ServiceManual - Ramirenttuotteet.ramirent.fi/sites/tuotteet.ramirent/files/product... · ServiceManual Refertoinsidecoverforadditionalserialnumberinformation ICPower (fromserialnumber100)

Part No. 110284Rev A1March 2006

Service ManualRefer to inside cover for additional serial number information

IC Power(from serial number 100)

Z-51/30J Part No. 110284

September 2005

ii

Introduction

Important

Read, understand and obey the safety rules andoperating instructions in the Genie Z-51/30JOperator'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]

Serial Number Information

Genie Industries offers the following ServiceManuals for these models:

Title Part No.

Copyright © 2005 by Genie Industries

110284 Rev A September 2005First Edition, First Printing

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

Printed on recycled paper

Printed in U.S.A.

Introduction

Part No. 110284 Z-51/30J

March 2006

Serial Number Legend

INTRODUCTION

iii

Z5130 05 - 12345

Model

Model year

Sequencenumber

PN - 77055

Country of manufacture: USA

This machine complies with:

Genie Industries

18340 NE 76th Street

Redmond, WA 98052

USA

EN 280:2001

Model: Z-51/30

Serial number: Z513005-12345

Electrical schematic number: E0384

Rated work load (including occupants): 500 lb / 227 kg

Maximum allowable inclination of the chassis:

4.5°

Nominal Power: 48 hp / 61 kW

Maximum allowable side force : 90 lb / 400 N

Maximum number of platfrm occupants: 2

Model year: Manufacture date: 04/12/052005

Maximum wind speed : 28 mph/ 12.5 m/s

Maximum platform height : 51 ft 3 in/ 15.6 m

Maximum platform reach : 30 ft 4 in/ 9.2 m

Machine unladen weight: 15,882 lbs / 7,204 kg

05

Gradeability: 45%

Serial numberstamped on chassis

Serial label(located under cover)

Z-51/30J Part No. 110284

September 2005

This page intentionally left blank.

iv

Part No. 110284 Z-51/30J

September 2005

v

Safety Rules

Section 1 • Safety Rules

DangerFailure to obey the instructions and safety rules inthis manual, and the Genie Z-51/30J Operator'sManual will result in death or serious injury.

Many of the hazards identified in the operator'smanual are also safety hazards when maintenanceand repair procedures are 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.

Z-51/30J Part No. 110284

September 2005

SAFETY RULES

vi

Section 1 • Safety Rules

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 machineuse 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.

Used to indicate the presence ofan imminently hazardous situationwhich, if not avoided, will result indeath or serious injury.

Used to indicate the presence of apotentially hazardous situationwhich, if not avoided, could resultin death or serious injury.

With safety alert symbol—used toindicate the presence of apotentially hazardous situationwhich, if not avoided, may result inminor or moderate injury.

Without safety alert symbol—usedto indicate the presence of apotentially hazardous situationwhich, if not avoided, may result inproperty damage.

Used to indicate operation ormaintenance information.

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 flammableand combustible materials like battery

gases and engine fuels. Always have an approvedfire extinguisher 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 componentsand cause 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.

Part No. 110284 Z-51/30J

March 2006

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

B Machine Specifications .......................................................................................... 2 - 1

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

A Hydraulic Specifications ........................................................................................ 2 - 2

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

A Deutz F3L-2011 Engine Specifications .................................................................. 2 - 4

A Machine Torque Specifications.............................................................................. 2 - 5

A Hydraulic Hose and Fitting Torque Specifications ................................................. 2 - 6

A SAE and Metric Fastener Torque Chart ................................................................ 2 - 7

Z-51/30J Part No. 110284

March 2006

TABLE OF CONTENTS

viii

Section 3 Rev Scheduled Maintenance Procedures

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

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

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

A Checklist A Procedures

A-1 Perform Pre-operation Inspection ................................................................ 3 - 7

A-2 Perform Function Tests ............................................................................... 3 - 7

A-3 Perform Engine Maintenance ...................................................................... 3 - 8

A-4 Check the High Pressure Hydraulic Filter Condition Indicator ...................... 3 - 8

A-5 Test the Oscillate Axle ................................................................................. 3 - 9

A-6 Perform 30 Day Service ............................................................................... 3 - 9

A-7 Inspect the Fuel Filter/Water Separator ..................................................... 3 - 10

A-8 Grease the Turntable Rotation Bearing and Rotate Gear .......................... 3 - 11

B Checklist B Procedures

B-1 Inspect the Battery ..................................................................................... 3 - 12

B-2 Inspect the Electrical Wiring ....................................................................... 3 - 12

B-3 Test the Key Switch ................................................................................... 3 - 13

B-4 Check the Exhaust System........................................................................ 3 - 14

B-5 Check the Oil Cooler and Cooling Fins ...................................................... 3 - 14

B-6 Check the Tires and Wheels (including lug nut torque) .............................. 3 - 15

B-7 Confirm the Proper Brake Configuration .................................................... 3 - 16

B-8 Check the Oