essential tosafe machine operation. The drive function shouldrespond quickly and smoothly to operator control.Drive performance should also be free ofhesitation, jerking and unusual noise over theentire proportionally controlled speed range.


2 Create start and finish lines by marking twolines on the ground 40 feet / 12.2 m apart.

3 Turn the key switch to platform control and pullout the red Emergency Stop button to the onposition at both the ground and platformcontrols.

4 Raise the primary boom more than5 feet / 1.5 m.

5 Choose a reference point on the machine; i.e.,contact patch of a tire, as a visual reference foruse when crossing the start and finish lines.

6 Bring the machine to maximum drive speedbefore reaching the start line. Begin timingwhen your reference point on the machinecrosses the start line.

7 Continue at full speed and note the time whenyour machine reference point passes over thefinish line. Refer to Section 2, Specifications.

Part No. 106373 Z-30/20N • Z-30/20N RJ 3 - 17



B-12Test the Alarm Package(if equipped)Note: Genie specifications require that thisprocedure be performed every 250 hours orquarterly, whichever comes first.

The alarm package includes:

• Travel alarm

• Descent alarm

• Flashing beacon

Alarms and a beacon are installed to alert operatorsand ground personnel of machine proximity andmotion. The alarm package is installed on theground controls side turntable cover.

1 Turn the key switch to ground controls and pullout the red Emergency Stop buttons to the onposition at both ground and platform controls.

Result: The flashing beacon should be on andflashing.

2 Hold the function enable toggle switch to eitherside, then move the primary boom toggle switchto the down position, hold for a moment thenrelease it.

3 Hold the function enable toggle switch to eitherside, then move the secondary boom toggleswitch to the down position, hold for a momentthen release it.

4 Hold the function enable toggle switch to eitherside, then move the jib boom toggle switch tothe down position, hold for a moment thenrelease it.

Result: The descent alarm should sound wheneach control toggle switch is held down.


Result: The flashing beacon should be onand flashing.

6 Press down the foot switch.

7 Move the primary boom toggle switch to thedown position, hold for a moment then releaseit.

8 Move the secondary boom toggle switch to thedown position, hold for a moment then releaseit.

9 Move the jib boom toggle switch to the downposition, hold for a moment then release it.

Result: The descent alarm should sound wheneach control toggle switch is held down.

10 Move the drive joystick off center, hold for amoment then release it. Move the drive joystickoff center in the opposite direction, hold for amoment then release it.

Result: The travel alarm should sound when thedrive joystick is moved off center in eitherdirection.

3 - 18 Z-30/20N • Z-30/20N RJ Part No. 106373



B-13Test the Turntable Rotation StopNote: Genie specifications require that thisprocedure be performed every 250 hours orquarterly, whichever comes first.

The turntable is capable of rotating the boom 359degrees and is stopped midpoint between the steerwheels by the rotation stop. Detecting a rotationstop malfunction is essential to safe operation andgood machine performance. If the turntable rotatespast the rotation stop, component damage mayresult.

1 Turn the key switch to platform controls and pullout the red Emergency Stop buttons to the onposition at both ground and platform controls.

2 Rotate the turntable to the left as far as itwill go.

Result: Movement should stop when theprimary boom reaches midpoint between thesteer tires.

3 Rotate the turntable to the right as far as itwill go.

Result: Movement should stop when theprimary boom reaches mid-point between thesteer tires.

B-14Check the Electrical Contactors


Maintaining the electrical contactors in goodcondition is essential to safe machine operation.Failure to locate a worn or damaged contactorcould result in an unsafe working condition andcomponent damage.


1 Remove the drive chassis cover from the non-steer end of the machine and locate theelectrical contactors mounted on the electricalcomponent mounting panel.

2 Visually inspect the contact points of eachcontactor for the following items:

• Excessive burns

• Excessive pitting

Note: Replace the contactors if any damage isfound.

Part No. 106373 Z-30/20N • Z-30/20N RJ 3 - 19



B-15Perform Hydraulic Oil Analysis


Replacement or testing of the hydraulic oil isessential for good machine performance andservice life. Dirty oil and suction strainers maycause the machine to perform poorly andcontinued use may cause component damage.Extremely dirty conditions may require oil changesto be performed more often.

Note: Before replacing the hydraulic oil, the oil maybe tested by an oil distributor for specific levels ofcontamination to verify that changing the oil isnecessary. If the hydraulic oil is not replaced atthe two year inspection, test the oil quarterly.Replace the oil when it fails the test. See E-1,Test or Replace the Hydraulic Oil.

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


REV DChecklist C Procedures

C-1Grease the Platform OverloadMechanism (if equipped)

Note: Genie specifications require that thisprocedure be performed every 500 hours or 6months, whichever comes first. Perform thisprocedure more often if dusty conditions exist.

Application of lubrication to the platform overloadmechanism is essential to safe machine operation.Continued use of an improperly greased platformoverload mechanism could result in the system notsensing an overloaded platform condition and willresult in component damage.

1 Locate the grease fittings on each pivot pin ofthe platform overload assembly.

2 Thoroughly pump grease into each greasefitting using a multi-purpose grease.



C-2Test the Platform OverloadSystem (if equipped)

Note: Genie specifications require that thisprocedure be performed every 500 hours or sixmonths, whichever comes first.

Testing the platform overload system regularly isessential to safe machine operation. Continueduse of an improperly operating platform overloadsystem could result in the system not sensing anoverloaded platform condition. Machine stablitycould be compromised resulting in the machinetipping over.

The platform overload system is designed to detectan overloaded platform and prevent machineoperation anytime the machine is turned on. Whenactivated, the system halts all normal boomoperation, giving visual and audible warning to theoperator.

Models equipped with the platform overload optionare provided with additional machine components:an adjustable spring-loaded platform supportsubassembly, a limit switch, an electronic modulewhich receives the overload signal and interruptspower, and an audio/visual warning indication toalert the operator of the overload.

Part No. 106373 Z-30/20N • Z-30/20N RJ 3 - 21


REV D CHECKLIST C PROCEDURES

The platform support subassembly utilizes two loadsupport arms that are opposed in a fullparallelogram link. This isolates platform loads intoa shear or vertical state, which translates into acompressive load. A spring in the parallelogramlink supports this purely compressive loadregardless of where the load is placed in theplatform.

As weight is added to the platform, the spring willcompress until, when the platform is overloaded,the lower arm contacts a limit switch and therebyactivating the overload signal. When adjustedcorrectly, the platform overload system willdeactivate normal boom operation at platformcapacity.

Note: Perform this procedure with the machine ona firm, level surface.

1 Turn the key switch to platform control. Start theengine and level the platform.

2 Determine the maximum platform capacity.Refer to the machine serial plate.

3 Remove all weight, tools and accessories fromthe platform.

Note: Failure to remove all weight, tools andaccessories from the platform will result in aninaccurate test.

4 Using a suitable lifting device, place a testweight equal to that of the available capacityone of the locations shown.Refer to Illustration 1.

Result: The platform overload indicator lightsshould be off at both the ground and platformcontrols and the alarm should not sound.

Result: The platform overload indicator lightsare on and the alarm is sounding. Calibrate theplatform overload system. Refer to RepairProceedure 2-3, How to Calibrate the PlatformOverload System (if equipped).

5 Carefully move the test weight to eachremaining location. Refer to Illustration 1.

Result: The platform overload indicator lightsshould be off at both the ground and platformcontrols and the alarm should not sound.

Result: The platform overload indicator lightsare on and the alarm is sounding. Calibrate theplatform overload system. Refer to RepairProceedure 2-3, How to Calibrate the PlatformOverload System (if equipped).

Illustration 1

6 Using a suitable lifting device, place anadditional 10 lbs / 4.5 kg of weight onto theplatform.

Result: The alarm should sound.The platform overload indicator lights should beflashing at both the ground and platformcontrols.

Result: The alarm does not sound and theplatform overload indicator lights are notflashing. Calibrate the platform overloadsystem. Refer to Repair Proceedure 2-3,How to Calibrate the Platform Overload System(if equipped).

Note: There may be a 2 second delay before theoverload indicator lights flash and the alarmsounds.

3 - 22 Z-30/20N • Z-30/20N RJ Part No. 106373


REV D

7 Carefully move the test weights to eachremaining location on the platform.Refer to Illustration 1.

Result: The alarm should sound.The platform overload indicator lights should beflashing at both the ground and platformcontrols.

Result: The alarm does not sound and theplatform overload indicator lights are notflashing. Calibrate the platform overloadsystem. Refer to Repair Proceedure 2-3,How to Calibrate the Platform OverloadSystem (if equipped).

Note: There may be a 2 second delay before theoverload indicator lights flash and the alarmsounds.

8 Test all machine functions from the platformcontrols.

Result: All platform control functions should notoperate.

9 Turn the key switch to ground control.

10 Test all machine functions from the groundcontrols.

Result: All ground control functions should notoperate.

11 Using auxiliary power, test all machine functionsfrom the ground controls.

Result: All ground control functions shouldoperate.

CHECKLIST C PROCEDURES

12 Using a suitable lifting device, lift the additionaltest weight from the platform.

Result: The platform overload indicator lightsshould turn off at both the ground and platformcontrols and the alarm should not sound.

Note: There may be an 2 second delay before theoverload indicator lights and alarm turn off.

13 Start the engine and test all machine functionsfrom the ground controls.

Result: All ground control functions shouldoperate normally.

14 Turn the key switch to platform control.


Result: All platform control functions shouldoperate.

Note: If the platform overload system is notoperating properly, Refer to Repair Procedure 2-3,How to Calibrate the Platform Overload System(if equipped).

16 Using a suitable lifting device, remove theremaining test weights from the platform.

Part No. 106373 Z-30/20N • Z-30/20N RJ 3 - 23


REV DChecklist D Procedures

D-1Check the Primary BoomWear Pads

Note: Genie specifications require that thisprocedure be performed every 1000 hours orannually, whichever comes first.

Maintaining the primary boom wear pads in goodcondition is essential to safe machine operation.Wear pads are placed on boom tube surfaces toprovide a low friction, replaceable wear padbetween moving parts. Improperly shimmed wearpads or continued use of worn out wear pads mayresult in component damage and unsafe operatingconditions.

1 Measure each wear pad. Replace the wear padonce it reaches the minimum allowablethickness. If the wear pad is still withinspecifications, shim as necessary to obtainminimum clearance with zero binding.

2 Extend and retract the primary boom throughthe entire range of motion to check for tightspots that could cause binding or scraping.

Note: Always maintain squareness between theprimary boom outer and inner tubes.

Models without rotating jib boom:

Primary boom wearpad specifications Minimum

Top and side wear pads 5/8 inch(extension end of boom) 15.9 mm

Bottom wear pads 5/8 inch(extension end of boom) 15.9 mm

Bottom and side wear pads 5/8 inch(pivot end of boom) 15.9 mm

Top wear pads 3/8 inch(pivot end of boom) 9.5 mm

Models with rotating jib boom:

Primary boom wearpad specifications Minimum

All wear pads 3/8 inch9.5 mm

3 - 24 Z-30/20N • Z-30/20N RJ Part No. 106373


REV DCHECKLIST D PROCEDURES

D-2Check the Free-wheelConfiguration


Proper use of the free-wheel configuration isessential to safe machine operation. Thefree-wheel configuration is used primarily fortowing. A machine configured to free-wheelwithout operator knowledge may cause death orserious injury and property damage.

Collision hazard. Select a worksite that is firm and level.

Component damage hazard. If themachine must be towed, do notexceed 2 mph / 3.2 km/h.

1 Chock the steer wheels to prevent the machinefrom rolling.

2 Center a lifting jack of ample capacity(15,000 lbs / 7000 kg) under the drive chassisbetween the non-steer wheels.

3 Lift the wheels off the ground and then placeblocks under the drive chassis for support.

4 Disengage the drive hubs by turning over thedrive hub disconnect caps on eachnon-steer wheel hub.

5 Manually rotate each non-steer wheel.

Result: Each non-steer wheel should rotate withminimum effort.

6 Engage the drive hubs by turning overthe drive hub disconnect caps.

7 Carefully remove the blocks, lower the machineand remove the jack.

Collision hazard. Failure to engagethe drive hubs could result indeath or serious injury andproperty damage.

disengaged position

engaged position

Part No. 106373 Z-30/20N • Z-30/20N RJ 3 - 25


REV D

D-3Check the Turntable RotationBearing Bolts


Maintaining proper torque on the turntable bearingbolts is essential to safe machine operation.Improper bolt torque could result in an unsafeoperating condition and component damage.

1 Raise the secondary boom and place a safetychock on the secondary boom lift cylinder.Carefully lower the secondary boom onto the liftcylinder safety chock.

Crushing hazard. Keep handsaway from the cylinder and allmoving parts when lowering thesecondary boom.

Note: A lift cylinder safety chock is availablethrough Genie Service Parts (Genie part no.36555).

2 Confirm that each turntable mounting bolt istorqued in sequence to specification. Refer toSection 2, Specifications.

Bolt torque sequence

CHECKLIST D PROCEDURES

3 Raise the secondary boom and remove thesafety chock. Lower the secondary boom to thestowed position.

4 Open the latch on the battery packs and swingthem out to expose the turntable bearing boltaccess hole.

5 Confirm that each turntable bearing mountingbolt is torqued in sequence to specification.Refer to Section 2, Specifications.

Bolt torque sequence

1

7

3

5

8

2

6

4

1

7

11

5

3

108

6

12

2

9

4

3 - 26 Z-30/20N • Z-30/20N RJ Part No. 106373


REV D

D-4Replace the Drive Hub Oil


Replacing the drive hub oil is essential for goodmachine performance and service life. Failure toreplace the drive hub oil at yearly intervals maycause the machine to perform poorly andcontinued use may cause component damage.

1 Select the drive hub to be serviced. Drive themachine until one of the two plugs is at thelowest point.

2 Remove both plugs and drain the oil into asuitable container.

3 Drive the machine until one plug is at the topand the other is at 90 degrees.

a drive hub plugs

4 Fill the hub with oil from the top hole until the oillevel is even with the bottom of the side plughole. Refer to Section 2, Specifications.


6 Repeat this procedure for the other drive hub.


D-5Replace the Hydraulic TankReturn Filter Element

Note: Genie specifications require that thisprocedure be performed every 1000 hours orannually, whichever comes first. Perform thisprocedure more often if dusty conditions exist.

Replacement of the hydraulic return filter element isessential for good machine performance andservice life. A dirty or clogged filter element maycause the machine to perform poorly andcontinued use may cause component damage.Extremely dirty conditions may require that thefilter element be replaced more often.

Bodily injury hazard. Beware ofhot oil. Contact with hot oil maycause severe burns.

1 Locate the hydraulic return filter housing on topof the hydraulic tank.

2 Clean the area around the oil filter housing caplocated on top of the reservoir.

3 Remove the cap from the housing.

4 Lift the handle on the filter element and rotatethe element counterclockwise to release theelement from the housing.

5 Remove the filter element from the filterhousing.

a

Part No. 106373 Z-30/20N • Z-30/20N RJ 3 - 27


REV D

6 Install the new oil filter element into the filterhousing.

7 Push the filter element down to be sure the o-ring on the element is fully seated into thehousing.

8 Rotate the filter element clockwise to lock it inplace.

9 Install the filter housing cap.

10 Clean up any oil that may have spilled duringthe replacement procedure.

11 Use a permanent ink marker to write the dateand number of hours from the hour meter onthe oil filter housing.

12 Turn the key switch to ground controls and pullout the red Emergency Stop button to the onposition.

13 Move and hold the function enable toggle switchto either side and move and hold the primaryboom toggle switch in the up direction.

14 Inspect the filter housing and relatedcomponents to be sure that there are no leaks.


D-6Inspect for Turntable BearingWear

Note: Genie requires that this procedure beperformed every 1000 hours or annually, whichevercomes first.

Periodic inspection of turntable bearing wear isessential to safe machine operation, good machineperformance and service life. Continued use of aworn turntable bearing could create an unsafeoperating condition, resulting in death or seriousinjury and component damage.

1 Grease the turntable bearing. See A-5, Greasethe Turntable Bearing and Rotate Gear.

2 Torque the turntable bearing bolts tospecification. See D-3, Check the TurntableRotation Bearing Bolts.

3 Raise the primary and secondary booms to fullheight using the ground controls. Do not extendthe primary boom.

3 - 28 Z-30/20N • Z-30/20N RJ Part No. 106373


REV DCHECKLIST D PROCEDURES

4 Place a dial indicator between the drive chassisand the turntable at a point that is directlyunder, or in line with, the boom and no morethan 1 inch / 2.5 cm from the bearing.

Note: To obtain an accurate measurement, placethe dial indicator no more than 1 inch / 2.5 cm fromthe turntable rotation bearing.

a turntableb dial indicatorc drive chassisd turntable rotation bearing

5 Adjust the dial indicator to "0".

6 Lower the secondary boom to the stowedposition and lower the primary boom to ahorizontal position. Fully extend the primaryboom.

7 Note the reading on the dial indicator.

Result: The measurement is less than0.055 inch / 1.4 mm. The bearing is good.

Result: The measurement is more than0.055 inch / 1.4 mm. The bearing is worn andneeds to be replaced.

8 Fully retract the primary boom. Raise theprimary and secondary booms to full height.Visually inspect the the dial indicator to be surethe needle returns to the "0" position.

9 Remove the dial indicator and rotate theturntable 90°.

10 Repeat steps 4 through 9 until the rotationbearing has been checked in at least fourequally spaced areas 90° apart.

11 Lower the primary and secondary booms to thestowed position and turn the machine off.

12 Remove the dial indicator from the machine.

a

b

c

d

Part No. 106373 Z-30/20N • Z-30/20N RJ 3 - 29


REV D

E-1Test or Replace the Hydraulic Oil

Note: Genie specifications require that thisprocedure be performed every 2000 hours or everytwo years, whichever comes first. Perform thisprocedure more often if dusty conditions exist.

Replacement or testing of the hydraulic oil isessential for good machine performance andservice life. Dirty oil and suction strainers maycause the machine to perform poorly andcontinued use may cause component damage.Extremely dirty conditions may require that the oilbe changed more often.

Note: Before replacing the hydraulic oil, the oil maybe tested by an oil distributor for specific levels ofcontamination to verify that changing the oil isnecessary. If the hydraulic oil is not replaced atthe two year inspection, test the oil quarterly.Replace the oil when it fails the test.

Note: When removing a hose assembly or fitting,the O-ring on the fitting and/or hose end must bereplaced and then torqued to specification duringinstallation. Refer to Section 2, Hydraulic Hose andFitting Torque Specifications.

1 Close the hydraulic shutoff valve located at thehydraulic tank.

Component damage hazard. Themachine must not be operatedwith the hydraulic tank shutoffvalve in the closed position orcomponent damage will occur. Ifthe tank valve is closed, removethe key from the key switch andtag the machine to informpersonnel of the condition.

2 Place a suitable container under the hydraulictank. Refer to Section 2, Specifications.

3 Tag, disconnect and plug the hydraulic hosefrom the hydraulic tank shutoff valve.

Bodily injury hazard. Sprayinghydraulic oil can penetrate andburn skin. Loosen hydraulicconnections very slowly to allowthe oil pressure to dissipategradually. Do not allow oil to squirtor spray.

4 Open the valve on the hydraulic tank andcompletely drain the oil into a suitablecontainer.


Checklist E Procedures

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


REV D

5 Tag, disconnect and plug the hydraulic hosesfrom the hydraulic tank return filter housing.Cap the fittings on the filter housing.



6 Remove the hydraulic tank mounting fasteners.Remove the hydraulic tank from the machine.

7 Remove the tank lid retaining fasteners andremove the lid and return filter assembly fromthe tank.

8 Remove the suction strainer from the hydraulictank and clean it using a mild solvent.

9 Rinse out the inside of the tank with a mildsolvent.

10 Install the suction strainer into the tank.

11 Install the lid and return filer assembly onto thehydraulic tank.

12 Install the hydraulic tank on the machine. Installthe hydraulic tank mounting fasteners andtorque them to 8 ft-lbs / 10.8 Nm.

Component damage hazard. Thehydraulic tank is plastic and maybecome damaged if the tankmounting fasteners are overtightened.

13 Install the hydraulic hoses.

14 Fill the tank with hydraulic oil until the fluid iswithin the FULL and ADD marks on the hydraulictank. Do not overfill. Refer to Section 2,Specifications.

15 Clean up any oil that may have spilled. Properlydiscard of used oil.

16 Open the hydraulic tank shutoff valve.

Component damage hazard. Besure to open the hydraulic tankshutoff valve after installing thehydraulic tank.

CHECKLIST E PROCEDURES

Part No. 106373 Z-30/20N • Z-30/20N RJ 3 - 31


REV D

E-2Grease the Steer AxleWheel Bearings

Note: Genie requires that this procedure beperformed every 2000 hours or every two years,whichever comes first.

Maintaining the steer axle wheel bearings isessential for safe machine operation and servicelife. Operating the machine with loose or wornwheel bearings may cause an unsafe operatingcondition and continued use may result incomponent damage. Extremely wet or dirtyconditions or regular steam cleaning and pressurewashing of the machine may require that thisprocedure be performed more often.

1 Loosen the wheel lug nuts. Do not removethem.

2 Block the non-steer wheels and center a liftingjack under the steer axle.

3 Raise the machine 6 inches / 15 cm and placeblocks under the drive chassis for support.

4 Remove the lug nuts. Remove the tire andwheel assembly.

5 Check for wheel bearing wear by attempting tomove the wheel hub side to side, then up anddown.

Result: There should be no side to side or upand down movement.

Skip to step 10 if there is no movement.

6 Remove the dust cap from the hub. Remove thecotter pin from the castle nut.

7 Tighten the castle nut to 158 ft-lbs / 214 Nm toseat the bearings.

Note: Rotate the hub by hand while torquing thecastle nut to make sure the bearings seat properly.

8 Loosen the castle nut one full turn and thentorque to 35 ft-lbs / 47 Nm.

9 Check for wheel bearing wear by attempting tomove the wheel hub side to side, then up anddown.

Result: If there is no side to side or up anddown movement, continue with step 10 togrease the wheel bearings.

Result: If there is side to side or up and downmovement, continue to step 10 and replace thewheel bearings with new ones.

Note: When replacing a wheel bearing, both theinner and outer bearings, including the pressed-inraces, must be replaced.

10 Remove the castle nut.

11 Pull the hub off of the spindle. The washer andouter bearing should fall loose from the hub.

12 Place the hub on a flat surface and gently prythe bearing seal out of the hub. Remove therear bearing.

13 Pack both bearings with clean, fresh grease.



CHECKLIST E PROCEDURES

3 - 32 Z-30/20N • Z-30/20N RJ Part No. 106373


REV DCHECKLIST E PROCEDURES

14 Place the large inner bearing into the rear of thehub.

15 Install a new bearing grease seal into the hub bypressing it evenly into the hub until it is flush.

Note: Always replace the bearing grease sealwhen the hub has been removed.

16 Slide the hub onto the yoke spindle.

Component damage hazard. Donot apply excessive force ordamage to the lip of the seal mayoccur.

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 toseat the bearings.



22 Install a new cotter pin. Bend the cotter pinto lock it in.

Note: Always use a new cotter pin when installinga castle nut.

23 Install the dust cap, then the tire and wheelassembly. Torque the wheel lug nuts tospecification. Refer to Section 2, Specifications.

Part No. 106373 Z-30/20N • Z-30/20N RJ 4 - 1

June 2008 Section 4 • Repair Procedures

Repair Procedures

Observe and Obey:

Repair procedures shall be completed by aperson trained and qualified on the repair of thismachine.


Repair any machine damage or malfunctionbefore operating the machine.

Before Repairs Start:

Read, understand and obey the safety rulesand operating instructions in the appropriateGenie Z-30/20N Operator’s Manual on yourmachine.

Be sure that all necessary tools and parts areavailable and ready for use.

Read each procedure completely and adhereto the instructions. Attempting shortcuts mayproduce hazardous conditions.

Unless otherwise specified, perform eachrepair procedure with the machine in thefollowing configuration:


• Boom in stowed position

• Turntable rotated with the boom betweenthe non-steer wheels


• Wheels chocked


About This SectionMost of the procedures in this section should onlybe performed by a trained service professionalin a suitably equipped workshop. Select theappropriate repair procedure after troubleshootingthe problem.

Perform disassembly procedures to the pointwhere repairs can be completed. Then tore-assemble, perform the disassembly steps inreverse order.

Symbols Legend






Indicates that a specific result is expected afterperforming a series of steps.

Indicates that an incorrect result has occurredafter performing a series of steps.

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

June 2008Section 4 • Repair Procedures

REV B

1-1Controllers

The drive joystick is connected to the drive motorcontroller, located under the drive chassis cover atthe non-steer end of the machine. Maintaining theboom function speed controller at the propersettings is essential to safe machine operation.The boom function speed controller should operatesmoothly and provide proportional speed controlthrough its entire range of motion. For furtherinformation or assistance, contact the GenieIndustries Service Department.

a boom function speed controllerb drive and brake printed circuit boardc drive joystick

Boom Function Speed ControllerAdjustments

Electrocution/burn hazard. Contactwith electrically charged circuitscould result in death or seriousinjury. Remove all rings, watchesand other jewelry.

Note: Do not adjust the boom function speedcontroller unless the static battery supply voltage isabove 24V DC.

1 Turn the key switch to platform controls and pullout the red Emergency Stop button to the onposition at both the ground and platformcontrols.

2 Open the platform control box lid and locate theboom function speed controller.

a black/red wireb diodec white/red wired boom function speed controllere ramp rate trimpotf threshold trimpotg max out trimpot

Platform Controls

a

b

c

a

b

c

d

f

g

e

Part No. 106373 Z-30/20N • Z-30/20N RJ 4 - 3


REV B PLATFORM CONTROLS

3 Locate the diode between the black/red wirefrom the boom function speed controller and thewhite/red wire. Disconnect the white/red wirefrom the diode on the black/red wire.

4 Connect the negative lead from a multi-meterset to measure amperage to the wire connectorof the white/red wire. Connect the positive leadof the multi-meter to the diode on the black/redwire.

5 Turn the boom function speed controller to theCREEP position.

6 Set the threshold: Press down the foot switchand move the primary boom toggle switch tothe up position. Adjust the amperage to 0.28A.Turn the threshold trimpot adjustment screwclockwise to increase the amperage orcounterclockwise to decrease the amperage.

7 Turn the boom function speed controller tothe 9 position.

8 Set the max out: Press down the foot switchand move the primary boom toggle switch tothe down position. Adjust the amperageto 0.65A. Turn the max out trimpot adjustmentscrew clockwise to increase the amperage orcounterclockwise to decrease the amperage.

9 Start a timer and simultaneously press downthe foot switch and move the primary boomtoggle switch in the down direction. Note howlong it takes to reach 0.65A.

10 Set the ramp rate: Turn the ramp rate trimpot toobtain a 2 second delay from 0 to 0.65A. Turnthe trimpot clockwise to increase the time orcounterclockwise to decrease the time.

11 Disconnect the leads from the multi-meter andconnect the white/red wire to the diode on theblack/red wire.

Boom function speedcontroller specifications

Threshold 0.28A(controller turned to CREEP)

Max out 0.65A(controller turned to 9)

Ramp rate 2 seconds

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

Section 4 • Repair Procedures

REV C

June 2008

2-1Platform Leveling Slave Cylinder

The slave cylinder and the rotator pivot are thetwo primary supports for the platform. The slavecylinder keeps the platform level through theentire range of primary boom motion. It operates ina closed loop hydraulic circuit with the mastercylinder. The slave cylinder is equipped withcounterbalance valves to prevent platformmovement in the event of a hydraulic line failure.

How to Remove the SlaveCylinderNote: Before cylinder removal is considered, bleedthe slave cylinder to be sure there is noair in the closed loop hydraulic circuit.


1 Extend the boom until the slave cylinderbarrel-end pivot pin is accessible.

2 Raise the boom slightly and place blocks underthe platform for support. Lower the boom untilthe platform is resting on the blocks.

3 Tag and disconnect the hydraulic hoses to theslave cylinder at the union and connect themtogether with a connector. Cap the fittings onthe cylinder hoses.

Bodily injury hazard. Sprayinghydraulic oil can penetrate andburn skin. Loosen hydraulicconnections very slowly to allowthe oil pressure to dissipategradually. Do not allow oil tosquirt or spray.

4 Remove the external snap rings from therod-end pivot pin. Do not remove the pin.

5 Remove the external snap rings from thebarrel-end pivot pin.

6 Place a block of wood under the barrel of theslave cylinder for support.

7 Use a soft metal drift to remove the rod-endpivot pin.

Crushing hazard. The platformcould fall if not properly supported.

8 Use a soft metal drift to remove the barrel-endpivot pin.

9 Carefully pull the cylinder with hydraulic hosesout of the boom.

Crushing hazard. The slavecylinder could fall if not properlysupported.

How to Bleed the Slave Cylinder1 Raise the jib boom to a horizontal position.

2 Move the platform level toggle switch up anddown through two platform leveling cycles toremove any air that might be in the system.

Platform Components

Part No. 106373 Z-30/20N • Z-30/20N RJ 4 - 5


REV C PLATFORM COMPONENTS

2-2Platform Rotator

The platform rotator is a hydraulically activatedhelical gear assembly used to rotate the platform180 degrees.

How to Remove thePlatform RotatorNote: When removing a hose assembly or fitting,the O-ring on the fitting and/or hose end must bereplaced and then torqued to specification duringinstallation. Refer to Section 2, Hydraulic Hose andFitting Torque Specifications.

1 Remove the platform.

2 Tag, disconnect and plug the hydraulic hosesfrom the platform rotate manifold.


3 Support the platform mounting weldment. Donot apply any lifting pressure.

4 Remove the six mounting bolts from theplatform mounting weldment. Remove thecenter bolt and slide the platform mountingweldment off of the platform rotator.

5 Support the platform rotator with a suitablelifting device. Do not apply any lifting pressure.

6 Remove the pin retaining fasteners from the jibboom and leveling links to platform rotator pivotpins. Do not remove the pins.

7 Support the jib boom, jib boom cylinder andleveling links with an overhead crane.

8 Use a soft metal drift to drive both pins out, thenremove the platform rotator from the machine.

Crushing hazard. The platformrotator may fall when the pins areremoved if not properly supported.

Note: When installing the platform rotator, be sureto torque the fasteners to specification. Refer toSection 2, Specifications.

How to Bleed the PlatformRotator Note: This procedure will require two people.

1 Move the function enable toggle switch to eitherside and activate the platform rotate toggleswitch to the right and then to the left throughtwo platform rotation cycles. Then hold theswitch to the right position until the platform isfully rotated to the right.

4 - 6 Z-30/20N • Z-30/20N RJ Part No. 106373


REV C

June 2008

b

c

d

a

PLATFORM COMPONENTS

2 Connect a clear hose to the top bleed valve.Place the other end of the hose in a containerto collect any drainage. Secure the container tothe boom.

3 Open the top bleed valve on the rotator, but donot remove it.

a clear hoseb top bleed valvec bottom bleed valved container

4 Move the function enable toggle switch to eitherside and hold the platform rotate toggle switchto the left position until the platform is fullyrotated to the left. Continue holding the toggleswitch until air stops coming out of the bleedvalve. Close the bleed valve.

Crushing hazard. Keep clear ofthe platform during rotation.

5 Connect the clear hose to the bottom bleedvalve and open the valve. Do not remove thebleed valve.

6 Move the function enable toggle switch to eitherside and hold the platform rotate toggle switchto the right position until the platform is fullyrotated to the right. Continue holding the toggleswitch until air stops coming out of the bleedvalve. Close the bleed valve.

Crushing hazard. Keep clear ofthe platform during rotation.

7 Remove the hose from the bleed valve andclean up any hydraulic oil that may have spilled.

8 Rotate the platform fully in both directions andinspect the bleed valves for leaks.

Part No. 106373 Z-30/20N • Z-30/20N RJ 4 - 7


REV C PLATFORM COMPONENTS

2-3Platform Overload System

How to Calibrate the PlatformOverload SystemCalibration of the platform overload system isessential to safe machine operation. Continueduse of an improperly calibrated platform overloadsystem could result in the system failing to sensean overloaded platform. The stability of themachine is compromised and it could tip over.

Note: Perform this procedure with the machine ona firm, level surface.


2 Determine the maximum platform capacity.Refer to the machine serial plate.

3 Remove all weight, tools and accessories fromthe platform.

Note: Failure to remove all weight, tools andaccessories from the platform will result in anincorrect calibration.

4 Using a suitable lifting device, place a testweight equal to the maximum platform capacityat the center of the platform floor.

5 Move the platform up and down by hand, so itbounces approximately 2.5 to 5 cm / 1 to 2inches. Allow the platform to settle.

Result: The overload indicator lights are off andthe alarm does not sound. Proceed to step 6.

Result: The overload indicator lights areflashing at the platform and ground controls,and the alarm is sounding. Slowly tighten theload spring adjustment nut in a clockwisedirection in 10° increments until the overloadindicator light turns off, and the alarm does notsound. Proceed to step 8.

Note: The platform will need to be moved up anddown and allowed to settle between eachadjustment.

Note: There may be a 2 second delay before theplatform overload indicator light and alarmresponds.


Result: The overload indicator lights are off atthe platform and ground controls, and the alarmdoes not sound. Slowly loosen the load springadjustment nut in a counterclockwise directionin 10° increments until the overload indicatorlight flashes at both the platform and groundcontrols, and the alarm sounds.Proceed to step 7.

Result: The overload indicator lights areflashing at the platform and ground controls,and the alarm is sounding. Repeat thisprocedure beginning with step 5.

Note: The platform will need to be moved up anddown and allowed to settle between eachadjustment.

Note: There may be a 2 second delay before theplatform overload indicator lights and alarmresponds.

4 - 8 Z-30/20N • Z-30/20N RJ Part No. 106373


REV C

June 2008

PLATFORM COMPONENTS


Result: The overload indicator lights are off andthe alarm does not sound. Proceed to step 8.

Result: The overload indicator lights areflashing at the platform and ground controls,and the alarm is sounding. Repeat thisprocedure beginning with step 5.


8 Add an additional 10 lb / 4.5 kg test weight tothe platform.

Result: The overload indicator light is flashing atboth the ground and platform controls, and thealarm is sounding. Proceed to step 9.

Result: The overload indicator light is off at boththe ground and platform controls, and the alarmdoes not sound. Remove the additional 10 lb /4.5 kg test weight. Repeat this procedurebeginning with step 6.



Result: All platform control functions should notoperate.

10 Turn the key switch to ground control.


Result: All ground control functions should notoperate.

12 Using a suitable lifting device, lift the test weightoff the platform floor.

Result: The platform overload indicator lightshould be off at both the ground and platformcontrols and the alarm should not sound.

Note: There may be a 2 second delay before theoverload indicator lights and alarm turn off.


Result: All ground control functions shouldoperate normally.



Result: All platform control functions shouldoperate normally.

Part No. 106373 Z-30/20N • Z-30/20N RJ 4 - 9


REV B

3-1Jib Boom

How to Remove the Jib BoomNote: When removing a hose assembly or fitting,the O-ring on the fitting and/or hose end must bereplaced and then torqued to specification duringinstallation. Refer to Section 2, Hydraulic Hose andFitting Torque Specifications.


2 Remove the platform mounting weldmentand the platform rotator. See 2-2, How toRemove the Platform Rotator.

3 Tag, disconnect and plug the jib boom liftcylinder hydraulic hoses. Cap the fittings on thejib boom lift cylinder.


4 Remove the cable cover from the side of thejib boom.

5 Remove the mounting fasteners from the jibboom/platform rotate manifold and lay themanifold to the side. Do not remove the hosesor disconnect the wiring.

Component damage hazard.Hoses and cables can bedamaged if they are kinked orpinched.

6 Models with rotating jib boom: Tag,disconnect and plug the hydraulic hoses fromthe jib boom rotator. Cap the fittings on therotator manifold.


7 Attach a lifting strap from an overhead crane tothe jib boom.

8 Models without rotating jib boom: Removethe pin retaining fastener from the jib boompivot pin at the jib boom bellcrank. Use a softmetal drift to remove the pin, then remove thejib boom from the jib boom bellcrank.

Crushing hazard. The jib boomcould fall when the pin is removedif not properly supported by theoverhead crane.

Models with rotating jib boom: Remove thepin retaining fastener from the jib boom pivotpin at the jib boom rotator. Use a soft metal driftto remove the pin, then remove the jib boomfrom the jib boom rotator.

Crushing hazard. The jib boomcould fall when the pin is removedif not properly supported by theoverhead crane.

Jib Boom Components

4 - 10 Z-30/20N • Z-30/20N RJ Part No. 106373


REV B

9 Remove the pin retaining fasteners from the jibboom lift cylinder rod-end pivot pin. Do notremove the pin.

10 Models without rotating jib boom: Removeboth of the jib boom leveling links from the bellcrank.

Models with rotating jib boom: Remove bothof the jib boom leveling links from the jib boomrotator.

11 Attach a lifting strap from an overhead crane tothe rod-end of the jib boom lift cylinder.

12 Models without rotating jib boom: Use a softmetal drift to remove the jib boom lift cylinderrod-end pivot pin. Remove the jib boom liftcylinder from the bell crank.

Models with rotating jib boom: Use a softmetal drift to remove the jib boom lift cylinderrod-end pivot pin. Remove the jib boom liftcylinder from the jib boom rotator.

Crushing hazard. The jib boomlift cylinder could fall when the pinis removed if not properlysupported by the overhead crane.

JIB BOOM COMPONENTS

3-2Jib Boom Bell Crank(models without rotatingjib boom)

How to Remove the Jib BoomBell CrankNote: Perform this procedure with the boom in thestowed position.


1 Remove the Jib Boom, See 3-1, How toRemove the Jib Boom.

2 Support and secure the jib boom bell crank toan appropriate lifting device.

3 Remove the pin retaining fasteners from theslave cylinder rod-end pivot pin. Do not removethe pin.

4 Place a block of wood under the platformleveling slave cylinder for support. Protect thecylinder rod from damage.

5 Remove the pin retaining fasteners from the jibboom bell crank at the extension boom. Use asoft metal drift to remove the pin.

6 Use a soft metal drift to remove the slavecylinder rod-end pivot pin.

7 Remove the jib boom bell crank from theextension boom.

Crushing hazard. The jib boombell crank could becomeunbalanced and fall when the pinsare removed if not properlysupported and secured to thelifting device.

Part No. 106373 Z-30/20N • Z-30/20N RJ 4 - 11


REV B

7 Place a block of wood under the platformleveling slave cylinder for support. Protect thecylinder rod from damage.

8 Remove the pin retaining fasteners from the jibboom bell crank at the extension boom. Use asoft metal drift to remove the pin.

9 Use a soft metal drift to remove the slavecylinder rod-end pivot pin.

10 Remove the jib boom bell crank from theextension boom.

Crushing hazard. The jib boombell crank could becomeunbalanced and fall when the pinsare removed if not properlysupported and secured to thelifting device.

3-3Jib Boom Rotator(models with rotating jib boom)

The platform rotator is a hydraulically activatedhelical gear assembly used to rotate the jib boom160 degrees.

How to Remove the Jib BoomRotatorNote: When removing a hose assembly or fitting,the O-ring on the fitting and/or hose end must bereplaced and then torqued to specification duringinstallation. Refer to Section 2, Hydraulic Hose andFitting Torque Specifications.

1 Remove the jib boom, See 3-1, How to Removethe Jib Boom.

2 Support and secure the jib boom rotator to anappropriate lifting device.

3 Remove the eight mounting bolts from the jibboom rotator mount.

4 Remove the center bolt. Carefully remove thejib boom rotator from the machine.

Crushing hazard. The jib boomrotator could become unbalancedand fall when removed from themachine if not properly supportedand secured to the lifting device.

Note: When installing the jib boom rotator, be sureto torque the fasteners to specification. Refer toSection 2, Specifications.

5 Support and secure the jib boom bell crank toan appropriate lifting device.

6 Remove the pin retaining fasteners from theslave cylinder rod-end pivot pin. Do not removethe pin.

JIB BOOM COMPONENTS

4 - 12 Z-30/20N • Z-30/20N RJ Part No. 106373


REV B

How to Bleed the Jib BoomRotatorNote: This procedure will require two people.

1 Turn the key switch to ground controls and pullout the red Emergency Stop buttons to the onposition at both the ground and platformcontrols.

2 Connect a clear hose to the top bleed valve.Place the other end of the hose in a containerto collect any drainage. Open the top bleedvalve, but do not remove it.

a top bleed valveb clear hosec containerd bottom bleed valve

3 Move and hold the function enable toggle switchto either side and move and hold the jib boomrotate toggle switch to the right forapproximately 5 seconds, then release it.Repeat three times.

Crushing hazard. Keep hands andhead clear of the platform pivotweldment during rotation.

4 Move and hold the function enable switch toeither side and move and hold the jib boomrotate toggle switch to the left for approximately5 seconds, then release it. Repeat three times.

5 Fully rotate the jib boom to the left and continueholding the jib boom rotate toggle switch untilair stops coming out of the bleed valve.Immediately release the platform rotate toggleswitch and close the bleed valve.


6 Rotate the jib boom to the right until the jibboom is centered.

7 Connect the clear hose to the bottom bleedvalve and open the valve.

8 Rotate the jib boom to the right and continueholding the platform rotate toggle switch until airstops coming out of the bleed valve.

Crushing hazard. Keep hands andhead clear of the jib boom duringrotation.

9 Close the bleed valve and remove the hose.

10 Rotate the jib boom full left and right andinspect the bleed valves for leaks.


11 Turn the key switch to the off position and cleanup any hydraulic oil that may have spilled.

JIB BOOM COMPONENTS

c

b

a

d

Part No. 106373 Z-30/20N • Z-30/20N RJ 4 - 13


REV B

3-4Jib Boom Lift Cylinder

How to Remove the Jib BoomLift Cylinder

Note: When removing a hose assembly orfitting, the O-ring on the fitting and/or hose endmust be replaced and then torqued tospecification during installation. Refer toSection 2, Hydraulic Hose and Fitting TorqueSpecifications.

1 Raise the jib boom slightly and place blocksunder the platform mounting weldment forsupport. Lower the jib boom until the platform isresting on the blocks.

2 Tag, disconnect and plug the jib boom liftcylinder hydraulic hoses. Cap the fittings on thecylinder.


3 Remove the pin retaining fasteners from the jibboom lift cylinder rod-end pivot pin. Do notremove the pin.

4 Use a soft metal drift to tap the rod-end pivotpin half way out and lower one of the levelinglinks to the ground. Tap the pin the otherdirection and lower the opposite leveling link.Do not remove the pin.

5 Attach a lifting strap from an overhead crane tothe rod end of the jib boom lift cylinder.

6 Remove the pin retaining fasteners from the jibboom lift cylinder barrel-end pivot pin. Use asoft metal drift to remove the barrel-end pivotpin.

7 Use a soft metal drift to remove the jib boom liftcylinder rod-end pivot pin. Remove the jib boomlift cylinder from the machine.

Crushing hazard. The jib boom liftcylinder could fall when the pinsare removed if not properlysupported by the overhead crane.

JIB BOOM COMPONENTS

4 - 14 Z-30/20N • Z-30/20N RJ Part No. 106373


REV B

4-1Cable Track

The primary boom cable track guides the cablesand hoses running up the boom. It can be repairedlink by link without removing the cables and hosesthat run through it. Removing the entire primaryboom cable track is only necessary whenperforming major repairs that involve removing theprimary boom.

How to Repair the Plastic CableTrack

Component damage hazard. Theprimary boom cable track can bedamaged if it is twisted.

Note: A 7-link repair section of cable track isavailable through the Genie Industries ServiceParts (Genie part no. 58919).

a link separation pointb lower clip

1 Use a slotted screwdriver to pry down on thelower 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.

4-2Primary Boom

How to Shim the Primary Boom1 Extend the boom until the wear pads are

accessible.

2 Loosen the wear pad mounting fasteners.

3 Install the new shims under the wear pad toobtain zero clearance and zero drag.

4 Tighten the mounting fasteners.

5 Extend and retract the boom through an entirecycle. Check for tight spots that could causescraping or binding.

Note: Always maintain squareness between theouter and inner boom tubes.

Primary Boom Components

a

b

Part No. 106373 Z-30/20N • Z-30/20N RJ 4 - 15


REV B PRIMARY BOOM COMPONENTS

How to Remove thePrimary Boom

Bodily injury hazard. Thisprocedure requires specific repairskills, lifting equipment and asuitable workshop. Attempting thisprocedure without these skills andtools could result in death orserious injury and significantcomponent damage. Dealerservice is strongly recommended.

Note: Perform this procedure with the boom in thestowed position.



2 Remove the platform rotator. See 2-3, How toRemove the Platform Rotator.

3 Remove the jib boom. See 3-1,How to Remove the Jib Boom.

4 Models without rotating jib boom: Removethe jib boom bellcrank. See 3-2, How toRemove the Jib Boom Bellcrank.

Models with rotating jib boom: Remove thejib boom rotator. See 3-3, How to Remove theJib Boom Rotator.

5 Tag, disconnect and cap the slave cylinderhydraulic hoses at the union. Plug the hosesfrom the slave cylinder.


6 Remove the upper cable track mountingfasteners from the platform end of the boom.

7 Remove the cable track mounting fasteners,then remove the cable track from the boom andlay it flat on the ground.

Component damage hazard. Thecable track can be damaged if it istwisted.

Component damage hazard.Cables and hoses can bedamaged if they are kinked orpinched.

8 Raise the secondary boom until the primaryboom lift cylinder rod-end pivot pin is accessibleabove the mid-pivot weldment. Turn themachine off.

9 Disconnect the battery packs from the machine.

10 Remove all the hose and cable clamps from theunderside of the primary boom and at the pivotend of the primary boom.

4 - 16 Z-30/20N • Z-30/20N RJ Part No. 106373


REV B

11 Attach a lifting strap of ample capacity from anoverhead 5 ton / 5000 kg crane to the primaryboom for support.

12 Locate the cables from the primary boom cabletrack to the platform control box. Number eachcable and its entry location at the platformcontrol box.

13 Open the platform conrol box.

14 Tag and disconnect each wire from the cablesin the platform control box.

15 Pull all the cables out of the platform controlbox.

16 Remove the front counterweight cover.

17 Remove the extension boom drive limit switchfrom the side of the primary boom at the pivotend. Do not disconnect the wiring.

18 Tag, disconnect and plug the hydraulic hosesfrom the jib boom/platform rotate manifold.

19 Pull all the electrical cables and hydraulic hosesout of the plastic cable track. Then pull all theelectrical cables and hydraulic hoses outthrough the boom rest pad.


20 Remove the pin retaining fastener from themaster cylinder rod-end pivot pin. Use a softmetal drift to remove the pivot pin. Pull thecylinder back and secure it from moving.

21 Tag, disconnect and plug the extension cylinderhydraulic hoses. Cap the fittings on thecylinder.


22 Attach a lifting strap from an overhead crane tothe primary boom lift cylinder.

23 Place 2 x 4 x 18 inch / 5 x 10 x 46 cm supportblocks under the cylinder, across the secondaryboom.

24 Remove the pin retaining fastener from theprimary boom lift cylinder rod-end pivot pin. Usea soft metal drift to remove the pin.

Crushing hazard. The primaryboom lift cylinder could fall when itis removed from the machine if notproperly supported.

25 Lower the rod end of the primary boom liftcylinder onto support blocks. Protect thecylinder rod from damage.

26 Remove the pin retaining fastener from theprimary boom pivot pin.

27 Remove the primary boom pivot pin with a softmetal drift. Carefully remove the primary boomassembly from the machine.

Crushing hazard. The primaryboom assembly could becomeunbalanced and fall whenremoved from the machine if notproperly supported by theoverhead crane.

PRIMARY BOOM COMPONENTS

Part No. 106373 Z-30/20N • Z-30/20N RJ 4 - 17



How to Disassemblethe Primary BoomNote: Complete disassembly of the boom is onlynecessary if the outer or inner boom tubes mustbe replaced. The extension cylinder can beremoved without completely disassembling theboom. See 4-4, How to Remove the ExtensionCylinder.

1 Remove the primary boom. See 4-2,How to Remove the Primary Boom.

2 Place blocks under the extension cylinder forsupport.

3 Remove the retaining fasteners from theextension cylinder barrel-end pivot pin. Use asoft metal drift to remove the pin.

4 Remove and label the location of the wear padsfrom the top side of the boom tube at theplatform end of the boom.

Note: Pay careful attention to the location andamount of shims used with each wear pad.

5 Support the extension tube with an overheadcrane at the platform end of the boom.

Crushing hazard. The boomextension tube could fall whenremoved from the boom if notproperly supported.

6 Support and slide the extension tube out of theprimary boom tube. Place the extension tubeon blocks for support.

Note: During removal, the overhead crane strapwill need to be carefully adjusted for properbalancing.

7 Remove the external snap rings from the slavecylinder barrel-end pivot pin.

8 Use a soft metal drift and drive the slavecylinder barrel-end pivot pin out.

9 Remove the slave cylinder from the primaryextension boom tube.

10 Remove the external snap rings from theextension cylinder rod-end pivot pins at theplatform end of the extension tube. Use a softmetal drift to remove the pins.

11 Support and slide the extension cylinder out ofthe pivot end of the boom extension tube. Placethe extension cylinder on blocks for support.


4 - 18 Z-30/20N • Z-30/20N RJ Part No. 106373


REV BPRIMARY BOOM COMPONENTS

4-3Primary Boom Lift Cylinder

The primary boom lift cylinder raises and lowersthe primary boom. The primary boom lift cylinder isequipped with counterbalance valves to preventmovement in the event of a hydraulic line failure.

How to Remove the PrimaryBoom Lift Cylinder



1 Raise the secondary boom enough to accessthe primary boom lift cylinder barrel-endpivot pin.

2 Raise the primary boom enough to access theprimary boom lift cylinder rod-end pivot pin.

3 Support the primary boom lift cylinder with asuitable lifting device. Place a block of woodacross the upper secondary boom to supportthe cylinder when the rod-end pin is removed.

4 Attach an overhead crane to the primary boomat the platform end for support. Raise theprimary boom using the overhead crane justenough to relieve the pressure on the primaryboom lift cylinder rod-end pivot pin.

5 Remove the counterweight cover fasteners.Remove the counterweight cover from themachine.

6 Place a block of wood between thecounterweight plate on the leveling link and thecross member of the upper secondary boom.Carefully lower the secondary boom onto theblock.

Crushing hazard. Keep handsaway from the block and allmoving parts when lowering thesecondary boom onto the block.

7 Remove the pin retaining fasteners from theprimary boom lift cylinder rod-end pivot pin. Usea soft metal drift to remove the pin.

Crushing hazard. The primaryboom lift cylinder may fall if notproperly supported when therod-end pivot pin is removed.

8 Lower the rod end of the cylinder onto theblocks that were placed on the uppersecondary boom.

9 Remove the pin retaining fastener from theground control side upper secondary levelinglink pivot pin at the upper pivot (same side ofmachine as the primary boom lift cylinderbarrel-end pivot pin retainer).

10 Place a rod through the upper secondaryleveling link pivot pin at the upper pivot andtwist to remove the pin.

Part No. 106373 Z-30/20N • Z-30/20N RJ 4 - 19


REV B

11 Swing the leveling link up out of the way andsecure it from moving.

12 Tag, disconnect and plug the primary boom liftcylinder hydraulic hoses. Cap the fittings on thecylinder.


13 Support the barrel end of the primary boom liftcylinder with straps or ropes to restrict it fromswinging freely.

14 Remove the pin retaining fastener from theprimary boom lift cylinder barrel-end pivot pin.Do not remove the pivot pin.

15 Place a rod through the barrel-end pivot pin andtwist to remove the pin.

Crushing hazard. The primaryboom lift cylinder may fall whenthe barrel-end pivot pin is removedif not properly supported.

16 Attach an overhead crane or similar liftingdevice to the lug on the rod-end of the primaryboom lift cylinder. Carefully loosen the strapsand allow the primary boom lift cylinder toslowly swing down.

17 Carefully remove the cylinder from the machine.

Crushing hazard. The primaryboom lift cylinder will fall if notproperly supported when it isremoved from the machine.

PRIMARY BOOM COMPONENTS

4-4Extension Cylinder

The extension cylinder extends and retracts theprimary boom extension tube. The extensioncylinder is equipped with counterbalance valves toprevent movement in the event of a hydraulic linefailure.

How to Remove theExtension Cylinder



1 Raise the primary boom to the horizontalposition. Extend the boom 3 to 4 feet / 1 m untilthe extension cylinder rod-end pivot pins areaccessible.

2 Remove the external snap rings from theextension cylinder rod-end pivot pins. Use asoft metal drift to remove the pins.

3 Remove the counterweight cover fasteners.Remove the counterweight cover from themachine.

4 Raise the secondary boom until the mastercylinder rod-end pivot pin is accessible.

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


REV BPRIMARY BOOM COMPONENTS

5 Remove the primary boom extend drive limitswitch from the pivot end of the primary boom.Do not disconnect the wiring.

6 Remove the retaining fastener from the mastercylinder rod-end pivot pin. Use a soft metal driftto remove the pin.

7 Manually retract the master cylinder and push ittoward the platform end of the boom to obtainenough clearance for extension cylinderremoval.

8 Tag, disconnect and plug the extension cylinderhydraulic hoses. Cap the fittings on thecylinder.


9 Remove the retaining fastener from theextension cylinder barrel-end pivot pin. Use asoft metal drift to remove the pin.

10 Carefully pull out and properly support theextension cylinder from the primary boom witha lifting strap from an overhead crane.

Crushing hazard. The cylindercould fall if not properly supportedwhen it is pulled out of theextension tube.

Note: To make installation of the extension cylindereasier, be sure that the cylinder rod is extended3 to 4 feet / 1 m.

Note:During removal, the overhead crane strap willneed to be carefully adjusted for proper balancing.

4-5Platform Leveling MasterCylinder

The platform leveling master cylinder acts as apump for the slave cylinder. It is part of the closed-loop hydraulic circuit that keeps the platform levelthrough the entire range of primary boom motion.The platform leveling master cylinder is locatedinside the upper mid-pivot at the pivot end of theprimary boom.

How to Remove the PlatformLeveling Master Cylinder



Note: Before cylinder removal is considered, bleedthe cylinder to be sure that there is no air in theclosed loop. See 2-2, How to Bleed the SlaveCylinder.

1 Remove the counterweight cover.

2 Raise the secondary boom until the mastercylinder barrel-end pivot pin is above theturntable counterweights.

3 Raise the primary boom until the mastercylinder rod-end pivot pin is accessible.

Part No. 106373 Z-30/20N • Z-30/20N RJ 4 - 21



4 Attach an overhead crane to the pivot end ofthe primary boom for support. Do not lift it.

5 Secure the upper secondary boom to the pivotend of the primary boom with a strap (this willprevent the upper secondary boom from fallingwhen the master cylinder barrel-end pivot pin isremoved from the cylinder).

6 Tag, disconnect and plug the master cylinderhydraulic hoses. Cap the fittings on thecylinder.


7 Attach a lifting strap from an overhead crane tothe lug on the rod end of the master cylinder,then secure the strap to the primary boom (usethis strap to lower the master cylinder out of theupper pivot).

8 Remove the pin retaining fastener from themaster cylinder rod-end pivot pin. Use a softmetal drift to remove the pin.

9 Remove the pin retaining fastener from themaster cylinder barrel-end pivot pin. Use a softmetal 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 toremove the cylinder. The pin should remain inone side of the upper secondary boom andupper pivot.

Crushing hazard. The uppersecondary boom and the upperpivot could fall if the pivot pin iscompletely removed.

10 Use the strap around the rod-end lug to lowerthe cylinder out of the machine.

4 - 22 Z-30/20N • Z-30/20N RJ Part No. 106373


REV BSecondary Boom Components

Secondary Booma upper pivotb upper compression armc mid-pivotd compression linke lower secondary boomf lower compression armg turntable pivoth counterweighti upper secondary boom

a

b

c

e

f

g

h

i

b

d

Part No. 106373 Z-30/20N • Z-30/20N RJ 4 - 23


REV B SECONDARY BOOM COMPONENTS

5-1Secondary Boom

How to Disassemble theSecondary Boom

Bodily injury hazard. Theprocedures in this section requirespecific repair skills, liftingequipment and a suitableworkshop. Attempting thisprocedure without these skills andtools could result in death orserious injury and significantcomponent damage. Dealerservice is required.


1 Remove the counterweight cover.

2 Place a suitable lifting device under the platformfor support.


4 Remove the cable cover from the side of the jibboom.

5 Remove the wire loom from the cables at theplatform control box.

6 Locate the cables from the primary boom cabletrack to the platform control box. Number eachcable and its entry location at the platformcontrol box.

7 Open the platform control box.

8 Tag and disconnect each wire from the cablesin the platform control box.


9 Pull the cables out of the platform control box.

10 Pull all of the electrical cables out of the plasticcable track. Do not pull out the hydraulic hoses.

11 Remove the hose clamps from the bottom sideof the primary boom.

12 Before serial number 5945: Tag, disconnectand plug the platform rotator hydraulic hoses atthe union located on the bottom side of theprimary boom. Cap the fittings on the union.

After serial number 5944: Tag, disconnect andplug the hydraulic hoses from the "P" and "T"ports at the jib boom/rotate manifold. Cap thefittings on the manifold.


4 - 24 Z-30/20N • Z-30/20N RJ Part No. 106373


REV BSECONDARY BOOM COMPONENTS

13 Remove the hose clamp from the side of theprimary boom at the pivot end.

14 Remove the primary boom extend drive speedlimit switch (LS1) mounted on the side of theprimary boom at the pivot end. Do notdisconnect the wiring.

15 Attach a lifting strap from an overhead crane tothe pivot end of the primary boom.

16 Carefully lift the secondary and primary boomassembly with the overhead crane until themaster cylinder and primary boom lift cylinderhydraulic hoses are accessible.

17 Remove the cable covers from the top of theupper secondary boom.

18 Tag, disconnect and plug the primary boom liftcylinder and master cylinder hydraulic hoses.Cap the fittings on the cylinders.


19 Lower the secondary boom to the fully stowedposition.

20 Pull all the cables and hoses through the upperpivot.


21 Position a lifting strap from the overhead craneapproximately 2 feet / 60 cm from the platformend of the primary boom. Measure from theplatform end of the primary boom tube.

22 Remove the pin retaining fasteners from theupper pivot to upper secondary compressionarm pivot pins. Use a soft metal drift to removethe pins.

23 Swing the compression arms down and out ofthe way. Secure them from moving.

24 Remove the pin retaining fasteners from theupper pivot to the upper secondary boom pivotpin. Use a soft metal drift to remove the pin.

25 Carefully remove the entire primary boomassembly from the machine (primary boomassembly, jib boom assembly, platform, mastercylinder, primary lift cylinder and upper pivot).

Crushing hazard. The primaryboom assembly could becomeunbalanced and fall whenremoved from the machine if notproperly supported by theoverhead crane. Do not removethe assembly from the machineuntil it is properly balanced.


26 Place the entire assembly onto a structurecapable of supporting it.

Part No. 106373 Z-30/20N • Z-30/20N RJ 4 - 25



27 Remove the pin retaining fasteners from theupper secondary compression arm pivot pins.Do not remove the pins.

28 Position a lifting strap from an overhead craneat the center of the control box side uppersecondary compression arm.

29 Use a soft metal drift to remove the uppersecondary boom compression arm pivot pinsand remove the compression arm from themachine. Repeat this step for the hydraulic tankside upper secondary compression arm.

Crushing hazard. The uppersecondary compression arm couldbecome unbalanced and fall whenremoved from the machine if notproperly supported by theoverhead crane.

30 Close the hydraulic tank shutoff valve. Tag,disconnect and plug the hydraulic hose fromthe hydraulic tank shutoff valve.


31 Open the valve on the hydraulic tank and drainthe oil into a container of suitable capacity.Refer to Section 2, Specifications.


32 Tag, disconnect and plug the hydraulic hosefrom the hydraulic tank return filter housing.Cap the fitting on the filter housing.




34 Open the ground controls side turntable cover.

35 Remove the terminal strip cover retainingfasteners. Remove the cover.

36 Remove the terminal strip retaining fasteners.Do not disconnect the wiring.

37 Remove the plastic plug in the bulkhead toaccess the secondary boom lift cylinder rod-endpivot pin.

38 Remove the pin retaining fastener from the rodend of the secondary boom lift cylinder. Use asoft metal drift to remove the pin through theaccess holes in the bulkheads. Secure thecylinder from moving.

39 Remove the pin retaining fastener from thelower pivot pin on the compression link. Use asoft metal drift to remove the pin.

4 - 26 Z-30/20N • Z-30/20N RJ Part No. 106373


REV BSECONDARY BOOM COMPONENTS

40 Attach a lifting strap from an overhead crane tothe upper secondary boom.

41 Remove the pin retaining fastener from themid-pivot to upper secondary boom pivot pin.Use a soft metal drift to remove the pin.

42 Remove the upper secondary boom withcompression link from the machine.

Crushing hazard. The uppersecondary boom withcompression link could becomeunbalanced and fall whenremoved from the machine if notproperly supported by theoverhead crane.

43 Remove the mounting fasteners from thecounterweight attached to the lower levelinglink.

44 Attach a lifting strap from an overhead crane tothe counterweight. Remove the counterweightfrom the lower leveling link.

Tip-over hazard. Thecounterweight is critical tomachine stability. If thecounterweight is not installedduring re-assembly of themachine, the machine will becomeunstable and tip over.

Crushing hazard. Thecounterweight could becomeunbalanced and fall whenremoved from the machine if notproperly supported by theoverhead crane.

45 Remove the mounting fasteners from thefunction manifold and slide the functionmanifold to the side. This will allow access tothe secondary boom lift cylinder barrel-endpivot pin.

46 Remove the mounting fasteners from theauxiliary power unit. Do not disconnect theelectrical cables or hydraulic hoses.

47 Slide the auxiliary power unit to the side toaccess the other secondary boom lift cylinderbarrel-end pivot pin.

48 Remove the retaining fasteners from thesecondary boom lift cylinder barrel-end pivotpins.

49 Attach a lifting strap from an overhead crane tothe lug on the rod end of the secondary boomlift cylinder.

50 Tag, disconnect and plug the hydraulic hosesfrom the secondary boom lift cylinder. Cap thefittings on the cylinder.


51 Use a slide hammer to remove the barrel-endpivot pins (access the pins from the accessholes in the bulkheads, one on each side).Remove the secondary boom lift cylinder fromthe machine.

Crushing hazard. The secondaryboom lift cylinder could becomeunbalanced and fall whenremoved from the machine if notproperly supported by theoverhead crane.

Part No. 106373 Z-30/20N • Z-30/20N RJ 4 - 27



52 Attach a lifting strap from an overhead crane tothe mid-pivot for support.

53 Remove the pin retaining fasteners from themid-pivot to the lower secondary compressionarm pivot pins. Use a slide hammer andremove the pins. Lower the compression armsdown.

54 Remove the pin retaining fasteners from themid-pivot to the lower secondary boom pivotpin. Use a soft metal drift to remove the pins.

55 Remove the mid-pivot from the machine.

Crushing hazard. The mid-pivotcould become unbalanced and fallwhen removed from the machine ifnot properly supported by theoverhead crane.

56 Remove the secondary boom drive speed limitswitch (LS4) mounted to the turntable riser onthe ground controls side. Do not disconnect thewiring.

57 Attach a lifting strap from an overhead crane tothe ground control side lower secondary boomcompression arm.

58 Remove the pin retaining fastener from thelower secondary boom compression arm toturntable riser pivot pin.

59 Use a slide hammer and remove the pin.Remove the compression arm from themachine. Repeat for the hydraulic tank sidelower secondary boom compression arm.

Crushing hazard. The lowersecondary compression arm couldbecome unbalanced and fall whenremoved from the machine if notproperly supported by theoverhead crane.

60 Attach a lifting strap from an overhead crane tothe lower secondary boom.

61 Remove the pin retaining fastener from thelower secondary boom to turntable riser pivotpin. Use a soft metal drift to remove the pin.

62 Remove the lower secondary boom from themachine.

Crushing hazard. The lowersecondary boom could becomeunbalanced and fall whenremoved from the machine if notproperly supported by theoverhead crane.

4 - 28 Z-30/20N • Z-30/20N RJ Part No. 106373


REV B

5-2Secondary Boom Lift Cylinder

The secondary boom lift cylinder raises andlowers the secondary boom. The secondaryboom lift cylinder is equipped with counterbalancevalves to prevent movement in the event of ahydraulic line failure.

How to Remove the SecondaryBoom Lift Cylinder



1 Rotate the turntable to either side until the boomis centered between the steer and non-steertires.

2 Raise the primary boom to full height. Do notextend it.

3 Swing out the battery pack that is directly belowthe secondary boom lift cylinder.


SECONDARY BOOM COMPONENTS

5 Open the hydraulic tank side turntable cover.

6 Tag and disconnect the power cables on theauxiliary power unit.


7 Close the hydraulic tank shutoff valve. Tag anddisconnect and plug the hydraulic hose fromthe hydraulic tank shutoff valve.


8 Open the valve on the hydraulic tank and drainthe oil into a container of suitable capacity.Refer to Section 2, Specifications.


9 Tag, disconnect and plug the hydraulic hosefrom the hydraulic tank return filter housing.Cap the fitting on the filter housing.



Part No. 106373 Z-30/20N • Z-30/20N RJ 4 - 29


REV B


11 Open the ground controls side turntable cover.

12 Remove the terminal strip cover retainingfasteners. Remove the cover.

13 Remove the terminal strip retaining fasteners.Do not disconnect the wiring.

14 Remove the plastic plug in the bulkhead toaccess the secondary boom lift cylinder rod-endpivot pin.

15 Remove the mounting fasteners from thefunction manifold and slide the manifold to theside This will allow access to the hydraulic tankside barrel-end pivot pin.

16 Attach a lifting strap from an overhead crane tothe lug on the rod end of the secondary boomlift cylinder.

17 From the bottom side of the cylinder, removethe retaining fasteners from the secondaryboom lift cylinder barrel-end pivot pins.

18 Remove the hose clamp under the lowersecondary boom.

19 Use a slide hammer to remove both barrel-endpivot pins (access the pins from the accessholes in the bulkheads, one on each side).

20 Remove the pin retaining fastener from thesecondary boom lift cylinder rod-end pivot pin.

SECONDARY BOOM COMPONENTS

21 Use a soft metal drift to remove the secondaryboom rod-end pivot pin.

Crushing hazard. The secondaryboom lift cylinder may fall whenthe rod-end pivot pin is removed ifnot properly supported by theoverhead crane.

22 Carefully lower the cylinder down through thesecondary boom, enough to access thehydraulic hoses. Do not pinch the hoses.

Component damage hazard.Hoses can be damaged if they arekinked or pinched.

23 Tag, disconnect and plug the hydraulic hosesfrom the secondary boom lift cylinder. Cap thefittings on the cylinder.


24 Remove the cylinder through the top of thesecondary boom.

Crushing hazard. The secondaryboom lift cylinder could becomeunbalanced and fall whenremoved from the machine if notproperly supported by theoverhead crane.

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


REV AHydraulic Pumps

6-1Auxiliary and Function Pump

How to Remove the AuxiliaryPump or Function PumpNote: When removing a hose assembly or fitting,the O-ring on the fitting and/or hose end must bereplaced and then torqued to specification duringinstallation. Refer to Section 2, Hydraulic Hose andFitting Torque Specifications.

1 Close the hydraulic shutoff valve located at thehydraulic tank.

Component damage hazard. Themachine must not be operatedwith the hydraulic tank shutoffvalve in the closed position orcomponent damage will occur. Ifthe tank valve is closed, removethe key from the key switch andtag the machine to informpersonnel of the condition.

2 Tag, disconnect and plug the hydraulic hosesfrom the pump. Cap the fittings on the pump.


3 Remove the pump mounting bolts from thepump. Carefully remove the pump from theelectric motor.

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



4 - 32 Z-30/20N • Z-30/20N RJ Part No. 106373


REV D

June 2008

7-1Function Manifold Components

The function manifold is locate behind the ground controls turntable cover.

Index SchematicNo. 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.

Manifolds

Part No. 106373 Z-30/20N • Z-30/20N RJ 4 - 33


REV D MANIFOLDS

21222324

5 6 7 98

20

15

19

18

17

12

13

14

16

10

1 43

11

2

4 - 34 Z-30/20N • Z-30/20N RJ Part No. 106373


REV D

June 2008

MANIFOLDS

Function Manifold Components, continued

The function manifold is locate behind the ground controls turntable cover.


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

23 Flow regulator valve,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

Part No. 106373 Z-30/20N • Z-30/20N RJ 4 - 35


REV D

21222324

5 6 7 98

20

15

19

18

17

12

13

14

16

10

1 43

11

2

MANIFOLDS

4 - 36 Z-30/20N • Z-30/20N RJ Part No. 106373


REV D

June 2008

7-2Valve Adjustments -Function Manifold

How to Adjust the System ReliefValve1 Connect a 0 to 5000 psi / 0 to 350 bar pressure

gauge to the test port on the function manifold.

2 Turn the key switch to ground control and pullout the red Emergency Stop button to the onposition.

3 Move and hold the function enable toggle switchto either side and move and hold the primaryboom extend/retract toggle switch in the retractdirection with the primary boom fully retracted.Observe the pressure reading on the pressuregauge. Refer to Section 2, Specifications.

4 Turn the machine off. Hold the system reliefvalve with a wrench and remove the cap(item R).

5 Adjust the internal hex socket. Turn it clockwiseto increase the pressure or counterclockwise todecrease the pressure. Install the relief valvecap.

Tip-over hazard. Do not adjustthe relief valve higher thanspecified.

6 Repeat steps 2 and 3 to confirm the relief valvepressure setting.

How to Adjust the Primary BoomDown Relief Valve1 Connect a 0 to 3000 psi / 0 to 200 bar pressure



3 Move and hold the function enable toggle switchto either side and move and hold the primaryboom up/down toggle switch in the downdirection with the primary boom fully lowered.Observe the pressure reading on the pressuregauge. Refer to Section 2, Specifications.

4 Turn the machine off. Hold the primary downrelief valve with a wrench and remove the cap(item F).

5 Adjust the internal hex socket. Turn it clockwiseto increase the pressure or counterclockwise todecrease the pressure. Then install the reliefvalve cap.



MANIFOLDS

Part No. 106373 Z-30/20N • Z-30/20N RJ 4 - 37


REV D

How to Adjust the SecondaryBoom Down Relief Valve1 Connect a 0 to 3000 psi / 0 to 200 bar pressure



3 Move and hold the function enable toggle switchto either side and move and hold the secondaryboom up/down toggle switch in the downdirection with the secondary boom fullylowered. Observe the pressure reading on thepressure gauge. Refer to Section 2,Specifications.

4 Turn the machine off. Hold the secondary boomdown relief valve with a wrench and remove thecap (item E).




How to Adjust the Primary BoomExtend Relief Valve1 Connect a 0 to 3000 psi / 0 to 200 bar pressure



3 Move and hold the function enable toggle switchto either side and move and hold the primaryboom extend/retract toggle switch in the extenddirection with the primary boom fully extended.Observe the pressure reading on the pressuregauge. Refer to Section 2, Specifications.

4 Turn the machine off. Hold the primary booomextend relief valve with a wrench and removethe cap (item G).


Tip-over hazard. Do not adjustthe relief valves higher thanspecified.


MANIFOLDS

4 - 38 Z-30/20N • Z-30/20N RJ Part No. 106373


REV D

June 2008

How to Adjust the TurntableRotate Relief Valve1 Connect a 0 to 3000 psi / 0 to 200 bar pressure



3 Move and hold the function enable toggle switchto either side and move and hold the turntablerotate toggle switch in the right direction (untilturntable stops against the rotation stop).Observe the pressure reading on the pressuregauge. Refer to Section 2, Specifications.

4 Turn the machine off. Hold the turntable reliefvalve(s) with a wrench and remove the cap(item D).




MANIFOLDS

Part No. 106373 Z-30/20N • Z-30/20N RJ 4 - 39


REV D MANIFOLDS

7-3Jib Boom and Platform / Jib Boom Rotate Manifold Components

The jib boom/platform rotate manifold is mounted to the jib boom.


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

4 Flow regulator valve,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)

4

5

1 2 31

2

4

Models withoutrotating jib boom

Models withrotating jib boom

4 - 40 Z-30/20N • Z-30/20N RJ Part No. 106373


REV D

June 2008

7-4Valve Coils

How to Test a CoilA properly functioning coil provides anelectromotive force which operates the solenoidvalve. Critical to normal operation is continuitywithin the coil that provides this force field.


1 Tag and disconnect the wiring from the coil tobe tested.

2 Test the coil resistance.

Coils with 2 terminals: Connect the leads fromthe ohmmeter to the valve coil terminals.

Coils with 1 terminal: Connect the positivelead from the ohmmeter to the valve coilterminal, then connect the negative lead fromthe ohmmeter to the internal ring of the valvecoil.

Result: The resistance should be withinspecification, plus or minus 30%.

Result: If the resistance is not withinspecification, plus or minus 30%, replace thecoil.

Valve Coil ResistanceSpecificationNote: The following coil resistance specificationsare at an ambient temperature of 68°F / 20°C. Asvalve coil resistance is sensitive to changes in airtemperature, the coil resistance will typicallyincrease or decrease by 4% for each 18°F / 10°Cthat your air temperature increases or decreasesfrom 68°F / 20°C.

Valve Coil Resistance Specification

Description Specification

Solenoid valve, 3 position 4 way, 20V DC 22 Ω(schematic items A, J, K, U, V, Y, AA, BB and CC)

Proportional solenoid valve, 24V DC 19.5 Ω(schematic item H)

Solenoid valve, N.C. poppet, 20V DC 23.5 Ω(schematic item M)

Solenoid valve, N.O. poppet, 20V DC 23.5 Ω(schematic item P)

MANIFOLDS

Part No. 106373 Z-30/20N • Z-30/20N RJ 4 - 41


REV D MANIFOLDS

9VBATTERY

10

RESISTOR

�

MULTIMETER

COIL

+

-

+

-

d

b

b

a

c

c

How to Test a Coil DiodeGenie incorporates spike suppressing diodes in allof its valve coils. Properly functioning coil diodesprotect the electrical circuit by suppressing voltagespikes. Voltage spikes naturally occur within afunction circuit following the interruption ofelectrical current to a coil. Faulty diodes can fail toprotect the electrical system, resulting in a trippedcircuit breaker or component damage.


1 Test the coil for resistance. See How to Test aCoil.

2 Connect a 10Ω resistor to the negative terminalof a known good 9V DC battery. Connect theother end of the resistor to a terminal on thecoil.

Note: The battery should read 9V DC or morewhen measured across the terminals.

Resistor, 10ΩΩΩΩΩGenie part number 27287

a multimeterb 9V DC batteryc 10Ω resistord coil

Note: Dotted lines in illustration indicate areversed connection as specified instep 6

3 Set a multimeter to read DC current.

Note: The multimeter, when set to read DCcurrent, should be capable of reading up to 800mA.

4 Connect the negative lead to the other terminalon the coil.

Note: If testing a single-terminal coil, connect thenegative lead to the internal metallic ring at eitherend of the coil.

5 Momentarily connect the positive lead from themultimeter to the positive terminal on the 9V DCbattery. Note and record the amperage reading.

6 At the battery or coil terminals, reverse theconnections. Note and record the currentreading.

Result: Both current readings are greater than0 mA and are different by a minimum of 20%.The coil is good.

Result: If one or both of the current readings are0 mA, or if the two current readings do not differby a minimum of 20%, the coil and/or itsinternal diode are faulty and the coil should bereplaced.

4 - 42 Z-30/20N • Z-30/20N RJ Part No. 106373


REV B

8-1Turntable Rotation HydraulicMotor

The turntable rotation hydraulic motor is the onlyserviceable component of the turntable rotationassembly. The worm gear must not be removedfrom the housing. In order to remove the housing,the turntable has to be removed.

How to Remove the TurntableRotation MotorNote: When removing a hose assembly or fitting,the O-ring on the fitting and/or hose end must bereplaced and then torqued to specification duringinstallation. Refer to Section 2, Hydraulic Hose andFitting Torque Specifications.

1 Tag, disconnect and plug the hydraulic hosesfrom the turntable rotation motor. Cap thefittings on the motor.


2 Remove the turntable rotation motor mountingbolts. Remove the motor from the machine.

Turntable Rotation Components

Part No. 106373 Z-30/20N • Z-30/20N RJ 4 - 43


REV CSteer Axle Components

9-1Hub and Bearings

How to Remove theHub and Bearings1 Loosen the wheel lug nuts. Do not remove

them.

2 Block the non-steer wheels and place a liftingjack under the steer axle.

3 Raise the machine. Place blocks underthe drive chassis for support.

4 Remove the lug nuts. Remove the tireand wheel assembly.

5 Remove the dust cap, cotter pin andcastle nut.

Note: Always use a new cotter pin when installing acastle nut.

6 Pull the hub off the yoke spindle. The washerand outer bearing should fall loose from thehub.

7 Place the hub on a flat surface and gently prythe grease seal out of the hub. Remove theinner bearing.

Note: When removing a bearing, always use a newinner bearing seal.

How to Install the Huband BearingsNote: When replacing a wheel bearing, both theinner and outer bearings, including the pressed-inraces, must be replaced.

1 Be sure that both bearings are packedwith clean, fresh grease.

2 Place the large inner bearing into the rear of thehub.

3 Install a new bearing grease seal into the hubby pressing it evenly into the hub until it is flush.

Note: Always replace the bearing grease sealwhen removing the hub.

4 Slide the hub onto the yoke spindle.

Component damage hazard. Donot apply excessive force ordamage to the lip of the seal mayoccur.

5 Fill the hub cavity with clean, fresh grease.

6 Place the outer bearing into the hub.

7 Install the washer and castle nut.

8 Tighten the castle nut to 158 ft-lbs / 214 Nmto seat the bearings.



10 Install a new cotter pin. Bend the cotter pin tolock it in place.

Note: Always use a new cotter pin when installing acastle nut.

11 Install the dust cap, then the tire and wheelassembly.

12 Lower the machine and remove the blocks.

13 Torque the wheel lug nuts to specification. Referto Section 2, Specifications.

4 - 44 Z-30/20N • Z-30/20N RJ Part No. 106373


REV B

10-1Motor Controller

The drive motor controller is located under the non-steer end drive chassis cover. The drive motorcontroller can recognize machine drivemalfunctions and display controller fault codes byflashing a LED at the ground controls and on themotor controller. See the Fault Code section of thismanual for a list of fault codes and additionalinformation. There are no adjustments needed onthe drive joystick controller. For further informationor assistance, consult the Genie Industries ServiceDepartment.

How to Test the Motor ControllerNote: Use the following procedure to test the motorcontroller. If the motor controller is found to befaulty, note which test failed and which fault code(if any) was present at the time of failure.

1 Turn the key switch to the off position anddisconnect the battery packs from the machine.

2 Tag and disconnect all power cables from themotor controller.


3 Press the release tab on the motor controllerharness connector and remove the motorcontroller harness connector from the motorcontroller.

4 Set an ohmmeter to diode test mode.

5 Connect the leads from an ohmmeter to testeach motor controller terminal combinationlisted below and check the forward / reversebias (diode test).

Result: All desired results must be within thespecified range. If any test has a result notwithin the specified range, replace the motorcontroller.

Forward Bias:

Test Desired result

Positive Lead Negative Lead

M- B+ 0.4 to 0.45

B- M- 0.4 to 0.45

F1 B+ 0.45 to 0.5

F2 B+ 0.45 to 0.5

B- F1 0.45 to 0.5

B- F2 0.45 to 0.5

Reverse Bias:

Test Desired result

Positive Lead Negative Lead

B+ M- Rises to .0L V

M- B- Rises to .0L V

B+ F1 Rises to .0L V

B+ F2 Rises to .0L V

F1 B- Rises to .0L V

F2 B- Rises to .0L V

Motor Controller

Part No. 106373 Z-30/20N • Z-30/20N RJ 5 - 1

June 2008 Section 5 • Fault Codes

Before Troubleshooting:

Read, understand and obey the safety rules andoperating instructions printed in theGenie Z-30/20N Operator’s Manual on yourmachine.

Be sure that all necessary tools and testequipment are available and ready for use.

Be aware of the following hazards and followgenerally accepted safe workshop practices.

Crushing hazard. When testingor replacing any hydrauliccomponent, always supportthe structure and secure itfrom movement.



Note: Perform all troubleshooting on a firm, levelsurface.

Note: Two persons will be required to safelyperform some troubleshooting procedures.

Fault Codes

Observe and Obey:

Troubleshooting and repair procedures shall becompleted by a person trained and qualified onthe repair of this machine.



Unless otherwise specified, perform eachrepair procedure with the machine in thefollowing configuration:


• Boom in stowed position

• Turntable rotated with the boom betweenthe non-steer wheels


• Wheels chocked


5 - 2 Z-30/20N • Z-30/20N RJ Part No. 106373

June 2008Section 5 • Fault Codes

REV AFAULT CODES

Tip-over hazard. When adjustingthe raised drive speed settings,the maximum raised drive speedmust not exceed 0.6 mph / 1Km/hor 40 feet/45 seconds /12.2 meters / 45 seconds. If themachine is allowed to drive fasterthan specification, the machinecould become unstable and will tipover.

Note: Additional troubleshooting of the fault codesmay by accomplished by using the hand-heldpendant motor controller programmer (Genie partnumber 56303).

Note: When using the hand-held pendant motorcontroller programmer, the M1 MAX SPEED needsto be set to 33. If needed, adjust the M1 MAXSPEED higher or lower to achieve the maximumraised drive speed of 0.6 mph / 1Km/h or 40 feet /45 seconds / 12.2 meters / 45 seconds.

The controller status indicator light will flash a faultcode to aid in troubleshooting. This indicator lightis mounted on the tilt level sensor mountingbracket, located behind the cover on the groundcontrols side.

Fault codes are two digits. The controller statusindicator light will blink the first digit of a two digitcode, pause for 1 second, and then blink thesecond digit. There will be a 2 second pausebetween codes.

For example: the indicator light blinks 4consecutive times, pauses for 1 second, and thenblinks 1 time. That would indicate Fault Code 41.

Part No. 106373 Z-30/20N • Z-30/20N RJ 5 - 3


REV AFault Code Chart

Fault Code Programmer Diagnostic Display Condition Possible Causes Solution

Fault code LED is off or is on,

but not blinking

COMMUNICATION ERROR Machine will not drive.

The key switch or Emergency Stop button(s) was cycled on and off faster than 5 seconds OR controller sensed an internal error during start up.

Push in the ground control red Emergency Stop button to the off position and wait for 5 seconds. Pull out the ground control red Emergency Stop button to the on position. If problem persists, replace the motor controller.

01 Normal operation.

12 HW FAILSAFE 1-2-3 Machine will not drive. The motor controller failed self test.

Replace the motor controller.

13 M- SHORTED Machine will not drive.

The motor controller has a internal short between M- and B- terminals.

Test the motor controller. See Repair Section.

FIELD OPEN Machine will not drive.

Motor wiring is loose OR motor is defective OR motor controller has an internal short.

Check for loose or open connections at the drive motors and motor controller OR replace the defective drive motor OR test the motor controller. See Repair Section.

ARM SENSOR Machine will not drive. Defective motor controller.


FLD SENSOR Machine will not drive. Defective motor controller.


5 - 4 Z-30/20N • Z-30/20N RJ Part No. 106373


REV AFAULT CODE CHART


21 THROTTLE FAULT 1 Machine will not drive.

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 to pins 14 and 16 at the motor controller OR pin 14 is internally shorted to power or ground OR the potentiometer on the drive joystick is defective.

Consult Genie Industries Service Department.

THROTTLE FAULT 2 Machine will not drive.

Pin 14 (wht/red #32) is shorted to power or ground OR the potentiometer on the drive joystick is defective.


31 CONT DRVR OC Machine will not drive.

Main contactor (PR1) coil defective OR brake release relay CR5 defective.

Replace main contactor PR1 or brake release relay CR5 OR replace the motor controller.

32 MAIN CONT WELDED Machine will not drive.

Main contactor (PR1) contacts stuck closed OR grn wire at pin 17 on motor controller shorted to ground OR open in motor armature wiring OR motor controller has an internal short to ground.


33 PRECHARGE FAULT Machine will not drive.

External short between B+ terminal on motor controller and ground OR motor controller is defective.

Repair short between B+ terminal on motor controller and ground OR replace motor controller. Note: Short can be on any part of circuit connected to the B+ terminal on the motor controller.

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


REV A FAULT CODE CHART


34 MISSING CONTACTOR Machine will not drive.

Motor controller does not detect the main contactor PR1 or brake release relay CR5.


MAIN CONT DNC Machine will not drive.

Main contactor PR1 or brake release relay CR5 did not close OR open in org/red wire to PR1 and/or CR5 OR main contactor and/or brake release relay is defective.


41 LOW BATTERY VOLTAGE Machine will not drive.

Battery supply voltage to motor controller less than 32V DC.

Completely charge batteries OR check battery cable condition OR check for corrosion or loose connections at battery terminals and motor controller.

42 OVERVOLTAGE Machine will not drive.

Battery supply voltage to motor controller more than 55V DC OR machine is being operated with the battery charger plugged in.

Be sure the battery charger is disconnected OR check for loose battery cables or poor connections.

43 THERMAL CUTBACK Machine will not drive.

Machine being operated outside of temperature range of -13°F to 185°F / -25°C to 85°C OR machine being driven under excessive load OR motor controller is not being cooled sufficently.

Operate machine within specified temperature limits OR check for debris around motor controller preventing proper cooling of the controller OR check for mechanical restrictions causing excessive load on the machine.

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



Part No. 106373 Z-30/20N • Z-30/20N RJ 6 - 1

June 2008 Section 6 • Schematics

Schematics

Observe and Obey:

Troubleshooting and repair procedures shall becompleted by a person trained and qualified onthe repair of this machine.



Before Troubleshooting:

Read, understand and obey the safety rulesand operating instructions printed in theGenie Z-30/20N Operator's Manual on yourmachine.

Be sure that all necessary tools and testequipment are available and ready for use.

About This SectionThere are two groups of schematics in this section.

Electrical Schematics


Hydraulic Schematics


General Repair Process

Malfunctiondiscovered

Identifysymptoms

Troubleshoot

Performrepair

Return toservice problem

solved

problemstill exists

Inspectand test

6 - 2 Z-30/20N • Z-30/20N RJ Part No. 106373

June 2008Section 6 • Schematics

REV A

Load Sensor Option Diagram(before serial number 6290)

CABLE#3

CABLE#1

CABLE#2

JIBF.S.

NCNCNO

P3TS1

TS15 TS12 TS10

TS11

TS13

TS8

P2

L1

WHT-FSLOAD CELL

L2+

TS7

TS9

RE

D/B

LK

BR

N

LOAD SENSEOPTION

5

NO CNC

976 8

- +

2 3 41

3

BLK

41

RE

D

WH

T

2

GR

N

WH

T

BR

N

RE

D/W

HT

WH

T-F

S

GRN

BLK/RED

RED

BP1

BR

N

BR

N

OVERLOAD LIGHT (OPTION)

BOOM EXTEND TOGGLE SWITCH

TURNTABLE ROTATE TOGGLE SWITCH

JIB ROTATE TOGGLE SWITCH (OPTION)

DRIVE ENABLE LIGHT

PRIMARY BOOM TOGGLE SWITCH

DRIVE ENABLE TOGGLE SWITCH

L1

L2

TS13

TS16

TS15

TS12

TS11

EMERGENCY STOP BUTTON

BOOM FUNCTION SPEED CONTROLLER

PLATFORM ROTATE TOGGLE SWITCH

SECONDARY BOOM TOGGLE SWITCH

HORN BUTTON

AUXILIARY TOGGLE SWITCH

DRIVE CONTROLLER

JIB BOOM UP/DOWN TOGGLE SWITCH

PLATFORM LEVEL TOGGLE SWITCH

DESCRIPTION

TS8

TS10

TS9

TS7

TS1

P3

BP1

DP1

LABEL

P2

TS16

L

R

DP1

21

34

57

68

91

0

Part No. 106373 Z-30/20N • Z-30/20N RJ 6 - 3

June 2008 Section 6 • Schematics

REV B

Electrical Symbols Legend

+

-

6V DCBattery

OR

G/B

LK-1

numbercablewithcolorWire

Connectionno terminal

P1

EmergencyStop button

normaly closed

KS1

GROUND

PLATFORM

Key switch(before serial number 6290)

PR4

Relay panelcontactor

Solenoid orrelay coil

Horn

Tilt sensor

NOHCLS1

Limit switchnormally open

held closed

HORN

P4

Horn buttonnormally open

T-circuitconnected

LED

AP1

Quick disconnectterminal

Diode

BLK

FS1

Foot switch

CR

4

Relay contactnormaly open

Relay contactnormally closed

TS3

STA

RT

EN

GIN

E

Toggle switchSPDT

Circuits crossingno connection

Auxiliary / Primarylift pump

PUMP

Boom functionspeed controller

WH

T

GRNRED

BP1

BL

K/R

ED

Pressureswitch

PSITerminal

TB20

T-circuitconnects at terminal

BLK #21 TB21

Circuit breaker

Brake releasejack

(before serial number 6290)

J1

Drive motor

A2

A1 S1

S2

FB

Flashingbeacon

Hour meter

Fuse

Limit switch

NO

LS3

NC

Toggle switchDPDT

TS6

RIG

HT

LEFT

GR

N/B

LK

TB17

Groundsupression

circuit

_

HM

+

PLATFORM

GROUND

KS1

Key switch(after serial number 6289)

6 - 4 Z-30/20N • Z-30/20N RJ Part No. 106373

June 2008Section 6 • Schematics

REV B

Hydraulic Symbols Legend

Fixed displacementpump

M

Pump prime mover(motor)

Check valve

Differentialsensing valve

Solenoid operatedproportional valve

Solenoid operated 3 position,4 way, directional valve

Pressure switch

N.C.COM

N.O.

Brake

Double actingcylinder

Orifice

0.045 /1.14 mm

Relief valve

Hydraulic filter

Counterbalance valve(dual)

Normally openpoppet valve

Normally closedpoppet valve

Filter with by-passcheck valve

Dual relief valve

Flow regulator valve

Counterbalance valve(single)

Bi-directional motor

Regen circuit

Shutoff valve

April 2007 Section 6 • Schematics

Power Cable Diagram(before serial number 6290)

REV A

April 2007Section 6 • Schematics

Power Cable Diagram(before serial number 6290)

1

2

3

4

5

6

7

8

A B C D E F G H I J K L M N

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

TANK SIDEBATTERY PACK+

-

+

_

-

+

+

-A1 D1

A2

F2 A2

F1A1 A2

F2

F1A1

48V DC

D1

+

- -

+ -

+

-

+

AP2 AP1

-

+

WHT (10 )Ga

BLK (10 )Ga

ACBATTERYCHARGER

+

-

-

+

+

-

-

+GROUND CONTROLS SIDEBATTERY PACK

24V DC

AUXILIARYLIFT PUMP

BLK (4 )Ga

PRIMARYLIFT PUMP

BL

K(4

)G

a

BLK (2 )Ga

BLK(2 Ga)

WH

T(1

0)

Ga

BL

K(1

0)

Ga

RED(2 Ga)

6V DC 6V DC

6V DC 6V DC

6V DC 6V DC

6V DC 6V DC

RIGHT SIDEDRIVE MOTOR

LEFT SIDEDRIVE MOTOR

RED (10 )Ga

RED (10 )GaR

ED

(10

)G

a

BLK (2 )Ga

PRIMARYLIFT PUMPCONTACTOR (PR2)

AUXILIARYLIFT PUMPCONTACTOR(PR3)

BLK (2 )Ga

MOTORCONTROLLER

BL

K(2

)G

a

RE

D(4

)G

a

BL

K(2

)G

a

RE

D(2

)G

a

RE

D(2

)G

au

ge

BL

K(2

)G

a

AMMETER

RED (2 )Ga

F2100A

F1500A

F3100A

BLK (2 )Ga

B+M-B-

F1 F2

RE

D(4

Ga

)

DRIVECONTACTOR(PR1)

CONTROLLER

BATTERY

3 DIODES

REV B


Power Cable Diagram(from serial number 6290 to 8354)

1

2

3

4

5

6

7

8

N M L K J I H G F E D C B A

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

LEFT SIDEBATTERY PACK

-

-

-

-

+

+

+

+

A1 D1

A2

F2

A2

F1

A1 A2

F2

F1

A1

48V DC

D1

+

- -

+ -

+

-

+

AP2 AP1

-

+

WHT (10)

BLK (10)

ACBATTERYCHARGER

+

+

+

+

-

-

-

-

RIGHT SIDEBATTERY PACK

24V DC

AUXILIARYPUMP

BLK (4)

PRIMARYLIFT PUMP

BL

K(4

)

BLK (2)

BLK (2)

WH

T(1

0)

BL

K(1

0)

RED (2)



RED (10)

RED (10) RED (10)

BLK (2)

PRIMARY LIFTPUMP CONTACTOR (PR2)

AUXILIARY PUMPCONTACTOR (PR3)

BLK (2)

RE

D(4

)

BL

K(2

)

RE

D(2

)

BL

K(2

)

RE

D(2

)

AMMETER

RED (2)

F2100A

F3100A

BLK (2)

B+M-B-

F1 F2

RE

D(4

)

10

BLK (2)

F1500A

CONTROLLER

BATTERY

DRIVECONTACTOR(PR1)

3 DIODES

10

NOTES:9. WIRE GAUGE NOTED IN PARENTHESES AFTER

WIRE COLOR.

DO NOT ROUTE POWER CABLES ACROSSFRONT OF MOTOR CONTROLLER. DOING SOCAN AFFECT INTERNAL CURRENT SENSORS,CAUSING REDUCED MOTOR PERFORMANCE.

MOTORCONTROLLER

Section 6 • SchematicsApril 2007

Power Cable Diagram(from serial number 6290 to 8354)


Power Cable Diagram(after serial number 8354)

REV A


Power Cable Diagram(after serial number 8354)

1

2

3

4

5

6

7

8


6 - 7 Z-30/20N • Z-30/20N RJ Part No. 106373

LEFT SIDEBATTERY PACK

+

+

_

+

+

A1 D1

A2

F2 A2

F1

A1 A2

F2

F1A1

48V

D1

+ +

++

AP2 AP1

+

WH (10)

BK (10)

ACBATTERYCHARGER

+

+

+

+

RIGHT SIDEBATTERY PACK

24V

AUXILIARYLIFT PUMP

BK (4)

PRIMARYLIFT PUMP

BK

(4)

BK (2)

BK (2)

WH

(10

)

BK

(10

)

RD (2)



RD (10)

RD (10) RD (10)

BK (2)

PRIMARY LIFTPUMP CONTACTOR

(PR2)

AUXILIARY LIFTPUMP CONTACTOR

(PR3)

BK (2)

100A

BK (2)

RD

(4)

BK

(2)

RD

(2)

RD

(2)

BK

(2)

AMMETER

DRIVE CONTACTOR(PR1)

RD (2)

NOTE: WIRE GAUGE NOTED IN PAENTHESES AFTER WIRE COLOR.

F2100A

F1500A

F3

BK (2)

B+M-B-

F1 F2

RD

(4)

CURTIS / SEPEXMOTOR CONTROLLER

BATTERY

CONTROLLER 3 DIODES

_

_

_ _

_ _

_

_

_

_ _

_

_

REV A


Power Panel Diagram(before serial number 6290)

1

2

3

4

5

6

7

8


Part No. 106373 Z-30/20N • Z-30/20N RJ 6 - 8

MOTORCONTROLLER

CR20 LIFT PUMP CONTACTORRELAY SOCKET WIRING(WIRE INSERTION SIDE SHOWN)

BRNGRN/WHT #CR3

GRN/WHT #PR2

OR

G/R

ED

#C

R2

0

OR

G/R

ED

#C

R2

1316 1519 18 17 14212224 23 20

ORG/RED #CR2

BLU/WHT #12

WHT #30

BLK #L3

ORG #40

BRN #CB2

WHT/BLK #31

BLK

GRN

GRN/WHT #PR2

1112 10 9 78 6 45 3 12

RED/BLK #CR5

GRN/WHT #CR3

ORG/RED #42

WHT/RED #32

RED/WHT #29

RED #CR3

RED #CB1

ORG/RED #CR20

PR2PRIMARY

LIFT PUMPCONTACTOR

PR1DRIVE

CONTACTOR

ORG/RED

48V DC

F410A

ORG/RED

CR20LIFT PUMP

CONTACTORRELAY

BRN

BRN

PR3AUXILIARY

PUMPCONTACTOR

24V DC


Power Panel Diagram(before serial number 6290)


Power Panel Diagram(from serial number 6290 to 8354)

REV A


Power Panel Diagram(from serial number 6290 to 8354)

1

2

3

4

5

6

7

8


6 - 9 Z-30/20N • Z-30/20N RJ Part No. 106373

MOTORCONTROLLER

CR20 LIFT PUMP CONTACTORRELAY SOCKET WIRING(WIRE INSERTION SIDE SHOWN)

BRNGRN/WHT #CR3

GRN/WHT #PR2

OR

G/R

ED

#C

R2

0

OR

G/R

ED

#C

R2

1316 1519 18 17 14212224 23 20

ORG/RED #CR2

BLU/WHT #12

WHT #30

BLK #L3

ORG #40

BRN #CB2

WHT/BLK #31

BLK

GRN

GRN/WHT #PR2

1112 10 9 78 6 45 3 12

RED/BLK #CR5

GRN/WHT #CR3

ORG/RED #42

WHT/RED #32

RED/WHT #29

RED #CR3

RED #CB1

ORG/RED #CR20

PR2PRIMARY

LIFT PUMPCONTACTOR

PR1DRIVE

CONTACTOR

ORG/RED

48V DC

F410A

ORG/RED

CR20LIFT PUMP

CONTACTORRELAY

BRN

BRN

PR3AUXILIARY

PUMPCONTACTOR

24V DC

REV A


Power Panel Diagram(after serial number 8354)

1

2

3

4

5

6

7

8


Part No. 106373 Z-30/20N • Z-30/20N RJ 6 - 10

C48

C49

SEEDETAIL-A

OR

/RD

#C

R2

0

C48-2 P42BAT OR/RD

P182BAT BK

BR

1316 1519 18 17 14212224 23 20

23456789101112

C49-6 C32JSL WH/RD

C49-2 C48BRK RD/BK

OR

/RD

#C

R2

P4

2B

AT

GR/WH #PR2 R42BAT

GR/WH #CR3 C19LPE BR

DETAIL-A

CR20RELAY SOCKET WIRING

(WIRE INSERTION SIDE SHOWN)

C49-11 C19LPE GR/WH

LIFT PUMPCONTACTOR

RELAY

CR20

C48-3 01GND BR

MOTOR CONTROLLER

CURTIS SEPEX

AUXILIARYLIFT PUMP

CONTACTOR

PR3

DRIVECONTACTOR

PR1PR2

PRIMARYLIFT PUMP

CONTACTOR

C49-5 C31REV WH/BK

C49-4 C30FWD WH

C49-7 C178CSL BK

24V

F410A

48V

BR

OR/RD

OR/RD

GR

C49-1 R27AUX RD

C48-1 P182BAT RD

C49-9 C4OLS OR

C49-8 C12FTS BL/WH

C49-10 R42BAT OR/RD

OR/RD #CR20

R42BAT GR/WH #PR2

C49-3 C29JSH RD/WH

1


Power Panel Diagram(after serial number 8354)

REV B


Electrical Schematic(before serial number 6290)

1

2

3

4

5

6

7

8


6 - 11 Z-30/20N • Z-30/20N RJ Part No. 106373

GROUND

+24V DC PR3 PR2

24V DC

RE

D#

CB

1

AU

XIL

IAR

YL

IFT

PU

MP

PR

IMA

RY

LIF

TP

UM

P

100A

M- B+

CURTIS 1244

SEPEX CONTROLLER

F1 F2

B-

9 14

2-W

IRE

PO

T.

WHT/RED #32

OF

F-L

IMIT

SP

EE

DIN

PU

T

PR1

10 A

CB1

P1

TB29RED/WHT #29

GND

PLT

CB210A

TB52

TB40 BLK-8

LS4

WH

T-8

WH

T-6

LS2

BL

K-7

LS1** Shown

withboom

extended

WH

T-7

TB22

P2

P3HORN

TB9

A1

ALARMTILT

FB

FL

AS

HIN

GB

EA

CO

NO

PT

ION

HO

RN

RE

LA

Y

48V DC

ORG/RED #CR2

AP1

AP1

AP2

AP2

+48V DC

BLK #22

BL

K-6

TB50

TB49

BLK-2

BL

K/R

ED

-3

RE

D/B

LK

-1

BL

K/R

ED

#C

R4

TB28

RE

D/B

LK

#2

8

OR

G/R

ED

1

5

17

OR

G/R

ED

#4

2

OR

G/R

ED

GR

N

BL

K

TB23

TB42

CR2

CR1

48

VD

CP

OW

ER

RE

LA

Y

48

VD

CP

OW

ER

RE

LA

Y

WHT

CO

NT

RO

LL

ER

FA

ULT

LIG

HT

PR1 RED

RED

TS55FUNCTIONENABLE

WHT/RED-1

RED/WHT-1

RED

BLU/WHT #12

ORG/RED-1

OR

G/R

ED

-1O

RG

/RE

D

RE

D/W

HT

WH

T-2

RE

D

CR4

TIL

TS

EN

SO

R

2 16

3

BL

U/W

HT

#1

2

L3

DR

IVE

CO

NTA

CT

OR

CO

IL

DR

IVE

CO

NTA

CT

OR

BRN

BLK-FS

LOAD SENSE OPTION (SEE DETAIL )

WHT-FS

FS1

+4

8V

DC

INP

UT

DIO

DE

RE

TU

RN

ORG #40

PO

T.

LO

W

INT

ER

LO

CK

STATUS LED

RED/WHT-1

KS1

(GND)

(GND)

F3100A

F2

F410A F1

500A

RE

D/W

HT

#2

3

PR1

RE

D/B

LK

BR

AK

E/R

EL

20

CR5

WHT/BLK-1WHT/BLK #31 TB31

WHT-1WHT #30 TB30

RE

VE

RS

E11

FO

RW

AR

D1

0

TB32 WHT/RED-1

WHT-1

WHT/BLK-1

--

--

--

--

++

++

++

++

PUMP PUMP

RED

RE

D/W

HT

-3

RE

D/W

HT

TB3

WH

T

BL

K

BL

K/R

ED

BR

N

RED

+

BR

N

85

8630

87

86

85

30

87

85

86

BL

K

BL

K

BL

K

BLKBLK

RED RED

BLKBLK

RE

D

RE

D

BL

K

RED RED

48

VD

CB

AT

TE

RY

CH

AR

GE

RW

HT

BL

K

30

87 85

86

22

21

22

21

13

14

MOTOR

MOTOR

F2

A2A2 F1F2

A1A1F1

HO

RN

BL

K#

22

LOAD SENSE OPTION

BLK-FSWHT-FS

OL

FS1P2

WHT

+

-

C

NC

NORED/BLKRE

D RED/WHT

LOAD SENSE PCB

8

+

BLK (24V DC)

ORG/RED #CR20 ORG/RED

BLK

BRN BRN

BRN

LS2PRIMARYBOOMUP/DOWN

LS1BOOMEXTEND/RETRACT

LS4SECONDARYBOOMUP/DOWN

REV B



1

2

3

4

5

6

7

8


Part No. 106373 Z-30/20N • Z-30/20N RJ 6 - 12

LE

FT

RIG

HT

SECONDARYBOOM

DO

WN

DO

WN

UP

UP

PRIMARYBOOM

PRIMARYBOOM

RE

TR

AC

T

EX

TE

ND

PLATFORMLEVEL

DO

WN

UP

PLATFORMROTATE

LE

FT

RIG

HT

JIBBOOM

DO

WN

UP

RL

TB4

TB5

TU

RN

TA

BL

ER

OTA

TE

RIG

HT

CO

IL

DE

SC

EN

TA

LA

RM

OP

TIO

N

SECBOOM

DN UP DN UP

PRIBOOM

PRIBOOM

RET EXT

PLATLVL

DN UP

PLATROT

L R

JIBBOOM

DN UP

TB11 TB10 TB2 TB1 TB8TB7

SE

CO

ND

AR

YB

OO

MU

PC

OIL

SE

CO

ND

AR

YB

OO

MD

OW

NC

OIL

PR

IMA

RY

BO

OM

UP

CO

IL

PR

IMA

RY

BO

OM

DO

WN

CO

IL

PR

IMA

RY

BO

OM

EX

TE

ND

CO

IL

PR

IMA

RY

BO

OM

RE

TR

AC

TC

OIL

PL

AT

FO

RM

LE

VE

LU

PC

OIL

PL

AT

FO

RM

LE

VE

LD

OW

NC

OIL

TB15TB14

PLATFORM LEVELCUTOUTCE VERSIONONLY

CR10

TB17TB18

ORG-JIB

BLU-JIB BLK-JIB

WHT-JIB

TB44TB43

ROTARYOEMFLOWCONTROL

RED

GRN

BLK/RED

WH

T/R

ED

-3

TB19

TB6

OR

G/R

ED

(48

V)

RE

D-6

GR

N/W

HT

RE

D#

27

LIF

TP

UM

PC

ON

TA

CT

OR

CO

ILP

R2

PR

3

CO

NTA

CT

OR

CO

IL

AU

XIL

IAR

YP

UM

P

AU

XIL

IAR

YC

ON

TR

OL

RE

LA

YC

OIL

AUXPOWER

RE

D

AUXON

RE

D-1

TB27

ST

EE

RR

IGH

TC

OIL

ST

EE

RL

EF

TC

OIL

GRN/WHT #19

BR

AK

ER

EL

EA

SE

N.O

.C

OIL

BR

AK

ER

EL

EA

SE

N.C

.C

OIL

PS

1

BR

AK

ER

EL

EA

SE

TR

AV

EL

AL

AR

M(A

2)

TB48

RE

D/W

HT

#4

8

JP1 (REMOVE FOR CE MODELS)

DRIVEENABLE

OR

G/R

ED

-3

RE

D-5

TB16

BR

N-5

LS3

WH

T-5

BL

K-5

TB12

TB13

BL

U/W

HT

-3

BL

U/R

ED

-3

FUNCTIONMANIFOLDGROUND

WHT

RED

WHT/BLK-1

RED/WHT-1

WHT-1

BLU/WHT #12

RED

RED

TS12TURNTABLEROTATE TS10 TS11 TS13 TS9 TS7 TS8

WH

T/B

LK

-3

WH

T-3

BL

U/B

LK

-3

BL

U-3

RE

D/B

LK

-3

RE

D-3

BL

K/W

HT

-3

BL

K-3

OR

G/B

LK

-3

OR

G-3 G

RN

-3

GR

N/B

LK

-3

GR

N/B

LK

-1

GR

N-1

TS59 TS57 TS58TS63

TS51

TS61TS60TS62TURNROT

JIBMANIFOLDGROUND

WH

T/R

ED

#6

OR

G#

14

OR

G/B

LK

#1

5

BL

K#

7

BL

K/W

HT

#8

RE

D#

1

RE

D/B

LK

#2

BL

U#

10

BL

U/B

LK

#11

WH

T/B

LK

#5

WH

T#

4

TS1TS15

BRN

PL

AT

FO

RM

LE

VE

LC

UT

OU

TR

EL

AY

CO

IL

WHT/RED #6

GR

N/W

HT

-3

F

E

BCI

RE

D

TB37

TB36

BL

U/B

LK

#3

7

BL

U#

36

BR

N-2

RE

D/W

HT

#4

8

6

7

8

9

10

ORG/RED-1

L

STEER

LIFT

DRIVEENABLELIMITSWITCH*

BR

AK

ER

EL

EA

SE

PR

ES

SU

RE

SW

ITC

H

(GND)

(GND)

RED/WHT

DP1

BL

U/B

LK

-1

BL

U-1

RE

D

BRN-JIB

BP1

RED

ORG-6

TU

RN

TA

BL

ER

OTA

TE

LE

FT

CO

IL

BCI OPTION

A3

RED

L1DRIVEENABLELED

RE

D/W

HT

A2

TB52

13 22

CR5

PR

OP.

FL

OW

CO

NT

RO

LC

OIL

5

4

3

2

1

WHT/RED-1

DRIVE

R

ORG/RED

REV

FWD

2114

+

87

30

+

5 6

1 2

7

8

14 13

LS2

86

8587

30

87A

+

ORG/RED

GR

N/W

HT

CR2030

87

85

LIF

TP

UM

PC

ON

TA

CT

OR

RE

LA

YC

R2

0

CR3

86

OR

G/R

ED

WH

T

RE

D/W

HT

SET TO "B" SET TO "N"

RESET

8 7

L.V.I.

6 5

O/B

DISCHARGE

4 3 2 1

O/R

OR

G

4BCI5 3

CR19 CR19

LVI/BCI OPTION

BLK

OR

G/R

ED

WH

T

BRN

CR19

BRN

RED

6

4

5

3

7

8

TS16

RIG

HT

LE

FT

OR

G-1

OR

G/B

LK

-1

TS66

GRN/WHT #19

RIG

HT

LE

FT

JIB BOOMROTATE

TB46TB47

JIB BOOMROTATE

RED-JIB

YEL-JIBH

OU

RM

ET

ER

HM

+

WH

T/B

LK

JIB BOOM ROTATE OPTION

+

BLK (24V DC)

J1BRAKERELEASEJACK

PLATFORMCONTROL BOXGROUND

* Shown

with boomrotated past

eithernon-steer

wheel

REV B


Electrical Schematic(from serial number 6290 to 8354)

1

2

3

4

5

6

7

8


6 - 13 Z-30/20N • Z-30/20N RJ Part No. 106373

GROUND

+24V DC PR3 PR2

24V DC

RE

D#

CB

1

AU

XIL

IAR

YL

IFT

PU

MP

PR

IMA

RY

LIF

TP

UM

P

LEFTMOTOR

RIGHTMOTOR

M- B+

CURTIS 1244

SEPEX CONTROLLER

F1 F2

B-

9 14

2-W

IRE

PO

T.

WHT/RED #32

OF

F-L

IMIT

SP

EE

DIN

PU

T

PR1

CB110A P1

TB29RED/WHT #29

GND

PLT

10 A

CB2 TB52

TB40 BLK-8

LS4

WH

T-8

WH

T-6

LS2

BL

K-7

LS1

WH

T-7

P2

P3HORN

TB9

TILTALARM(A1)

FB

FL

AS

HIN

GB

EA

CO

NO

PT

ION

HO

RN

RE

LA

Y

48V DC

ORG/RED #CR2

AP1

AP1

AP2

AP2

+48V DC

BLK #22

BL

K-6

TB50

TB49

BLK-2

BL

K/R

ED

-3

RE

D/B

LK

-1

BL

K/R

ED

#C

R4

TB28

RE

D/B

LK

#2

8

OR

G/R

ED

1

5

17

OR

G/R

ED

#4

2

OR

G/R

ED

GR

N

BL

K

TB23

TB42

CR2

CR1

48

VD

CP

OW

ER

RE

LA

YC

R2

48

VD

CP

OW

ER

RE

LA

YC

R1

WHT

DR

IVE

CO

NT

RO

LL

ER

STA

TU

SL

ED

(L3

)

RED

TS55FUNCTIONENABLE

WHT/RED-1

RED/WHT-1

BLU/WHT #12

ORG/RED-1

OR

G/R

ED

-1O

RG

/RE

D

RE

D/W

HT

WH

T-2

RE

D

CR4T

ILT

SE

NS

OR

2 16

3

BL

U/W

HT

#1

2

DR

IVE

CO

NTA

CT

OR

CO

IL-P

R1

BRN

BLK-FSWHT-FS

FS1

+4

8V

DC

INP

UT

DIO

DE

RE

TU

RN

ORG #40

PO

T.L

OW

INT

ER

LO

CK

STATUS LED

RED/WHT-1

KS1

(GND)

(GND)

F3100A

F2100A

F410A F1

500A

RE

D/W

HT

#2

3

DR

IVE

CO

NTA

CT

OR

RE

D/B

LK

BR

AK

E/R

EL

20

CR5

WHT/BLK-1WHT/BLK #31 TB31

WHT-1WHT #30 TB30

RE

VE

RS

E11

FO

RW

AR

D1

0

TB32 WHT/RED-1

WHT-1

WHT/BLK-1

--

--

++

++

--

--

++

++

PUMP PUMP

RED

RE

D/W

HT

-3

RE

D/W

HT

TB3

WH

T

BL

K

BL

K/R

ED

BR

N

RED

+

BR

N

85

8630

87

86

85

30

87

85

86

BL

K

BL

K

BL

K

BLKBLK

RED RED

BLKBLK

RE

D

RE

D

BL

K

RED RED

48

VD

CB

AT

TE

RY

CH

AR

GE

RW

HT

BL

K

30

87 85

86

22

21

22

21

13

14

2

F2

A2A2 F1F2

A1A1F1

3

HO

RN

BL

K#

22

+

BLK (24V DC)

ORG/RED #CR20 ORG/RED

BLK

BRN BRN

A C

B

L45

1 3

5

U33

8

7

4

12

6

TB134

A6

BL/WH-1

TB22

D40

D39

L48

LS18

L4

RED

BLU/RED-1

2

NOTES:1. ALL LIMIT SWITCHES WITH BOOM IN STOWED POSITION EXCEPT AS NOTED

SWITCH SHOWN WITH BOOM EXTENDED

3 REDUNDANT COIL SUPPRESION DIODE FOR PR1 IS INSIDE CONTROLLER BETWEEN J1-9 AND J1-17.

ADD D40 ONLY IF UNIT HAS BOTH L4 & L48.

CE & PLATFORM LOAD SENSE OPTION.

ANSI/CSA ONLY

5

7

6

5

5 5

56

7

LS

1-

EX

T/R

ET

LS

2P

RIM

AR

YU

P/D

OW

N

LS

4S

EC

ON

DA

RY

UP

/DO

WN

REV B



1

2

3

4

5

6

7

8


Part No. 106373 Z-30/20N • Z-30/20N RJ 6 - 14

L R

SECONDARYBOOM

DN UP

PRIMARYBOOM

PRIMARYBOOM

DN UP RET EXT

PLATFORMLEVEL

DN UP

PLATFORMROTATE

L R

JIBBOOM

DN UP

RL

TB4

TB5

DE

SC

EN

TA

LA

RM

OP

TIO

N

SECBOOM

DN UP DN UP

PRIBOOM

PRIBOOM

RET EXT

PLATLVL

DN UP

PLATROT

L R

JIBBOOM

DN UP

TB11 TB10 TB2 TB1 TB8TB7

SE

CO

ND

AR

YB

OO

MD

OW

NC

OIL

SE

CO

ND

AR

YB

OO

MU

PC

OIL

PR

IMA

RY

BO

OM

DO

WN

CO

IL

PR

IMA

RY

BO

OM

UP

CO

IL

PR

IMA

RY

BO

OM

EX

TE

ND

CO

IL

PR

IMA

RY

BO

OM

RE

TR

AC

TC

OIL

PL

AT

FO

RM

LE

VE

LD

OW

NC

OIL

PL

AT

FO

RM

LE

VE

LU

PC

OIL

TB15TB14

PLATFORM LEVELCUTOUTCE VERSIONONLY

CR10

TB17TB18

ORG-JIB

BLU-JIB BLK-JIB

WHT-JIB

TB44TB43


RED

GRN

BLK/RED

WH

T/R

ED

-3

TB19

TB6

FL

OW

CO

NT

RO

LC

OIL

OR

G/R

ED

(48

V)

RE

D-6

GR

N/W

HT

RE

D#

27

LIF

TP

UM

PC

ON

TA

CT

OR

CO

ILP

R2

AU

XIL

IAR

YC

ON

TR

OL

RE

LA

YC

OIL

AUXON

RE

D

AUXON

RE

D-1

TB27

ST

EE

RR

IGH

TC

OIL

ST

EE

RL

EF

TC

OIL

GRN/WHT #19

BR

AK

ER

EL

EA

SE

N.O

.C

OIL

BR

AK

ER

EL

EA

SE

N.C

.C

OIL

PS

1

BR

AK

ER

EL

EA

SE

TR

AV

EL

AL

AR

M(A

2)

TB48

RE

D/W

HT

#4

8

JP1 (REMOVE FOR CE VERSION)

OR

G/R

ED

-3

RE

D-5

TB16

BR

N-5

LS3

WH

T-5

BL

K-5

TB12

TB13

BL

U/W

HT

-3

BL

U/R

ED

-3

GROUNDMANIFOLDFUNCTION

WHT

WHT/BLK-1

RED/WHT-1

WHT-1

BLU/WHT #12

RED

RED

TS12TURNTABLEROTATE

TS10 TS11 TS13 TS9 TS7 TS8

WH

T/B

LK

-3

WH

T-3

BL

U/B

LK

-3

BL

U-3

RE

D/B

LK

-3

RE

D-3

BL

K/W

HT

-3

BL

K-3

OR

G/B

LK

-3

OR

G-3 G

RN

-3

GR

N/B

LK

-3

GR

N/B

LK

-1

GR

N-1

TS59 TS57 TS58TS63

TS51

TS61TS60TS62TURNROT

JIB

MANIFOLDGROUND

WH

T/R

ED

#6

OR

G#

14

OR

G/B

LK

#1

5

BL

K#

7

BL

K/W

HT

#8

RE

D#

1

RE

D/B

LK

#2

BL

U#

10

BL

U/B

LK

#11

WH

T/B

LK

#5

WH

T#

4

TS1 TS15DRIVEENABLE

BRNP

LA

TF

OR

ML

EV

EL

CU

TO

UT

RE

LA

YC

OIL

WHT/RED #6

GR

N/W

HT

-3

F

E

BCI

RE

D

TB37

TB36

BL

U/B

LK

#3

7

BL

U#

36

BR

N-2

6

7

8

9

10

ORG/RED-1

L

STEER

LIFT

PR

3A

UX

ILIA

RY

PU

MP

CO

NTA

CT

OR

CO

IL

DRIVEENABLELIMITSWITCH

BR

AK

ER

EL

EA

SE

PR

ES

SU

RE

SW

ITC

H

(GND)

(GND)

RED/WHT

DP1

BL

U/B

LK

-1

BL

U-1

BRN-JIB

BP1

RED

ORG-6

TU

RN

TA

BL

ER

OTA

TE

LE

FT

CO

IL

TU

RN

TA

BL

ER

OTA

TE

RIG

HT

CO

IL

BCI OPTION

A3

RED

DRIVEENABLELED (L1)

RE

D/W

HT

A2

TB52

13 22

CR5

PR

OP

OR

TIO

NA

L

5

4

3

2

1

WHT/RED-1

DRIVE

R

ORG/RED

REV

FWD

2114

+

87

30

+

5 6

1 2

7

8

14 13

LS2

86

8587

30

87A

5

+

ORG/RED

GR

N/W

HT

CR2030

87

85

LIF

TP

UM

PC

ON

TA

CT

OR

RE

LA

YC

R2

0

CR3

86

OR

G/R

ED

WH

T

RE

D/W

HT


RESET

8 7

L.V.I.

6 5

O/B

DISCHARGE

4 3 2 1

O/R

OR

G

4BCI5 3

CR19 CR19

LVI/BCI OPTION

BLK

OR

G/R

ED

WH

T

BRN

CR19

BRN

RED

6

4

5

3

7

8

TS16

RL

OR

G-1

OR

G/B

LK

-1

TS66

GRN/WHT #19

RL

JIB BOOMROTATE

TB46TB47

JIBROT

RED-JIB

YEL-JIB

HO

UR

ME

TE

R

HM

+

WH

T/B

LK

JIB ROTATE OPTION

+

5

NOTES:SWITCH SHOWN WITH BOOM ROTATED PAST EITHER NON-STEER WHEEL

BLK (24V)

PLATFORMCONTROL BOXGROUND

REV A



1

2

3

4

5

6

7

8


6 - 15 Z-30/20N • Z-30/20N RJ Part No. 106373

LS

4-S

EC

.U

P/D

WN

LS

2-P

RI.

UP

/DW

N

LS

1-E

XT

/RE

T

C48-3TB52

C9

HR

NB

K/R

D

C19LPE GR/WHP42BAT OR/RD

85

86

PR

IMA

RY

LIF

TP

UM

PP

R2

33

R1

9L

PE

GR

/WH

PR2

CR20

30

87

AU

XIL

IAR

YL

IFT

PU

MP

PR

3

PR

IMA

RY

LIF

TP

UM

PC

ON

TA

CT

OR

RE

LA

Y

33

PR3

C4

9-1

1C

19

LP

EG

R/W

H

C4

9-1

R2

7A

UX

RD

87a

CR3

87

30

P42BAT OR/RD C48-2

C7

B-2

P2

3B

AT

WH

C7

P-2

C4

8-1

P1

82

BA

TR

D

P2

2B

AT

BK

RD

C134PWR RD TB134

R42BAT OR/RD

C12FTS

10A

CB3

C1

33

PL

AB

L/R

DC

2P

-1C

2B

-1

U33

U6AMOTOR CONTROLLER

500 A

F4

C3

B-9

C1

B-1

2

H2

GR/BK

RD

TB134

C1P-12C132PLI BL/WH

C7

B-1

1 3

4

6 7

5

12 8

C40LS

C4

9-9

TB40

C29JSH RD/WH

C32JSL WH/RD

C30FWD WH

C31REV WH/BK

BK 2 GA

CH

AS

SIS

GR

OU

ND

J2

-BK

RD

P26BAT

13LS1

(EXT)

14 2

P2

2B

AT

BK

C7P-1

HO

RN

B

A C

P42BAT OR/RD

C4

9-7

C1

78

CS

LB

K

C49-10

C4

9-8

BK

C11

-3B

K-6

C11

-4W

H-6

C1

0-2

WH

-7

C1

0-1

BK

-7P

22

LS

BK

C5

2-1

BK

-8

C5

2-2

WH

-8

J1-WH

C4

9-3

C4

9-6

C4

9-5

C4

9-4

C2

B-4

C3

B-3

C1

B-2

C1

B-3

C1

B-4

C1

B-5

C1

B-6

C9P-2

C9P-3

R4

2B

AT

OR

/RD

C2

P-4

C3

BA

TR

D/W

HC

3P

-3

C2

8T

TA

RD

/BK

C1

P-2

C9

HR

NB

K/R

DC

3P

-9

C2

9JS

HR

D/W

HC

1P

-3

C3

2JS

LW

H/R

DC

1P

-6

C3

1R

EV

WH

/BK

C1

P-5

CR5

P182BAT BK

C19LPE GR/WH

R42BAT OR/RD

P24BAT WH

RD

C12DRE BL/WH

CR3

GND BR

ALARMTILT

RD

WH-(FS)

FS1

H1

RD-(FS)

PLATFORM

GROUND

P1KS1

TB22

P3HORN

P2

RD

C9P-1 BK

+

RD

P182BAT RD

BK-(FS)

OR

/RDCR1

CR2

TB42

RD

/WH

30

8785

86

87

3086

85

BR

N

BR

N

PR

1

OF

F-L

IMT

SP

DIN

P

INT

ER

LO

CK

LE

DL

3

53 17

C1

82

PW

RG

R

LS4(SEC)

OR

/RD

LS2(PRI)

RD

/BK

OR

/RD

C4

9-2

C4

8B

RK

RD

/BK

OR

/RD

20

CR

5

22

21

22

21

86

85

CO

NT

RO

LL

ER

STA

TU

S

CB2

10 A

C1

P-4

RD

20

AP2

24 V

100 A

FO

RW

AR

D

PO

T.L

OW

DIO

DE

RE

TU

RN

+4

8V

INP

UT

PO

T.H

I

RE

VE

RS

E

10

1 9 11

16

14

PR1

10 A

AP2 48V

R4

2B

AT

OR

/RD

WH

WH

/BK

WH

/RD

RD

/WH

F3

F5

F2

+

++

+

LEFTBOX

-

--

-

+48 V

C3

0F

WD

WH

2

48

VP

OW

ER

RE

LA

YC

R1

FL

AS

HIN

GB

EA

CO

NO

PT

ION

48

VP

OW

ER

RE

LA

YC

R2

FB

+

HO

RN

RE

LA

Y

BA

SE

CO

NT

RO

LB

OX

GR

OU

ND

CR4

TIL

TS

EN

SO

RR

D

WH

BK

BR

N

F1

+

86

85

30

87

BR

N

BR

AK

ER

EL

EA

SE

RE

LA

YC

R5

PR

1D

RIV

EC

ON

TA

CT

OR

AP1

AU

XIL

IAR

YL

IFT

PU

MP

PR

IMA

RY

LIF

TP

UM

P

PR3 PR2100 A

WH

BK

AC POWER

F2 F1

A2

A1

A2

A1+

-

PUMP

+

++

+

CHARGER

LEFTMOTOR

RIGHTBOX

-

--

-

GROUND

+24 V

SWITCH SHOWN WITH BOOM EXTENDED.

NOTES:

1. ALL LIMIT SWITCHES SHOWN WITH BOOM IN STOWED POSITION EXCEPT AS NOTED.

SWITCH SHOWN WITH BOOM ROTATED PAST EITHER NON-STEER WHEEL.

4. ALL SOLENOID AND RELAY COILS ARE 24VDC EXCEPT WHERE NOTED.

F2

F2F1 B+M-AP1 B-

PUMP

RIGHTMOTOR

2

3

5

BL

/WH

L48

REV A



1

2

3

4

5

6

7

8


Part No. 106373 Z-30/20N • Z-30/20N RJ 6 - 16

JIB ROTATE OPTION

JIBROTATE

RE

TR

AC

T





NOTES:

(GND)

CR3

TU

RN

TA

BL

ER

OTA

TE

LE

FT

TU

RN

TA

BL

ER

OTA

TE

RIG

HT

DE

SC

EN

TA

LA

RM

OP

TIO

N

SE

CO

ND

AR

YB

OO

MD

OW

N

SE

CO

ND

AR

YB

OO

MU

P

A3

+

WH

/BK

WH

TB4

BL

/BK

BL

TB5 TB11 TB10

CE OG/BK C11-2

OR

/BK

OR

PR

IMA

RY

BO

OM

UP

PR

IMA

RY

BO

OM

DO

WN

BO

OM

RE

TR

AC

T

BO

OM

EX

TE

ND

PL

AT

FO

RM

LE

VE

L

DO

WN

CO

IL

PL

AT

FO

RM

LE

VE

LU

PC

OIL

PL

AT

FO

RM

LE

VE

LC

UT

-OU

TO

PT

ION

BK

/WH

BK

RD

/BK

RD

TB2 TB1 TB8 TB7

87

30

87

30

85

86

85

CR10B

CR10A 86

TB15 TB14

PL

AT

FO

RM

RO

TA

TE

LE

FT

/JIB

BO

OM

DO

WN

PL

AT

FO

RM

RO

TA

TE

RIG

HT

/JIB

BO

OM

UP

BR-6

CE RD C11-1

14

13RD-6

LS2

PRIMARYBOOM

C19LPE GR/WH

TS55

C12DRE BL/WH

RD

CR5

RD

C2

PB

DR

D/B

K

C1

0S

BU

BL

C11

SB

DB

L/B

K

C5

TR

RW

H/B

K

C4

TR

LW

H

RIG

HT

TURNTABLEROTATE

ENABLEFUNCTION

LE

FT

TS62

RD

C3

B-4

C3

B-5

SECONDARYBOOM

TS60

DO

WN

UP

C3

B-1

1

C3

B-1

0

C3

B-1

C3

B-2

C3

P-4

C3

P-5

LE

FT

TS12

RIG

HT

TURNTABLEROTATE

C3

P-1

0

C3

P-1

1

C1

PB

UR

D

C3

P-2

C3

P-1

SECONDARYBOOM

DO

WN

2

6

CR19

UP

TS10

DO

WN

CR19

1

5

TS11

UP

C30FWD WH

C29JSH RD/WH

C31REV WH/BK

C32JSL WH/RD

R42BAT OR/RD

P24BAT WH

C1

7P

RR

BL

PLATFORMROTATE

PLATFORMROTATE

C1

8P

RR

GR

/BK

C1

7P

RL

GR

C1

5P

LD

OR

/BK

C1

4P

LU

OR

C7

PB

EB

K

C8

PB

RB

K/W

H

DO

WN

TS61

UP

PRIMARYBOOM

TS63

EX

TE

ND

PRIMARYBOOM

C3

B-7

C3

B-8

PLATFORMLEVEL

DO

WN

TS59

C4

B-6

C4

B-5

C4

B-3

C4

B-2

C3

P-7

C3

P-8

EX

TE

ND

PRIMARYBOOM

RE

TR

AC

T

TS13

DO

WN

TS9

C4

P-3

C4

P-2

C4

P-5

C4

P-6

PLATFORMLEVEL

UP

RIG

HT

LE

FT

TS7

C4

7JR

RR

D

C4

6JR

LY

L

C4

7JR

RO

R/B

K

C4

6JR

LO

R

C4

4JD

WH

C4

3JU

BK

C1

8P

RL

OR

C4

3JU

GR

C4

4JD

GR

/BK

RIG

HT

LE

FT

TS57

C2

B-6

C2

B-5

JIB MANIFOLD

DO

WN

TS58

UP

JIBBOOM

C2

B-2

C2

B-3

C2

P-5

C2

P-6

DO

WN

TS8

UP

JIBBOOM

C2

P-3

C2

P-2

RIG

HT

LE

FT

TS16

C7

P-3

BA

TG

ND

BR

N

C8

-4

C8

-3

C1

6D

EO

R/R

D

PS

1

GR/WHP

RO

PO

RT

ION

AL

CO

NT

RO

LV

ALV

E

AU

XIL

IAR

YC

ON

TR

OL

RE

LA

Y

TB6

WH

/RD

GR/WH

CR3

TB19

86

85

C19LPE

RD

HO

UR

ME

TE

R

_

BR

AK

ER

EL

EA

SE

NC

CO

IL

ST

EE

RR

IGH

T

ST

EE

RL

EF

T

BR

AK

ER

EL

EA

SE

PR

ES

SU

RE

SW

ITC

H

+

WH

/BK

HM

+

TB19

R48BRK

GR/WH

BL

BL

/BK

R4

8B

RK

RD

/WH

TB48

C8

-1

C7

B-3

BA

TG

ND

BR

N

C8

-2

TR

AV

EL

AL

AR

M

A2

TB52

SWITCH

ENABLE

13

RD

-5

RD

/WH

14

BR

N-5

22

LS321

LIMIT

DRIVE

BK

-5

TB16

WH

-5

DRIVEENABLETS15

DP1

C6

MF

VW

H/R

D

C1

9L

PE

GR

/WH BCI OPTION

C1

9L

PE

GR

/WH

LE

FT

TS66

RIG

HT

JIBROTATE

C3

B-6

C4

B-7

TB27C27AUX RD

RD

AUXILIARYPUMPTS51


BP1

C3

P-6

BK/RD

RD

GR

C4

P-7

+

BCIE

F

C3

7S

CW

BL

/BK

C1

B-1

TB37

TB3687

30

CR5

C1

B-1

1

C1

B-1

0

AUXILIARYPUMPTS1

C2

7A

UX

RD

C1

P-1

STEER

L R 10

9

LIFT

DRIVE

FWD

RD

-AU

X

REV

20K

4

8

7

6

5

3

2

1

CE OPTION:

REMOVE

JUMPER

AND ADD

RELAY

C1

P-1

1

C1

P-1

0C

36

SC

CB

LR

D

LVI/BCI OPTION

P24BAT WH

C32JSL WH/RD

C30FWD WH

C31REV WH/BK

C29JSH RD/WH

C1

3D

EL

BL

/RD

C1

2F

TS

BL

/WH

C1

2F

TS

BL

/WH

OR

/RD

C1

3D

EL

BL

/RD

BR

N

C3

B-1

2

TB12

C4

B-4

C4

B-1

C3

P-1

2

C1

6D

EO

R/R

DC

4P

-4

C4

P-1

L1

OR

/RD

7

8

BRN

SETUP ENABLE: USE TO SET THE BATTERY INDICATOR PROFILES.

UP

UP

C4

7-2

C4

7-1

C4

7-4

C4

7-3

C2

P-5

C2

P-5

3

2

3

5

OR

BR

AK

ER

EL

EA

SE

NO

CO

IL

CR19


RESET

8 7

L.V.I.

6 5

OR

/BK

DISCHARGE

4 3 2 1

OR

/RD

OR

G

4BCI5 3

WH

REV A


Electrical Schematic - CE Models(from serial number 8355 to 9346)

1

2

3

4

5

6

7

8


6 - 17 Z-30/20N • Z-30/20N RJ Part No. 106373

LS

4-S

EC

.U

P/D

WN

LS

2-P

RI.

UP

/DW

N

LS

1-E

XT

/RE

T

C48-3TB52

C9

HR

NB

K/R

D


85

86

PR

IMA

RY

LIF

TP

UM

PP

R2

33

R1

9L

PE

GR

/WH

PR2

CR20

30

87

AU

XIL

IAR

YL

IFT

PU

MP

PR

3

PR

IMA

RY

LIF

TP

UM

PC

ON

TA

CT

OR

RE

LA

Y

33

PR3

C4

9-1

1C

19

LP

EG

R/W

H

C4

9-1

R2

7A

UX

RD

87a

CR3

87

30

P42BAT OR/RD C48-2

C7

B-2

P2

3B

AT

WH

C7

P-2

C4

8-1

P1

82

BA

TR

D

P2

2B

AT

BK

RD

C134PWR RD TB134

R42ABT OR/RD

C12FTS

10A

CB3

CE & PLATFORM LOAD SENSE OPT.

C1

33

PL

AB

L/R

DC

2P

-1C

2B

-1

D39

L4

H6 L45

U33

U6AMOTOR CONTROLLER

500 A

F4

ADD D40 ONLY IF UNIT HAS L4 AND L48.

C3

B-9

C1

B-1

2

H2

GR/BK

RD

TB134

C1P-12C132PLI BL/WH

C7

B-1

LS18

D40

1 3

4

6 7

5

12 8

C40LS

C4

9-9

TB40

C29JSH RD/WH

C32JSL WH/RD

C30FWD WH

C31REV WH/BK

BK 2 GA

CH

AS

SIS

GR

OU

ND

J2

-BK

RD

P26BAT

13LS1

(EXT)

14 2

P2

2B

AT

BK

C7P-1

HO

RN

B

A C

P42BAT OR/RD

C4

9-7

C1

78

CS

LB

K

C49-10

C4

9-8

BK

C11

-3B

K-6

C11

-4W

H-6

C1

0-2

WH

-7

C1

0-1

BK

-7P

22

LS

BK

C5

2-1

BK

-8

C5

2-2

WH

-8

J1-WH

C4

9-3

C4

9-6

C4

9-5

C4

9-4

C2

B-4

C3

B-3

C1

B-2

C1

B-3

C1

B-4

C1

B-5

C1

B-6

C9P-2

C9P-3

R4

2B

AT

OR

/RD

C2

P-4

C3

BA

TR

D/W

HC

3P

-3

C2

8T

TA

RD

/BK

C1

P-2

C9

HR

NB

K/R

DC

3P

-9

C2

9JS

HR

D/W

HC

1P

-3

C3

2JS

LW

H/R

DC

1P

-6

C3

1R

EV

WH

/BK

C1

P-5

CR5

P182BAT BK

C19LPE GR/WH

R42BAT OR/RD

P24BAT WH

RD

C12DRE BL/WH

CR3

GND BR

ALARMTILT

RD

WH-(FS)

FS1

H1

RD-(FS)

PLATFORM

GROUND

P1KS1

TB22

P3HORN

P2

RD

C9P-1 BK

+

RD

P182BAT RD

BK-(FS)

OR

/RDCR1

CR2

TB42

RD

/WH

30

8785

86

87

3086

85

BR

N

BR

N

PR

1

OF

F-L

IMT

SP

DIN

P

INT

ER

LO

CK

LE

DL

3

53 17

C1

82

PW

RG

R

LS4(SEC)

OR

/RD

LS2(PRI)

RD

/BK

OR

/RD

C4

9-2

C4

8B

RK

RD

/BK

OR

/RD

20

CR

5

22

21

22

21

86

85

CO

NT

RO

LL

ER

STA

TU

S

CB2

10 A

C1

P-4

RD

20

AP2

24 V

100 A

FO

RW

AR

D

PO

T.

LO

W

DIO

DE

RE

TU

RN

+4

8V

INP

UT

PO

T.

HI

RE

VE

RS

E

10

1 9 11

16

14

PR1

10 A

AP2 48V

R4

2B

AT

OR

/RD

WH

WH

/BK

WH

/RD

RD

/WH

F3

F5

F2

+

++

+

LEFTBOX

-

--

-

+48 V

C3

0F

WD

WH

2

48

VP

OW

ER

RE

LA

YC

R1

FL

AS

HIN

GB

EA

CO

NO

PT

ION

48

VP

OW

ER

RE

LA

YC

R2

FB

+

HO

RN

RE

LA

Y

BA

SE

CO

NT

RO

LB

OX

GR

OU

ND

CR4

TIL

TS

EN

SO

RR

D

WH

BK

BR

N

F1

+

86

85

30

87

BR

N

BR

AK

ER

EL

EA

SE

RE

LA

YC

R5

PR

1D

RIV

EC

ON

TA

CT

OR

AP1

AU

XIL

IAR

YL

IFT

PU

MP

PR

IMA

RY

LIF

TP

UM

P

PR3 PR2100 A

WH

BK

AC POWER

F2 F1

A2

A1

A2

A1+

-

PUMP

+

++

+

CHARGER

LEFTMOTOR

RIGHTBOX

-

--

-

GROUND

+24 V


NOTES:




F2

F2F1 B+M-AP1 B-

PUMP

RIGHTMOTOR

2

3

5

6

5

6

BL

/WH

5

L48

REV A



1

2

3

4

5

6

7

8


Part No. 106373 Z-30/20N • Z-30/20N RJ 6 - 18

JIB ROTATE OPTION

JIBROTATE

RE

TR

AC

T





NOTES:

(GND)

CR3

TU

RN

TA

BL

ER

OTA

TE

LE

FT

TU

RN

TA

BL

ER

OTA

TE

RIG

HT

DE

SC

EN

TA

LA

RM

OP

TIO

N

SE

CO

ND

AR

YB

OO

MD

OW

N

SE

CO

ND

AR

YB

OO

MU

P

A3

+

WH

/BK

WH

TB4

BL

/BK

BL

TB5 TB11 TB10

CE OG/BK C11-2

OR

/BK

OR

PR

IMA

RY

BO

OM

UP

PR

IMA

RY

BO

OM

DO

WN

BO

OM

RE

TR

AC

T

BO

OM

EX

TE

ND

PL

AT

FO

RM

LE

VE

L

DO

WN

CO

IL

PL

AT

FO

RM

LE

VE

LU

PC

OIL

PL

AT

FO

RM

LE

VE

LC

UT

-OU

TO

PT

ION

BK

/WH

BK

RD

/BK

RD

TB2 TB1 TB8 TB7

87

30

87

30

85

86

85

CR10B

CR10A 86

TB15 TB14

PL

AT

FO

RM

RO

TA

TE

LE

FT

/JIB

BO

OM

DO

WN

PL

AT

FO

RM

RO

TA

TE

RIG

HT

/JIB

BO

OM

UP

BR-6

CE RD C11-1

14

13RD-6

LS2

PRIMARYBOOM

C19LPE GR/WH

TS55

C12DRE BL/WH

RD

CR5

RD

C2

PB

DR

D/B

K

C1

0S

BU

BL

C11

SB

DB

L/B

K

C5

TR

RW

H/B

K

C4

TR

LW

H

RIG

HT

TURNTABLEROTATE

ENABLEFUNCTION

LE

FT

TS62

RD

C3

B-4

C3

B-5

SECONDARYBOOM

TS60

DO

WN

UP

C3

B-1

1

C3

B-1

0

C3

B-1

C3

B-2

C3

P-4

C3

P-5

LE

FT

TS12

RIG

HT

TURNTABLEROTATE

C3

P-1

0

C3

P-1

1

C1

PB

UR

D

C3

P-2

C3

P-1

SECONDARYBOOM

DO

WN

2

6

CR19

UP

TS10

DO

WN

CR19

1

5

TS11

UP

C30FWD WH

C29JSH RD/WH

C31REV WH/BK

C32JSL WH/RD

R42BAT OR/RD

P24BAT WH

C1

7P

RR

BL

PLATFORMROTATE

PLATFORMROTATE

C1

8P

RR

GR

/BK

C1

7P

RL

GR

C1

5P

LD

OR

/BK

C1

4P

LU

OR

C7

PB

EB

K

C8

PB

RB

K/W

H

DO

WN

TS61

UP

PRIMARYBOOM

TS63

EX

TE

ND

PRIMARYBOOM

C3

B-7

C3

B-8

PLATFORMLEVEL

DO

WN

TS59

C4

B-6

C4

B-5

C4

B-3

C4

B-2

C3

P-7

C3

P-8

EX

TE

ND

PRIMARYBOOM

RE

TR

AC

T

TS13

DO

WN

TS9

C4

P-3

C4

P-2

C4

P-5

C4

P-6

PLATFORMLEVEL

UP

RIG

HT

LE

FT

TS7

C4

7JR

RR

D

C4

6JR

LY

L

C4

7JR

RO

R/B

K

C4

6JR

LO

R

C4

4JD

WH

C4

3JU

BK

C1

8P

RL

OR

C4

3JU

GR

C4

4JD

GR

/BK

RIG

HT

LE

FT

TS57

C2

B-6

C2

B-5

JIB MANIFOLD

DO

WN

TS58

UP

JIBBOOM

C2

B-2

C2

B-3

C2

P-5

C2

P-6

DO

WN

TS8

UP

JIBBOOM

C2

P-3

C2

P-2

RIG

HT

LE

FT

TS16

C7

P-3

BA

TG

ND

BR

N

C8

-4

C8

-3

C1

6D

EO

R/R

D

PS

1

GR/WHP

RO

PO

RT

ION

AL

CO

NT

RO

LV

ALV

E

AU

XIL

IAR

YC

ON

TR

OL

RE

LA

Y

TB6

WH

/RD

GR/WH

CR3

TB19

86

85

C19LPE

RD

HO

UR

ME

TE

R

_

BR

AK

ER

EL

EA

SE

NC

CO

IL

ST

EE

RR

IGH

T

ST

EE

RL

EF

T

BR

AK

ER

EL

EA

SE

PR

ES

SU

RE

SW

ITC

H

+

WH

/BK

HM

+

TB19

R48BRK

GR/WH

BL

BL

/BK

R4

8B

RK

RD

/WH

TB48

C8

-1

C7

B-3

BA

TG

ND

BR

N

C8

-2

TR

AV

EL

AL

AR

M

A2

TB52

SWITCH

ENABLE

13

RD

-5

RD

/WH

14

BR

N-5

22

LS321

LIMIT

DRIVE

BK

-5

TB16

WH

-5

DRIVEENABLETS15

DP1

C6

MF

VW

H/R

D

C1

9L

PE

GR

/WH BCI OPTION

C1

9L

PE

GR

/WH

LE

FT

TS66

RIG

HT

JIBROTATE

C3

B-6

C4

B-7

TB27C27AUX RD

RD

AUXILIARYPUMPTS51


BP1

C3

P-6

BK/RD

RD

GR

C4

P-7

+

BCIE

F

C3

7S

CW

BL

/BK

C1

B-1

TB37

TB3687

30

CR5

C1

B-1

1

C1

B-1

0

AUXILIARYPUMPTS1

C2

7A

UX

RD

C1

P-1

STEER

L R 10

9

LIFT

DRIVE

FWD

RD

-AU

X

REV

20K

4

8

7

6

5

3

2

1

CE OPTION:

REMOVE

JUMPER

AND ADD

RELAY

C1

P-1

1

C1

P-1

0C

36

SC

CB

LR

D

LVI/BCI OPTION

P24BAT WH

C32JSL WH/RD

C30FWD WH

C31REV WH/BK

C29JSH RD/WH

C1

3D

EL

BL

/RD

C1

2F

TS

BL

/WH

C1

2F

TS

BL

/WH

OR

/RD

C1

3D

EL

BL

/RD

BR

N

C3

B-1

2

TB12

C4

B-4

C4

B-1

C3

P-1

2

C1

6D

EO

R/R

DC

4P

-4

C4

P-1

L1

OR

/RD

7

8

BRN


UP

UP

C4

7-2

C4

7-1

C4

7-4

C4

7-3

C2

P-5

C2

P-5

3

2

3

5

OR

BR

AK

ER

EL

EA

SE

NO

CO

IL

CR19


RESET

8 7

L.V.I.

6 5

OR

/BK

DISCHARGE

4 3 2 1

OR

/RD

OR

G

4BCI5 3

WH

REV A


Electrical Schematic(after serial number 9346)

1

2

3

4

5

6

7

8


6 - 19 Z-30/20N • Z-30/20N RJ Part No. 106373

LS

4-S

EC

.U

P/D

WN

LS

2-P

RI.

UP

/DW

N

LS

1-E

XT

/RE

T

C48-3TB52

C9

HR

NB

K/R

D


85

86

PR

IMA

RY

LIF

TP

UM

PP

R2

33

R1

9L

PE

GR

/WH

PR2

CR20

30

87

AU

XIL

IAR

YL

IFT

PU

MP

PR

3

PR

IMA

RY

LIF

TP

UM

PC

ON

TA

CT

OR

RE

LA

Y

33

PR3

C4

9-1

1C

19

LP

EG

R/W

H

C4

9-1

R2

7A

UX

RD

87a

CR3

87

30

P42BAT OR/RD C48-2

C7

B-2

P2

3B

AT

WH

C7

P-2

C4

8-1

P1

82

BA

TR

D

P2

2B

AT

BK

RD

C134PWR RD TB134

R42BAT OR/RD

C12FTS

10A

CB3

C1

33

PL

AB

L/R

DC

2P

-1C

2B

-1

U33

U6AMOTOR CONTROLLER

500 A

F4

C3

B-9

C1

B-1

2

H2

GR/BK

RD

TB134

C1P-12C132PLI BL/WH

C7

B-1

1 3

4

6 7

5

12 8

C40LS

C4

9-9

TB40

C29JSH RD/WH

C32JSL WH/RD

C30FWD WH

C31REV WH/BK

BK 2 GA

CH

AS

SIS

GR

OU

ND

J2

-BK

RD

P26BAT

13LS1

(EXT)

14 2

P2

2B

AT

BK

C7P-1

HO

RN

B

A C

P42BAT OR/RD

C4

9-7

C1

78

CS

LB

K

C49-10

C4

9-8

BK

C11

-3B

K-6

C11

-4W

H-6

C1

0-2

WH

-7

C1

0-1

BK

-7P

22

LS

BK

C5

2-1

BK

-8

C5

2-2

WH

-8

J1-WH

C4

9-3

C4

9-6

C4

9-5

C4

9-4

C2

B-4

C3

B-3

C1

B-2

C1

B-3

C1

B-4

C1

B-5

C1

B-6

C9P-2

C9P-3

R4

2B

AT

OR

/RD

C2

P-4

C3

BA

TR

D/W

HC

3P

-3

C2

8T

TA

RD

/BK

C1

P-2

C9

HR

NB

K/R

DC

3P

-9

C2

9JS

HR

D/W

HC

1P

-3

C3

2JS

LW

H/R

DC

1P

-6

C3

1R

EV

WH

/BK

C1

P-5

CR5

P182BAT BK

C19LPE GR/WH

R42BAT OR/RD

P24BAT WH

RD

C12DRE BL/WH

CR3

GND BR

ALARMTILT

RD

WH-(FS)

FS1

H1

RD-(FS)

PLATFORM

GROUND

P1KS1

TB22

P3HORN

P2

RD

C9P-1 BK

+

RD

P182BAT RD

BK-(FS)

OR

/RDCR1

CR2

TB42

RD

/WH

30

8785

86

87

3086

85

BR

N

BR

N

PR

1

OF

F-L

IMT

SP

DIN

P

INT

ER

LO

CK

LE

DL

3

53 17

C1

82

PW

RG

R

LS4(SEC)

OR

/RD

LS2(PRI)

RD

/BK

OR

/RD

C4

9-2

C4

8B

RK

RD

/BK

OR

/RD

20

CR

5

22

21

22

21

86

85

CO

NT

RO

LL

ER

STA

TU

S

CB2

10 A

C1

P-4

RD

20

AP2

24 V

100 A

FO

RW

AR

D

PO

T.

LO

W

DIO

DE

RE

TU

RN

+4

8V

INP

UT

PO

T.

HI

RE

VE

RS

E

10

1 9 11

16

14

PR1

10 A

AP2 48V

R4

2B

AT

OR

/RD

WH

WH

/BK

WH

/RD

RD

/WH

F3

F5

F2

+

++

+

LEFTBOX

-

--

-

+48 V

C3

0F

WD

WH

2

48

VP

OW

ER

RE

LA

YC

R1

FL

AS

HIN

GB

EA

CO

NO

PT

ION

48

VP

OW

ER

RE

LA

YC

R2

FB

+

HO

RN

RE

LA

Y

BA

SE

CO

NT

RO

LB

OX

GR

OU

ND

CR4

TIL

TS

EN

SO

RR

D

WH

BK

BR

N

F1

+

86

85

30

87

BR

N

BR

AK

ER

EL

EA

SE

RE

LA

YC

R5

PR

1D

RIV

EC

ON

TA

CT

OR

AP1

AU

XIL

IAR

YL

IFT

PU

MP

PR

IMA

RY

LIF

TP

UM

P

PR3 PR2100 A

WH

BK

AC POWER

F2 F1

A2

A1

A2

A1+

-

PUMP

+

++

+

CHARGER

LEFTMOTOR

RIGHTBOX

-

--

-

GROUND

+24 V


NOTES:




F2

F2F1 B+M-AP1 B-

PUMP

RIGHTMOTOR

2

3

5

BL

/WH

L48

REV A



1

2

3

4

5

6

7

8


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

JIB ROTATE OPTION

JIBROTATE

RE

TR

AC

T





NOTES:

(GND)

CR3

TU

RN

TA

BL

ER

OTA

TE

LE

FT

TU

RN

TA

BL

ER

OTA

TE

RIG

HT

DE

SC

EN

TA

LA

RM

OP

TIO

N

SE

CO

ND

AR

YB

OO

MD

OW

N

SE

CO

ND

AR

YB

OO

MU

P

A3

+

WH

/BK

WH

TB4

BL

/BK

BL

TB5 TB11 TB10

CE OG/BK C11-2

OR

/BK

OR

PR

IMA

RY

BO

OM

UP

PR

IMA

RY

BO

OM

DO

WN

BO

OM

RE

TR

AC

T

BO

OM

EX

TE

ND

PL

AT

FO

RM

LE

VE

L

DO

WN

CO

IL

PL

AT

FO

RM

LE

VE

LU

PC

OIL

PL

AT

FO

RM

LE

VE

LC

UT

-OU

TO

PT

ION

BK

/WH

BK

RD

/BK

RD

TB2 TB1 TB8 TB7

87

30

87

30

85

86

85

CR10B

CR10A 86

TB15 TB14

PL

AT

FO

RM

RO

TA

TE

LE

FT

/JIB

BO

OM

DO

WN

PL

AT

FO

RM

RO

TA

TE

RIG

HT

/JIB

BO

OM

UP

BR-6

CE RD C11-1

14

13RD-6

LS2

PRIMARYBOOM

C19LPE GR/WH

TS55

C12DRE BL/WH

RD

CR5

RD

C2

PB

DR

D/B

K

C1

0S

BU

BL

C11

SB

DB

L/B

K

C5

TR

RW

H/B

K

C4

TR

LW

H

RIG

HT

TURNTABLEROTATE

ENABLEFUNCTION

LE

FT

TS62

RD

C3

B-4

C3

B-5

SECONDARYBOOM

TS60

DO

WN

UP

C3

B-1

1

C3

B-1

0

C3

B-1

C3

B-2

C3

P-4

C3

P-5

LE

FT

TS12

RIG

HT

TURNTABLEROTATE

C3

P-1

0

C3

P-1

1

C1

PB

UR

D

C3

P-2

C3

P-1

SECONDARYBOOM

DO

WN

2

6

CR19

UP

TS10

DO

WN

CR19

1

5

TS11

UP

C30FWD WH

C29JSH RD/WH

C31REV WH/BK

C32JSL WH/RD

R42BAT OR/RD

P24BAT WH

C1

7P

RR

BL

PLATFORMROTATE

PLATFORMROTATE

C1

8P

RR

GR

/BK

C1

7P

RL

GR

C1

5P

LD

OR

/BK

C1

4P

LU

OR

C7

PB

EB

K

C8

PB

RB

K/W

H

DO

WN

TS61

UP

PRIMARYBOOM

TS63

EX

TE

ND

PRIMARYBOOM

C3

B-7

C3

B-8

PLATFORMLEVEL

DO

WN

TS59

C4

B-6

C4

B-5

C4

B-3

C4

B-2

C3

P-7

C3

P-8

EX

TE

ND

PRIMARYBOOM

RE

TR

AC

T

TS13

DO

WN

TS9

C4

P-3

C4

P-2

C4

P-5

C4

P-6

PLATFORMLEVEL

UP

RIG

HT

LE

FT

TS7

C4

7JR

RR

D

C4

6JR

LY

L

C4

7JR

RO

R/B

K

C4

6JR

LO

R

C4

4JD

WH

C4

3JU

BK

C1

8P

RL

OR

C4

3JU

GR

C4

4JD

GR

/BK

RIG

HT

LE

FT

TS57

C2

B-6

C2

B-5

JIB MANIFOLD

DO

WN

TS58

UP

JIBBOOM

C2

B-2

C2

B-3

C2

P-5

C2

P-6

DO

WN

TS8

UP

JIBBOOM

C2

P-3

C2

P-2

RIG

HT

LE

FT

TS16

C7

P-3

BA

TG

ND

BR

N

C8

-4

C8

-3

C1

6D

EO

R/R

D

PS

1

GR/WHP

RO

PO

RT

ION

AL

CO

NT

RO

LV

ALV

E

AU

XIL

IAR

YC

ON

TR

OL

RE

LA

Y

TB6

WH

/RD

GR/WH

CR3

TB19

86

85

C19LPE

RD

HO

UR

ME

TE

R

_

BR

AK

ER

EL

EA

SE

NC

CO

IL

ST

EE

RR

IGH

T

ST

EE

RL

EF

T

BR

AK

ER

EL

EA

SE

PR

ES

SU

RE

SW

ITC

H

+

WH

/BK

HM

+

TB19

R48BRK

GR/WH

BL

BL

/BK

R4

8B

RK

RD

/WH

TB48

C8

-1

C7

B-3

BA

TG

ND

BR

N

C8

-2

TR

AV

EL

AL

AR

M

A2

TB52

SWITCH

ENABLE

13

RD

-5

RD

/WH

14

BR

N-5

22

LS321

LIMIT

DRIVE

BK

-5

TB16

WH

-5

DRIVEENABLETS15

DP1

C6

MF

VW

H/R

D

C1

9L

PE

GR

/WH

C1

9L

PE

GR

/WH

LE

FT

TS66

RIG

HT

JIBROTATE

C3

B-6

C4

B-7

TB27C27AUX RD

RD

AUXILIARYPUMPTS51


BP1

C3

P-6

BK/RD

RD

GR

C4

P-7

+

BCIE

F

C3

7S

CW

BL

/BK

C1

B-1

TB37

TB3687

30

CR5

C1

B-1

1

C1

B-1

0

AUXILIARYPUMPTS1

C2

7A

UX

RD

C1

P-1

STEER

L R 10

9

LIFT

DRIVE

FWD

RD

-AU

X

REV

20K

4

8

7

6

5

3

2

1

CE OPTION:

REMOVE

JUMPER

AND ADD

RELAY

C1

P-1

1

C1

P-1

0C

36

SC

CB

LR

D

LVI/BCI OPTION

P24BAT WH

C32JSL WH/RD

C30FWD WH

C31REV WH/BK

C29JSH RD/WH

C1

3D

EL

BL

/RD

C1

2F

TS

BL

/WH

C1

2F

TS

BL

/WH

OR

/RD

C1

3D

EL

BL

/RD

BR

N

C3

B-1

2

TB12

C4

B-4

C4

B-1

C3

P-1

2

C1

6D

EO

R/R

DC

4P

-4

C4

P-1

L1

OR

/RD

4

8

2 3

76

1

5

LVI/BCI

BK

7

8

CR19

BRN

WH


WH/RD

WH

UP

UP

5

C4

7-2

C4

7-1

C4

7-4

C4

7-3

C2

P-5

C2

P-5

3

2

3

5

OR

BR

AK

ER

EL

EA

SE

NO

CO

IL

REV A


Electrical Schematic - CE Models(after serial number 9346)

1

2

3

4

5

6

7

8


6 - 21 Z-30/20N • Z-30/20N RJ Part No. 106373

LS

4-S

EC

.U

P/D

WN

LS

2-P

RI.

UP

/DW

N

LS

1-E

XT

/RE

T

C48-3TB52

C9

HR

NB

K/R

D


85

86

PR

IMA

RY

LIF

TP

UM

PP

R2

33

R1

9L

PE

GR

/WH

PR2

CR20

30

87

AU

XIL

IAR

YL

IFT

PU

MP

PR

3

PR

IMA

RY

LIF

TP

UM

PC

ON

TA

CT

OR

RE

LA

Y

33

PR3

C4

9-1

1C

19

LP

EG

R/W

H

C4

9-1

R2

7A

UX

RD

87a

CR3

87

30

P42BAT OR/RD C48-2

C7

B-2

P2

3B

AT

WH

C7

P-2

C4

8-1

P1

82

BA

TR

D

P2

2B

AT

BK

RD

C134PWR RD TB134

R42BAT OR/RD

C12FTS

10A

CB3

CE & PLATFORM LOAD SENSE OPT.

C1

33

PL

AB

L/R

DC

2P

-1C

2B

-1

D39

L4

H6 L45

U33

U6AMOTOR CONTROLLER

500 A

F4

ADD D40 ONLY IF UNIT HAS L4 AND L48.

C3

B-9

C1

B-1

2

H2

GR/BK

RD

TB134

C1P-12C132PLI BL/WH

C7

B-1

LS18

D40

1 3

4

6 7

5

12 8

C40LS

C4

9-9

TB40

C29JSH RD/WH

C32JSL WH/RD

C30FWD WH

C31REV WH/BK

BK 2 GA

CH

AS

SIS

GR

OU

ND

J2

-BK

RD

P26BAT

13LS1

(EXT)

14 2

P2

2B

AT

BK

C7P-1

HO

RN

B

A C

P42BAT OR/RD

C4

9-7

C1

78

CS

LB

K

C49-10

C4

9-8

BK

C11

-3B

K-6

C11

-4W

H-6

C1

0-2

WH

-7

C1

0-1

BK

-7P

22

LS

BK

C5

2-1

BK

-8

C5

2-2

WH

-8

J1-WH

C4

9-3

C4

9-6

C4

9-5

C4

9-4

C2

B-4

C3

B-3

C1

B-2

C1

B-3

C1

B-4

C1

B-5

C1

B-6

C9P-2

C9P-3

R4

2B

AT

OR

/RD

C2

P-4

C3

BA

TR

D/W

HC

3P

-3

C2

8T

TA

RD

/BK

C1

P-2

C9

HR

NB

K/R

DC

3P

-9

C2

9JS

HR

D/W

HC

1P

-3

C3

2JS

LW

H/R

DC

1P

-6

C3

1R

EV

WH

/BK

C1

P-5

CR5

P182BAT BK

C19LPE GR/WH

R42BAT OR/RD

P24BAT WH

RD

C12DRE BL/WH

CR3

GND BR

ALARMTILT

RD

WH-(FS)

FS1

H1

RD-(FS)

PLATFORM

GROUND

P1KS1

TB22

P3HORN

P2

RD

C9P-1 BK

+

RD

P182BAT RD

BK-(FS)

OR

/RDCR1

CR2

TB42

RD

/WH

30

8785

86

87

3086

85

BR

N

BR

N

PR

1

OF

F-L

IMT

SP

DIN

P

INT

ER

LO

CK

LE

DL

3

53 17

C1

82

PW

RG

R

LS4(SEC)

OR

/RD

LS2(PRI)

RD

/BK

OR

/RD

C4

9-2

C4

8B

RK

RD

/BK

OR

/RD

20

CR

5

22

21

22

21

86

85

CO

NT

RO

LL

ER

STA

TU

S

CB2

10 A

C1

P-4

RD

20

AP2

24 V

100 A

FO

RW

AR

D

PO

T.L

OW

DIO

DE

RE

TU

RN

+4

8V

INP

UT

PO

T.H

I

RE

VE

RS

E

10

1 9 11

16

14

PR1

10 A

AP2 48V

R4

2B

AT

OR

/RD

WH

WH

/BK

WH

/RD

RD

/WH

F3

F5

F2

+

++

+

LEFTBOX

-

--

-

+48 V

C3

0F

WD

WH

2

48

VP

OW

ER

RE

LA

YC

R1

FL

AS

HIN

GB

EA

CO

NO

PT

ION

48

VP

OW

ER

RE

LA

YC

R2

FB

+

HO

RN

RE

LA

Y

BA

SE

CO

NT

RO

LB

OX

GR

OU

ND

CR4

TIL

TS

EN

SO

RR

D

WH

BK

BR

N

F1

+

86

85

30

87

BR

N

BR

AK

ER

EL

EA

SE

RE

LA

YC

R5

PR

1D

RIV

EC

ON

TA

CT

OR

AP1

AU

XIL

IAR

YL

IFT

PU

MP

PR

IMA

RY

LIF

TP

UM

P

PR3 PR2100 A

WH

BK

AC POWER

F2 F1

A2

A1

A2

A1+

-

PUMP

+

++

+

CHARGER

LEFTMOTOR

RIGHTBOX

-

--

-

GROUND

+24 V


NOTES:




F2

F2F1 B+M-AP1 B-

PUMP

RIGHTMOTOR

2

3

5

6

5

6

BL

/WH

5

L48

REV A



1

2

3

4

5

6

7

8


Part No. 106373 Z-30/20N • Z-30/20N RJ 6 - 22

JIB ROTATE OPTION

JIBROTATE

RE

TR

AC

T





NOTES:

(GND)

CR3

TU

RN

TA

BL

ER

OTA

TE

LE

FT

TU

RN

TA

BL

ER

OTA

TE

RIG

HT

DE

SC

EN

TA

LA

RM

OP

TIO

N

SE

CO

ND

AR

YB

OO

MD

OW

N

SE

CO

ND

AR

YB

OO

MU

P

A3

+

WH

/BK

WH

TB4

BL

/BK

BL

TB5 TB11 TB10

CE OG/BK C11-2

OR

/BK

OR

PR

IMA

RY

BO

OM

UP

PR

IMA

RY

BO

OM

DO

WN

BO

OM

RE

TR

AC

T

BO

OM

EX

TE

ND

PL

AT

FO

RM

LE

VE

L

DO

WN

CO

IL

PL

AT

FO

RM

LE

VE

LU

PC

OIL

PL

AT

FO

RM

LE

VE

LC

UT

-OU

TO

PT

ION

BK

/WH

BK

RD

/BK

RD

TB2 TB1 TB8 TB7

87

30

87

30

85

86

85

CR10B

CR10A 86

TB15 TB14

PL

AT

FO

RM

RO

TA

TE

LE

FT

/JIB

BO

OM

DO

WN

PL

AT

FO

RM

RO

TA

TE

RIG

HT

/JIB

BO

OM

UP

BR-6

CE RD C11-1

14

13RD-6

LS2

PRIMARYBOOM

C19LPE GR/WH

TS55

C12DRE BL/WH

RD

CR5

RD

C2

PB

DR

D/B

K

C1

0S

BU

BL

C11

SB

DB

L/B

K

C5

TR

RW

H/B

K

C4

TR

LW

H

RIG

HT

TURNTABLEROTATE

ENABLEFUNCTION

LE

FT

TS62

RD

C3

B-4

C3

B-5

SECONDARYBOOM

TS60

DO

WN

UP

C3

B-1

1

C3

B-1

0

C3

B-1

C3

B-2

C3

P-4

C3

P-5

LE

FT

TS12

RIG

HT

TURNTABLEROTATE

C3

P-1

0

C3

P-1

1

C1

PB

UR

D

C3

P-2

C3

P-1

SECONDARYBOOM

DO

WN

2

6

CR19

UP

TS10

DO

WN

CR19

1

5

TS11

UP

C30FWD WH

C29JSH RD/WH

C31REV WH/BK

C32JSL WH/RD

R42BAT OR/RD

P24BAT WH

C1

7P

RR

BL

PLATFORMROTATE

PLATFORMROTATE

C1

8P

RR

GR

/BK

C1

7P

RL

GR

C1

5P

LD

OR

/BK

C1

4P

LU

OR

C7

PB

EB

K

C8

PB

RB

K/W

H

DO

WN

TS61

UP

PRIMARYBOOM

TS63

EX

TE

ND

PRIMARYBOOM

C3

B-7

C3

B-8

PLATFORMLEVEL

DO

WN

TS59

C4

B-6

C4

B-5

C4

B-3

C4

B-2

C3

P-7

C3

P-8

EX

TE

ND

PRIMARYBOOM

RE

TR

AC

T

TS13

DO

WN

TS9

C4

P-3

C4

P-2

C4

P-5

C4

P-6

PLATFORMLEVEL

UP

RIG

HT

LE

FT

TS7

C4

7JR

RR

D

C4

6JR

LY

L

C4

7JR

RO

R/B

K

C4

6JR

LO

R

C4

4JD

WH

C4

3JU

BK

C1

8P

RL

OR

C4

3JU

GR

C4

4JD

GR

/BK

RIG

HT

LE

FT

TS57

C2

B-6

C2

B-5

JIB MANIFOLD

DO

WN

TS58

UP

JIBBOOM

C2

B-2

C2

B-3

C2

P-5

C2

P-6

DO

WN

TS8

UP

JIBBOOM

C2

P-3

C2

P-2

RIG

HT

LE

FT

TS16

C7

P-3

BA

TG

ND

BR

N

C8

-4

C8

-3

C1

6D

EO

R/R

D

PS

1

GR/WHP

RO

PO

RT

ION

AL

CO

NT

RO

LV

ALV

E

AU

XIL

IAR

YC

ON

TR

OL

RE

LA

Y

TB6

WH

/RD

GR/WH

CR3

TB19

86

85

C19LPE

RD

HO

UR

ME

TE

R

_

BR

AK

ER

EL

EA

SE

NC

CO

IL

ST

EE

RR

IGH

T

ST

EE

RL

EF

T

BR

AK

ER

EL

EA

SE

PR

ES

SU

RE

SW

ITC

H

+

WH

/BK

HM

+

TB19

R48BRK

GR/WH

BL

BL

/BK

R4

8B

RK

RD

/WH

TB48

C8

-1

C7

B-3

BA

TG

ND

BR

N

C8

-2

TR

AV

EL

AL

AR

M

A2

TB52

SWITCH

ENABLE

13

RD

-5

RD

/WH

14

BR

N-5

22

LS321

LIMIT

DRIVE

BK

-5

TB16

WH

-5

DRIVEENABLETS15

DP1

C6

MF

VW

H/R

D

C1

9L

PE

GR

/WH

C1

9L

PE

GR

/WH

LE

FT

TS66

RIG

HT

JIBROTATE

C3

B-6

C4

B-7

TB27C27AUX RD

RD

AUXILIARYPUMPTS51


BP1

C3

P-6

BK/RD

RD

GR

C4

P-7

+

BCIE

F

C3

7S

CW

BL

/BK

C1

B-1

TB37

TB3687

30

CR5

C1

B-1

1

C1

B-1

0

AUXILIARYPUMPTS1

C2

7A

UX

RD

C1

P-1

STEER

L R 10

9

LIFT

DRIVE

FWD

RD

-AU

X

REV

20K

4

8

7

6

5

3

2

1

CE OPTION:

REMOVE

JUMPER

AND ADD

RELAY

C1

P-1

1

C1

P-1

0C

36

SC

CB

LR

D

LVI/BCI OPTION

P24BAT WH

C32JSL WH/RD

C30FWD WH

C31REV WH/BK

C29JSH RD/WH

C1

3D

EL

BL

/RD

C1

2F

TS

BL

/WH

C1

2F

TS

BL

/WH

OR

/RD

C1

3D

EL

BL

/RD

BR

N

C3

B-1

2

TB12

C4

B-4

C4

B-1

C3

P-1

2

C1

6D

EO

R/R

DC

4P

-4

C4

P-1

L1

OR

/RD

4

8

2 3

76

1

5

LVI/BCI

BK

7

8

CR19

BRN

WH


WH/RD

WH

UP

UP

5

C4

7-2

C4

7-1

C4

7-4

C4

7-3

C2

P-5

C2

P-5

3

2

3

5

OR

BR

AK

ER

EL

EA

SE

NO

CO

IL

Section 6 • Schematics April 2007

Ground Control Panel Wiring Diagram(before serial number 6290)

REV A


Ground Control Panel Wiring Diagram(before serial number 6290)

1

2

3

4

5

6

7

8


6 - 23 Z-30/20N • Z-30/20N RJ Part No. 106373

RED-SP1RED-3 PRIMARY BOOM UPRED-MH

D C B A

ORG/RED-1

BLU/RED-1

BLK/WHT-1

BLU/BLK-1

BLU-1

WHT/BLK-1

WHT-1

RED/WHT-1

RED-1

WHT-2

BLK-2

RED/BLK-1

GRN/WHT-3

GRN/BLK-3

ORG/RED-3

ORG-3

ORG/BLK-3

GRN-3

BLU-3

BLU/BLK-3

BLU/WHT-3

BLK-3

BLK/WHT-3

BLK/RED-3

BLU/RED-3

WHT-3

WHT/BLK-3

RED/BLK-3

WHT/RED-3 WHT/RED-MH

WHT/BLK-MH

RED/BLK-MH

WHT-MH

BLK/WHT-MH

BLK/RED-CR4

BLK-MH

ORG-MH *

BLU/WHT-CH

WHT-5

BLK-CR4

WHT/BLK-CH

RED/WHT-CH

WHT-TILT

BLU/BLK-MH

BLU-MH

BLK-8

FOOTSWITCH

HORN

BOOM FUNCTION FLOW CONTROL

BOOM EXTEND

SECONDARY BOOM DOWN

SECONDARY BOOM UP

LIFT PUMP

BOOM RETRACT

PLATFORM LEVEL UP

PLATFORM LEVEL DOWN

PLATFORM ROTATE LEFT

PLATFORM ROTATE RIGHT

DRIVE ENABLE LIGHT

PRIMARY BOOM DOWN

TURNTABLE ROTATE LEFT

TURNTABLE ROTATE RIGHT

BLU/BLK-SP11

6

2

5

4

3

10

7

9

8

WHT/RED-SP

WHT-SP

RED/BLK-SP

RED/WHT-CR1

WHT/BLK-SP

BLU-SP

BLK-SP

BLK/WHT-SP

16

15

14

12

13

19

19

18

17

ORG-SP

ORG/BLK-SP

BLK-5

GRN/WHT-MH

GRN-SP

GRN/BLK-SP

OFF-LIMIT SPEED

STEER RIGHT

2-WIRE POT.

DRIVE FORWARD

DRIVE REVERSE

AUXILIARY PUMP SELECT

KEY SWITCH POWER

+24V DC TO PLATFORM

TILT ALARM

STEER LEFT

23

22

29

30

31

27

28

RED-SP

BLK-SP

WHT-SP

37

36

42

40

GRN-1

JIB BOOM DOWN

JIB BOOM UP

44

43

GRN/BLK-1 GRN/BLK-SP

GRN-SP

WHT-8 50WHT-6RED/WHT-TB3D

ORG/RED-CH

ORG/RED-42D

RED/WHT-48C

5

1 2 3

GRN/WHT-19C

4

KS1

TS51

TS57

TS55

P1

LABEL

TS61

TS63

TS62

CB1

J1

TS59

BOOM EXTEND/RETRACT TOGGLE SWITCH

CIRCUIT BREAKER, CONTROLS, 10A

PRIMARY BOOM UP/DOWN TOGGLE SWITCH



BRAKE RELEASE JACK


DESCRIPTION


KEY SWITCH


TS60 SECONDARY BOOM UP/DOWN TOGGLE SWITCH

TS58 JIB BOOM UP/DOWN TOGGLE SWITCH

ORG-CH

*

*

PLATFORM LEVEL CUTOUT (CE VERSION ONLY)

BLU/BLK-MH

BLU-MH

BRN-52A

HOURMETERHM

CHASSIS HARNESSCH

FUNCTION ENABLE TOGGLE SWITCH

MANIFOLD HARNESSMH

10B10A

SP SWITCH PANEL

GRN/WHT-CH

ORG-MH

ORG-14B

48V DC RELAY COIL POWER

DRIVE ENABLE

LIFT PUMPGRN/WHT-SP

GRN/WHT-CR3TB36/TB37

RED-CR3

WHT-CH

BLK-1

SWITCHED 48V DCORG/RED-CH ORG/RED-L3

BRN-5 BRN-2

BLK-6

48

49

52

52

RED/WHT-SP

BRN-CR4

BRN-SP

BLK [OPTION 2]

BLK-7

BRN-MH

BRN-CB2

RED-5

ORG/BLK-MH *

LS1-LS2 JUNCTION

BRAKE RELEASE

GROUND

GROUND

LS2-LS4 JUNCTION

ORG/BLK-MH

ORG/BLK-15B

CR_ CONTROL RELAY

SWITCH PANEL

RED-CH

BLK/RED-1

SPARE WIRE LIST

RED/WHT-3

WHT/RED-CH32WHT/RED-1 JOYSTICK POT. LOW

ORG/RED-CR1

DESCENT ALARM (OPTION)

BRAKE RELEASE/TRAVEL ALARM

A3

A2

WHT-7

OPTION NUMBERS

3 - DESCENT ALARM

1 - PLATFORM LEVEL CUTOUT

2 - FLASHING BEACON

ORG/BLK-SPORG/BLK-3

ORG-6

ORG-3

ORG/BLK-CR10B

14

15

ORG-CR10A ORG-SP

PLAT. LEVEL DOWN

PLAT. LEVEL UP

[** JIB BOOM ROTATE OPTION]

CONTROL RELAY I.D.

CR10B - PLATFORM LEVEL CUTOUT (CE ONLY)

CR10A - PLATFORM LEVEL CUTOUT (CE ONLY)

CR5 - BRAKE RELEASE

CR4 - HORN

CR3 - AUXILIARY PUMP

CR2 - PRIMARY 48V DC POWER

CR1 - SECONDARY 48V DC POWER

[OPTION 2]

RED-27D

23 KEY SWITCH POWER

BLU/WHT-1

BLK/RED-9D

BLK/RED-HORN

BLK-22B

RED/BLK-CH

ORG/RED-16A

RED-6

RED/WHT-CR5

BLU/BLK-19D

BLU-19D

L3CB2BLK-CH

ORG/RED-42A

BRN-52D

BRN-CH

GRN/WHT-1

TS58

TS66

TS60

TS62

TS61

TS63

TS51

HM

NO NO

ORG/RED-CR5

WHT/BLK-SP

WHT/BLK-SPA2

RED/WHT BRN

TILT SENSOR

WHT-28D

RED-23D

BLK BRN-CB2

U

D

U

D D

U

L R R E

L R

CONTROLLER STATUS LEDL3

RED/WHT-MH

RED-TILT

BRN-CH

ORG/BLK-SP **47ORG/BLK-1

ORG-1 46 ORG-SP **

JIB BOOM ROTATE RIGHT

JIB BOOM ROTATE LEFT

TS66 JIB BOOM ROTATE TOGGLE SWITCH (OPTION)

J1

CB1

P1

NC

NC

TS55

TS59

TS57

BLK-22A

WHT-23A

RED-27A

ORG/BLK-15A

ORG/BLK-47A

WHT/RED-6A

BLK-7A

BLK/WHT-8A

WHT-4A

WHT/BLK-5A

GRN-17A

RED-1A

GRN-43A

RED/BLK-2A

ORG-14A

GRN/BLK-18A

GRN/WHT-19A

WHT/BLK-19D/48D

BRN-52A

RED-CH

RED/WHT-48A

BLU/BLK-11A

BLU-10A

L R

D

U

ORG-46A

GRN/BLK-44A

JIB ROTATE(OPTION)

RED

RED

KS1

CB2 CIRCUIT BREAKER, CONTROLS RETURN, 10A

[* SEE OPTIONAL WIRING]

REV A


Ground Control Panel Wiring Diagram(from serial number 6290 to 8354)

1

2

3

4

5

6

7

8


Part No. 106373 Z-30/20N • Z-30/20N RJ 6 - 24

RED-SP1RED-3 PRIMARY BOOM UPRED-MH

D C B A

ORG/RED-1

BLU/BLK-1

BLU-1

WHT/BLK-1

WHT-1

RED/WHT-1

RED-1

BLK-C23-4

RED/BLK-1

GRN/WHT-3

GRN/BLK-3

ORG/RED-3

ORG-3

ORG/BLK-3

GRN-3

BLU-3

BLU/BLK-3

BLU/WHT-3

BLK-3

BLK/WHT-3

BLK/RED-3

BLU/RED-3

WHT-3

WHT/BLK-3

RED/BLK-3

WHT/RED-3 WHT/RED-MH

WHT/BLK-MH

RED/BLK-MH

WHT-MH

BLK/WHT-MH

BLK/RED-CR4

BLK-MH

ORG-MH *

BLU/WHT-CH

WHT-5

BLK-CR4

WHT/BLK-CH

RED/WHT-CH

RED/BLK-TILT

BLU/BLK-MH

BLU-MH

BLK-8

FOOTSWITCH

HORN

BOOM FUNCTION F.C.

BOOM EXTEND

SEC. BOOM DOWN

SEC. BOOM UP

LIFT PUMP

BOOM RETRACT

PLAT. LEVEL UP

PLAT. LEVEL DOWN

PLAT. ROTATE LEFT

PLAT. ROTATE RIGHT

DRIVE ENABLE LIGHT

PRIMARY BOOM DOWN

TURN. ROTATE LEFT

TURN. ROTATE RIGHT

BLU/BLK-SP11

6

2

5

4

3

10

7

9

8

WHT/RED-SP

WHT-SP

RED/BLK-SP

RED/WHT-CR1

WHT/BLK-SP

BLU-SP

BLK-SP

BLK/WHT-SP

16

15

14

12

13

19

19

18

17

ORG-SP

ORG/BLK-SP

BLK-5

GRN/WHT-MH

GRN-SP

GRN/BLK-SP

OFF-LIMIT SPEED

STEER RIGHT

2-WIRE POT.

FORWARD

REVERSE


+24V TO PLATFORM

TILT ALARM

STEER LEFT

23

22

29

30

31

27

28

RED-SP

BLK-SP

37

36

42

40

GRN-1

JIB DOWN

JIB UP

44

43

GRN/BLK-1 GRN/BLK-SP

GRN-SP

WHT-8 50WHT-6

ORG-CH

*

*

BLU/BLK-MH

BLU-MH

48V RELAY COIL PWR.

DRIVE ENABLE

LIFT PUMPGRN/WHT-SP

GRN/WHT-CR3TB36/TB37

RED-CR3

WHT-CH

SWITCHED 48VORG/RED-CH ORG/RED-L3

BRN-5 BRN-2

BLK-6

48

49

52

52

RED/WHT-SP

BRN-CR4

BRN-SP

BLK [OPTION 2]

BLK-7

BRN-MH

BRN-CB2

RED-5

ORG/BLK-MH *

LS1-LS2 JUNCTION

BRAKE RELEASE

GROUND

GROUND

LS2-LS4 JUNCTION

SWITCH PANEL

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

SPARE WIRE LIST

RED/WHT-3

WHT/RED-CH32WHT/RED-1 JOYSTICK POT. LOW

ORG/RED-CR1

WHT-7

OPTION NUMBERS1 - PLATFORM LEVEL CUTOUT2 - FLASHING BEACON3 - DESCENT ALARM

[** JIB ROTATE OPTION]

CONTROL RELAY I.D.

CR1 - SECONDARY 48V DC POWERCR2 - PRIMARY 48V DC POWERCR3 - AUXILIARY PUMPCR4 - HORNCR5 - BRAKE RELEASECR10A - PLATFORM LEVEL CUTOUT (CE ONLY)CR10B - PLATFORM LEVEL CUTOUT (CE ONLY)

RED/WHT-CR5

BLU/BLK-19D

BLU-19D

TS58

TS66

TS60

TS62

TS61

TS63

TS51

HM

ORG/RED-CR5

WHT/BLK-SP

WHT/BLK-SP

A2

RED/WHT-48A BRN

TS60

TS58 TS61

TS62TS55

TS66 TS63

CB1

J1

TS51

HM

A2

KS1

P1

NO NO

ORG

NC

NC

BRN

A3

ORG

OR

GBRN

DESCENT ALARM WIRING (OPTION)

U

D

U

D D

U

L R R E

L R

RED/WHT-MH

RED/WHT-TB3D

ORG/RED-CH

ORG/RED-42D

RED/WHT-48C

5

1 2 3

GRN/WHT-19C

4

PLATFORM LEVEL CUTOUT (CE MODELS ONLY)

BRN-52A

10B10A

GRN/WHT-CH

ORG-MH

ORG-14B

ORG/BLK-MH

ORG/BLK-15B

RED-CH

ORG/BLK-SPORG/BLK-3

ORG-6

ORG-3

ORG/BLK-CR10B

14

15

ORG-CR10A ORG-SP

PLAT. LEVEL DOWN

PLAT. LEVEL UP

RED-27D

BLK/RED-9D

BLK/RED-HORN

BLK-22B

RED/BLK-CH

ORG/RED-16A

RED-6

BRN-CH

ORG/BLK-SP **47ORG/BLK-1

ORG-1 46 ORG-SP **

JIB RIGHT

JIB LEFT

TS57

TS59

ORG

L45

CB1

P1

NC

NC

TS55

TS59

TS57

BLK-22A

RED-27A

ORG/BLK-15A

ORG/BLK-47A

WHT/RED-6A

BLK-7A

BLK/WHT-8A

WHT-4A

WHT/BLK-5A

GRN-17A

RED-1A

GRN-43A

RED/BLK-2A

ORG-14A

GRN/BLK-18A

GRN/WHT-19A

WHT/BLK-19D/48D

BRN-52A

RED-CH

BLU/BLK-11A

BLU-10A

L R

D

U

ORG-46A

GRN/BLK-44A

JIB ROTATE(OPTION)

LIFT LOCKOUT

BATTERY LIGHT

TRACTION CONTROL

26

25

24

KS1

[* SEE OPTIONAL WIRING]

L3CB2BLK-CH

ORG/RED-42A

BRN-52D

BRN-CH

TILT SENSOR

RED/BLK-28D

RED/WHT-134D

BLK BRN-CB2

WHT

RED A

C

B

KS1

TS51

TS57

TS55

P1

LABEL

TS61

TS63

TS62

CB1

J1

TS59






BRAKE RELEASE JACK


DESCRIPTION


KEY SWITCH


TS60 SECONDARY BOOM UP/DOWN TOGGLE SWITCH

TS58 JIB BOOM UP/DOWN TOGGLE SWITCH

HOURMETERHM

CHASSIS HARNESSCH

FUNCTION ENABLE TOGGLE SWITCH

MANIFOLD HARNESSMH

SP SWITCH PANEL

CR CONTROL RELAY


PLATFORM OVERLOAD ALARM (CE MODELS)

BRAKE RELEASE/TRAVEL ALARM

A3

A6

A2


TS66 JIB BOOM ROTATE TOGGLE SWITCH (OPTION)

CB2 CIRCUIT BREAKER, CONTROLS RETURN, 10A

L45

U33

PLATFORM OVERLOAD LED (CE MODELS)

PLATFORM OVERLOAD MODULE (CE MODELS)

KEYSWITCH POWER

KEYSWITCH POWER

[OPTION 2]

RED-A6 RED-KSI

134A

134WHT-2RED/WHT-TILT

12876543

RE

DA

6

GR

N/B

LK

H6

BL

U/W

HT

-1

BL

K2

2C

BL

K-2

BR

N/G

ND

U33

1

C23

RED/134A

RED-C23-6

RED-C23-7

A6

BLU/RED-1

RED 134B

RED C23-1

GRN/BLK


Ground Control Panel Wiring Diagram(from serial number 6290 to 8354)


Ground Control Panel Wiring Diagram(after serial number 8354)

REV A


Ground Control Panel Wiring Diagram(after serial number 8354)

1

2

3

4

5

6

7

8


6 - 25 Z-30/20N • Z-30/20N RJ Part No. 106373

KS1

TS51

TS57

TS55

P1

LABEL

TS61

TS63

TS62

CB1

J1

TS59

BOOM EXTEND/RETRACT SWITCH


PRIMARY BOOM UP/DOWN SWITCH

PLATFORM ROTATE SWITCH

TURNTABLE ROTATE SWITCH

BRAKE RELEASE JACK

PLATFORM LEVEL SWITCH

DESCRIPTION

AUXILIARY SWITCH

KEY SWITCH


TS60 SECONDARY BOOM UP/DOWN SWITCH

TS58 JIB UP/DOWN SWITCH

HOURMETERHM

CHASSIS HARNESSCH

FUNCTION ENABLE SWITCH

MANIFOLD HARNESSMH

SP SWITCH PANEL

CR CONTROL RELAY

SWITCH PANEL


TRAVEL ALARM

A3

A2

L3

CB2BK-C49-7

OR/RD-42A

BR-52D

BR-C48-3

TS58

TS66

TS60

TS62

TS61

TS63

TS51

HM

A2RD/WH-48A

TS60

TS58 TS61

TS62

TS55

TS66 TS63

CB1

J1

TS51

HM

A2

KS1

P1

NO NO

OR

NC

NC

BR-52AA3

OR

DESCENT ALARM WIRING (OPTION)

TILT SENSOR

RD/BK-C1B-2

RD/WH-134D

BK BR-CB2

U

D

U

D D

U

L R R E

L R


TS66 JIB ROTATE SWITCH (OPTION)

TS57

TS59

OR

L45

CB1

P1

NC

NC

TS55

TS59

TS57

BK-22A

RD-27A

OR/BK-15A

OR/BK-C2-3

WH/RD-6A

BK-7A

BK/WH-8A

WH-4A

WH/BK-5A

GN-17A

RD-1A

GN-43A

RD/BK-2A

OR-14A

GN/BK-18A

GN/WH-19A

WH/BK-19D/48D

BR-52A

RD-C48-1

BL/BK-11A

BL-10A

L R

D

U

OR-C2-2

GN/BK-44A

JIB ROTATE(OPTION)

KS1

CB2 CIRCUIT BRKR., CONTROLS RETURN, 10A

WH

RDA

C

B

L45 PLATFORM OVERLOAD LED

12876543

RD

A6

GN

/BK

A6

BL

/WH

C1

32

PL

I

BK

22

C

BK

P2

2B

AT

BR

/GN

D

U33PLATFORM OVERLOAD

(OPTION)

1

C32

RD/134A

RD-C23-6

RD-C32-7

A6

RD C23-1

GN/BK

BR HM(-)

BK C7-1

BK 22C

BL/WH C1-12

TO TERMINAL BASEAND CONNECTORS

RD 134B

BL/RD C2B-1

BR-52A

BR C32-12

RD

-C2

3-6

A6 PLATFORM OVERLOAD (CE OPTION)

REV A


Ground Control Panel Terminal Strip Wiring Diagram(after serial number 8354)

1

2

3

4

5

6

7

8


Part No. 106373 Z-30/20N • Z-30/20N RJ 6 - 26

RD-C32-1

BR-52D

C32-3BL/WH PLAT OVERLOAD INPUT

C133PLA

C132PLI

BL/RD PLAT OVERLOAD ALARMA6(-)C2B-1

C1B-12

DESC.TOFROMCIRCUIT#WIRES

C1B-5

C1B-4

C1B-3

C4B-6

C4B-5

CR4

C8-4

TILT-C

C52-2

CR1

C2B-5

C2B-6

C11-4

C11-3

C1B-6

C2B-3

C2B-2

WIRES FROM CONNECTOR TO CONNECTORTERMINAL BASE (TB)

OR RELAY BLOCK

TO TERMINAL BASE

C49

C48

CHASSISHARNESS(CH)

MANIFOLDHARNESS(MH)

C1B

C2B

C4B

C3B

CABLE#3

CABLE#1

CABLE#2 C7B

C11

C8

C52

C10

LS4-SECONDARYUP/DOWN

LS3-DRIVE ENABLE

LS2-PRIMARYUP/DOWN

LS1-PRIMARYEXTEND/RETRACT

RD/WH-TILT WH C7B-2 134

134

RD-KSI-4RD-A6 (CE OPTION)

RD/WH (FLASH. BEACON OPT.)

24

25

26

TRACTION CONTROL

BATTERY LIGHT

LIFT LOCK-OUT

JIB ROTATE LEFT (OPTION)

JIB ROTATE RIGHT (OPTION)

SPC46JRLOR

OR/BK C47JRR SP

BR- MH

RD/WH-MHWH/BK-SP

WH/BK-SP

OR/RD-CR5

BL-19D

BL/BK-19D

RD/WH-CR5

RD-C11-1

OR/RD-16A

RD/BK-C49-2

BK-22A

BK/RD-MH-HORN

BK/RD-C3B-9

CR5 - BRAKE RELEASE

RD-27D

CR1 - SECONDARY 48V POWER

CR9 - PLAT. LEVEL CUTOUT (CE ONLY)

CR3 - AUXILIARY PUMP

CR2 - PRIMARY 48V POWER

CR10 - PLAT. LEVEL CUTOUT (CE ONLY)

CR4 - HORN

CONTROL RELAY I.D.

PLAT. LEVEL UP

PLAT. LEVEL DOWN

OR-SPOR-CR9

15

14

OR/BK-CR10

OR C4B-2

OR/BK C11-2

OR/BK C4B-3 OR/BK-SP

WH C10-2

OR/RD-CR1

JOYSTICK POT. LOWWH/RD C32JSL CH

C3B-3

RD-C49-1

OR/BK-15A

OR/BK-MH

LS2-LS4 JUNCTION

LS1-LS2 JUNCTION

OR/BK-MH

OR/RD C8-1

BR-CB2

BRBK

BK (FLASH. BEACON OPT.)

BR-SP

BR-CR4

RD/WH-SP

52

52J1

48

C52-1BR C7B-3BR C8-2

OR/RD-L3OR/RD C49-10

CH

RD-CR3

TB36/TB37 GR/WH-CR3

GR/WH-SP

48V RELAY COIL PWR.

OR-14A

OR-MH

GR/WH-19C

CR10A CR10B

BR-52A

BL-MH

BL/BK-MH

PLATFORM LEVEL CUTOUT (CE VERSION ONLY)

CH

CR4

GR/WH-C49-11

CR3CR2CR1

CR5

RD/WH-48D

OR/RD-42D

OR/RD-C48-2

RD/WH-C3B-3

WH J2 C10-2

SP

SPGR/BK

C43JU

C44JD

JIB UP

JIB DOWN

GR

C40LS

42

36

37

BK-CR4

RD-SP

C28TTA

27

C31REV

C30FWD

C29JSH

22

TILT ALARM

REVERSE

FORWARD

2-WIRE POT.

OFF-LIMIT SPEED

SP

SP

GR/WH-MH

BK C8-3

OR/BK-SP

OR-SP

C17PRL

C18PRR

19

19

C13DEL

12

14

15

16

BK/WH-SP

BK-SP

BL-SP

WH/BK-SPRD/WH

RD/BK-SP

WH-SP

WH/RD-SP

8

C9HRN7

10

C3BAT

4

5

2

6

11 BL/BK-SP

DRIVE ENABLE LIGHT

PLAT. ROTATE RIGHT

PLAT. ROTATE LEFT

HORN

ORBL-MH

BL/BK-MH

RD/BK

CH

CHBK-SP

BL/RD

BL/WH-CH

OR-MH

BK-MHBK/RD

BK/WH-MH

WH-MH

RD/BK-MH

WH/BK-MH

WH/RD-MHWH/RD C3B-6

RD/BK C3B-2

WH/BK C3B-5

WH C3B-4

C4B-1

C3B-9

BK/WH C3B-8

BK C3B-7

BL/WH C3B-12

BL/BK C3B-11

BL C3B-10GR

OR/BK C4B-3

OR C4B-2

OR/RD C4B-4

GR/BK

GR/WH C4B-7

C1B-2

BK-C23-4

RD C1B-1

RD/WH

WH

WH/BK

BL C1B-10

BL/BK C1B-11

OR/RD C2B-4

ABCD

RD-MHRD C3B-1 1 RD-SP C1PBU

C12FTS

C6MFV

C7PBE

C11SBD

C10SBU

C19LPE

C8PBR

C14PLU

C15PLD

C2PBD

C4TRL

C5TRR

C37SCW

C27AUX

P22BAT

C36SCC

C16DE

C19LPE

R42BAT

C48BRK

BATGND

BATGND

C134PWR

C134PWR

CIRCUIT #DESCRIPTION

KEYSWITCH POWER

KEYSWITCH POWER

GROUND

GROUND

BRAKE RELEASE

SWITCHED 48V

LIFT PUMP

DRIVE ENABLE

STEER LEFT

+24V TO PLATFORM


STEER RIGHT

TURN. ROTATE RIGHT

TURN. ROTATE LEFT

PRIMARY BOOM DOWN

PLAT. LEVEL DOWN

PLAT. LEVEL UP

BOOM RETRACT

LIFT PUMP

SEC. BOOM UP

SEC. BOOM DOWN

BOOM EXTEND

BOOM FUNCTION F.C.

FOOTSWITCH

PRIMARY BOOM UP

30

8586

87A

87

(CE OPTION)

(CE OPTION)

REF.


Ground Control Panel Terminal Strip Wiring Diagram(after serial number 8354)


Platform Control Box Wiring Diagram(before serial number 6290)

REV A


Platform Control Box Wiring Diagram(before serial number 6290)

1

2

3

4

5

6

7

8


6 - 27 Z-30/20N • Z-30/20N RJ Part No. 106373

CABLE#3

CABLE#1

CABLE#2

JIB

F.S.

A1NO

NC

NC

WH

T-2

BL

K-F

S

BL

K-2

BL

K/R

ED

-3

BL

U-1

WH

T-1

WH

T/B

LK

-1

RE

D-1

BL

K-3

BL

K/W

HT

-3

BLK/RED-1

BLK/WHT-1

BLK-1

BL

K-J

IB

WH

T-J

IB

BL

UE

-JIB

OR

G-J

IB

SPARE WIRES

21 43 5

P3HORN

P2EMERGENCY

STOP BUTTON

TS1AUXILIARY

POWERTS15

TS12

TS10

TS11

TS13

TS16TS8

DP1

L1DRIVEENABLELED

TS16

DP1

BP1

TS1

P2

LABEL

TS10

TS12

TS11

TS13

TS9

TS7

TS8




SECONDARY BOOM UP/DOWN TOGGLE SWITCH



JIB BOOM ROTATE TOGGLE SWITCH (OPTION)


DESCRIPTION


DRIVE CONTROLLER


AUXILIARY POWER TOGGLE SWITCH

P3 HORN BUTTON

DRIVE ENABLE LIGHTL1

REMOVE JUMPERFOR CE MODELS

WH

T/R

ED

-1

BL

U/B

LK

-1

GR

N

RE

D

BL

K/R

ED

BL

U/R

ED

-3

WH

T-F

S

BR

N-J

IB

OR

G/R

ED

-1

A1 TILT ALARM

BCI BATTERY CHARGE INDICATOR (OPTION)

GRN/WHT-1

BLU/WHT-1

RE

D/W

HT

-3

OR

G/R

ED

BCI(OPTION)

REMOVE THIS WIRE WHEN LOADSENSE OPTION IS REQUIRED.

RE

D

BP1BOOM

FUNCTIONSPEED

CONTROL

6 7 8 9 10

RE

D/W

HT

-1

WHT

BR

N-2

RE

D

WH

T

BLU/RED-1

RED

BRN

BRN

WHT

L R

TS7

TS9

TS15 DRIVE ENABLE TOGGLE SWITCH

OR

G/B

LK

-3

YE

L-J

IB

RE

D-J

IB

OR

G-1

OR

G/B

LK

-1

OR

G-3

RE

D-3

RE

D/B

LK

-3

GR

N/B

LK

-1

GR

N/W

HT

-3

GR

N-1

GR

N-3

GR

N/B

LK

-3

WH

T/R

ED

-3

BL

U-3

BL

U/B

LK

-3

WH

T-3

WH

T/B

LK

-3

OR

G/R

ED

-3

BL

U/W

HT

-3

RE

D/B

LK

-1

JIB BOOM ROTATEOPTION

LOAD SENSE(ACCESSORY)

REV A


Platform Control Box Wiring Diagram(from serial number 6290 to 8354)

1

2

3

4

5

6

7

8


Part No. 106373 Z-30/20N • Z-30/20N RJ 6 - 28

CA

BL

E#

3#

2C

AB

LE

#1

JIB

F.S

.

A1N

ON

CN

CN

O

BL

K-F

S

BL

K-2

BL

K/R

ED

-3

BL

U-1

WH

T-1

WH

T/B

LK

-1

RE

D-1

BL

K-3

BL

K/W

HT

-3

BL

K-J

IB

WH

T-J

IB

BL

UE

-JIB

OR

G-J

IB

SPARE WIRESBLK-1BLK/WHT-1BLK/RED-1

21 43 5

P3

TS

1

TS

15

TS

12

TS

10

TS

11

TS

13

TS

16

TS

8

DP

1P

2

L1

TS16

DP1

BP1

TS1

P2

LABEL

TS10

TS12

TS11

TS13

TS9

TS7

TS8



EXTEND/RETRACT TOGGLE SWITCH

SECONDARY BOOM UP/DOWN TOGGLE SWITCH



JIB ROTATE TOGGLE SWITCH (OPTION)


DESCRIPTION


DRIVE CONTROLLER



P3 HORN BUTTON

DRIVE ENABLE LIGHTL1

WH

T/R

ED

-1

BL

U/B

LK

-1

GR

N

RE

D

BL

K/R

ED

BL

U/R

ED

-3

WH

T-F

S

BR

N-J

IB

OR

G/R

ED

-1

A1 TILT ALARM

BCI BATTERY CHARGE INDICATOR (OPTION)

RE

D/W

HT

-3

OR

G/R

ED

BC

I(O

PT

ION

)

BP

1

6

6 7 8 9 10

RE

D/W

HT

-1

WHT

BR

N-2

RE

D

WH

T

RED

BRN

BRN

WHT

U

UU D

DD

LR

LR

E R

L R

RL

TS

7

D UTS

9

TS15 DRIVE ENABLE TOGGLE SWITCH

OR

G/B

LK

-3

YE

L-J

IB

RE

D-J

IB

OR

G-1

OR

G/B

LK

-1

OR

G-3

RE

D-3

RE

D/B

LK

-3

GR

N/B

LK

-1

GR

N/W

HT

-3

GR

N-1

GR

N-3

GR

N/B

LK

-3

WH

T/R

ED

-3

BL

U-3

BL

U/B

LK

-3

WH

T-3

WH

T/B

LK

-3

OR

G/R

ED

-3

BL

U/W

HT

-3

WH

T-2

JIB ROTATEOPTION

NOTE:REMOVE JUMPER JP1 FOR CE VERSION.6

LS

18

L4

L4

8

PLATFORM OVERLOAD LEDL48

L4 TILT ALARM LED

RE

D/B

LK

-1

BL

U/R

ED

-1

BL

U/W

HT

-1

RE

D

RE

D

RED/BLK

GRN/BLK


Platform Control Box Wiring Diagram(from serial number 6290 to 8354)


Platform Control Box Wiring Diagram(after serial number 8354)

REV A


Platform Control Box Wiring Diagram(after serial number 8354)

1

2

3

4

5

6

7

8


6 - 29 Z-30/20N • Z-30/20N RJ Part No. 106373

CE OPT.

Y

Y

JIB

A1

BR

N-J

IBB

RN

-2

F.S.

C2P

C9

C7B

C1P

C47

C4POPT.

C3P

PB

OX

RD/BK

RD

C1

32

PL

IB

L/W

HC

1P

-12

C1

33

PL

AB

L/R

DC

2P

-1

C2

8T

TA

RD

/BK

C1

P-2

TURNTABLE TILT ALARM LED (CSA OPTION)L4

L48

LS18

JIB ROTATEOPTION

P2

3B

AT

WH

C7

P-2

C1

2F

TS

BL

/WH

C3

P-1

2

C1

6D

RE

OR

/RD

C4

P-4

C5

TR

RW

H/B

KC

3P

-5

C4

TR

LW

HC

3P

-4

C11

SB

DB

L/B

KC

3P

-11

C1

0S

BU

BL

C3

P-1

0

C6

MF

VW

H/R

DC

3P

-6

C1

8P

RR

GR

/BK

C4

P-6

C1

7P

RL

GR

C4

P-5

C4

3JU

GR

C2

P-5

C1

9L

PE

GR

/WH

C4

P-7

C4

4JD

GR

/BK

C2

P-6

C2

PB

DR

D/B

KC

3P

-2

C1

PB

UR

DC

3P

-1

C1

4P

LU

OR

C4

P-2

C4

7JR

RO

R/B

KC

2P

-3

C4

6JR

LO

RC

2P

-2

C4

7JR

RR

DC

47

-6

C4

6JR

LY

LC

47

-5

C1

5P

LD

OR

/BK

C4

P-3

DRIVE ENABLE SWITCHTS15

TS9

UD

TS7

L

R

RE

R

L

R

L

D

D

DU

U

U

WH

BRN

RD

RD

C2

9JS

HR

D/W

HC

1P

-3

109876

BP1

BCI

OR

G/R

D

C3

BA

TR

D/W

HC

3P

-3

BATTERY CHARGE INDICATOR (OPTION)BCI

TILT ALARMA1

R4

2B

AT

OR

/RD

C2

P-4

P2

4B

AT

WH

C9

P-2

C1

3D

EL

BL

/RD

C4

P-1

BK

/RD

RD

GR

N

C3

7S

CW

BL

/BK

C1

P-1

1

C3

2JS

LW

H/R

DC

1P

-6

REMOVE JUMPER JP1 FOR CE VERSION.

NOTES:

L1 DRIVE ENABLE LED

HORN BUTTONP3

AUXILIARY SWITCH


DRIVE CONTROLLER


DESCRIPTION

PLATFORM ROTATE SWITCH

JIB ROTATE SWITCH (OPTION)

JIB UP/DOWN SWITCH

PRIMARY BOOM UP/DOWN SWITCH

SECONDARY BOOM UP/DOWN SWITCH

EXTEND/RETRACT SWITCH

PLATFORM LEVEL SWITCH

TURNTABLE ROTATE SWITCH

TS8

TS7

TS9

TS13

TS11

TS12

TS10

LABEL

P2

TS1

BP1

DP1

TS16

L1

P2

DP1

TS8TS16

TS13

TS11

TS10

TS12

TS15

TS1

P3

53 41 2

C1

8P

RL

OR

C4

7-1

C1

7P

RR

BL

C4

7-2

C4

4JD

WH

C4

7-3

C4

3JU

BK

C4

7-4

C8

PB

RB

K/W

HC

3P

-8

C7

PB

EB

KC

3P

-7

C2

7A

UX

RD

C1

P-1

C3

1R

EV

WH

/BK

C1

P-5

C3

0F

WD

WH

C1

P-4

C3

6S

CC

BL

C1

P-1

0

C9

HR

NB

K/R

DC

3P

-9

P2

2B

AT

BK

C7

P-1

P2

6B

AT

BK

C9

P-1

NC

NC

NO

1

1

L4

2

2 TURNTABLE TILT ALARM LED (CSA OPTION).

3

3 ADD D40 ONLY IF UNIT HAS L4 AND L48.

PLATFORM OVERLOAD LED (CE OPTION)L48

4

4 PLATFORM OVERLOAD LED (CE OPTION).

REV A


1

2

3

4

5

6

7

8


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

LVI / BCI Option Wiring Diagram(from serial number 8355 to 9346)

C3P

C4P

C1P

C2P

LS18

OPT.

C47 JIB

C7B

C9 F.S.

TS2

TS4TS6

RD

BL

BK

TS7TS9

TS1 L1

OR

/RD

10986 75431 2

DP1

C3

P-1

C1

PB

UR

D

C3

P-1

0C

10

SB

UB

L

OR

/RD

CR19

BP1

21

2

6

4

3

1

5

3

4

7

7

5

8

8

6

BK/RD

RD

GR

LIFT LOCKOUTRELAY

P2

TS8

TS13 TS11 TS10

TS12

TS15

P3

NC

NC

NO

GND BRN


RESET

8 7

L.V.I.

6 5

DISCHARGE

4 3 2 1

4

BCI

53

OR

/BK

OR

WH

OR

/BK

OR

C2

P-4

R4

2B

AT

OR

/RD


LVI / BCI Option Wiring Diagram(from serial number 8355 to 9346)


1

2

3

4

5

6

7

8


Part No. 106373 Z-30/20N • Z-30/20N RJ 6 - 31

LVI / BCI Option Wiring Diagram(after serial number 9346)

C3P

C4P

C1P

C2P

LS18

OPT.

C47 JIB

C7B

C9 F.S.

TS2

TS4TS6

RD

BL

CR

19

LV

IB

K

GN

DB

RN

P2

4B

AT

WH

TS7TS9

TS1 L1

R4

2B

AT

OR

/RD

10986 75431 2

DP1

C3

P-1

C1

PB

UR

D

C3

P-1

0C

10

SB

UB

L

C2

P-4

R4

2B

AT

OR

/RD

CR19

BP1

LVI/BCI

21

2

6

4

3

1

5

3

4

7

7

5

8

8

6

BK/RD

RD

GR

LIFT LOCKOUTRELAY

P2

TS8

TS13 TS11 TS10

TS12

TS15

P3

NC

NC

NO

15

48

GN

DB

RN

CR

19

LV

IB

K

SETUP ENABLE (+) WIRE

WH/RD

ENABLE WHEN IT IS TEMPORARILY CONNECTED TO 24VDC

WH

BK

BRN

P2

4B

AT

WH

1

1


LVI / BCI Option Wiring Diagram(after serial number 9346)

REV C

January 2008 Section 6 • Schematics

Hydraulic Schematic

1

2

3

4

5

6

7

8


Part No. 106373 Z-30/20N • Z-30/20N RJ 6 - 32

L2

2800 psi193 bar

AUXILIARYPUMP0.5 gpm1.89 L/min

100 MESH10 MICRON

HYDRAULIC RESERVOIR

M

PRIMARYPUMP2.1 gpm7.95 L/min

T1

M

COM

0.045 inch1.14 mm

0.090 inch /2.29 mm

0.045 inch1.14 mm

P1 G1 BRAKE

BRAKESM M

S2

0.8 gpm3 L/min

3000 psi207 bar

3:1

3000 psi207 bar

3:1(before serialnumber 6462)

3200 psi221 bar

3:1(after serial

number 6461)

3000 psi207 bar

1.5:1N.O.

N.C.

PS

S1

STEERCYLINDER

MASTER

L1P2

3000 psi207 bar

4.5:1

SLAVE

PLATFORM LEVELING

1600 psi110 bar

1600 psi110 bar

1.55.7(before serialnumber 10808)

gpmL/min

1100 psi75.8 bar

TURNTABLE ROTATEMOTOR

5.9 cu in/rev96.7 cc/rev

(before serialnumber 10808)

TR1 TR2 SC1 SC2 PC1 PC2

0.035 inch0.89 mm

Note:Orifice added after serial number 5396

T2

JIB BOOM

SECONDARY BOOMCYLINDER

3000 psi207 bar

1.5:1

P

0.025 inch0.635 mm

JR1 JR2 J1

3300 psi227.5 bar

3:1

3300 psi227.5 bar

3:1

JIB BOOM ROTATEOPTION

JR1 JR2

PRIMARY BOOMCYLINDER

J2

0.3 gpm1.14 L/min

PR1

T

PR2

PLATFORM ROTATE

PR1 PR2

JIB BOOM MANIFOLD

ROTATE MANIFOLD(PLATFORM)

ROTATE MANIFOLD(JIB BOOM)

1800 psi124 bar

2500 psi172 bar

3:1

2500 psi172 bar

3:1

EXT RET

EXTENSION CYLINDER(MODELS WITHOUT

ROTATING JIB BOOM)

EXTENSION CYLINDER(MODELS WITH

ROTATING JIB BOOM)

0.032 inch0.81 mm

FUNCTION MANIFOLD

AACC

DD

EEBB

AX

W

Y

B

D

E

U V

F

G

K

S

C

H

OQ

R

P I J

L

M

N

T

7.6 cu in/rev124.5 cc/rev(after serial

number 10807)

1.86.8(after serialnumber 10807)

gpmL/min

Section 6 • SchematicsJanuary 2008

Hydraulic Schematic

Dis

trib

ute

d B

y:

Genie North America

Genie Australia Pty Ltd.

Genie China

Genie Malaysia

Genie Japan

Genie Korea

Genie Brasil

Genie Holland

Phone 425.881.1800

Toll Free USA and Canada

800.536.1800

Fax 425.883.3475

Phone +61 7 3375 1660

Fax +61 7 3375 1002

Phone +86 21 53852570

Fax +86 21 53852569

Phone +65 98 480 775

Fax +65 67 533 544

Phone +81 3 3453 6082

Fax +81 3 3453 6083

Phone +82 25 587 267

Fax +82 25 583 910

Phone +55 11 41 665 755

Fax +55 11 41 665 754

Phone +31 183 581 102

Fax +31 183 581 566

Genie Scandinavia

Genie France

Genie Iberica

Genie Germany

Genie U.K.

Genie Mexico City

Phone +46 31 575100

Fax +

Phone +33 (0)2 37 26 09 99

Fax +33 (0)2 37 26 09 98

Phone +34 93 579 5042

Fax +34 93 579 5059

Phone 0800 180 9017

Fax +49 422 149 1820

Phone +44 (0)1476 584333

Fax +44 (0)1476 584334

Phone +52 55 5666 5242

Fax +52 55 5666 3241

46 31 579020

Phone +49 422 149 1818

genie boom 30z 20n

Documents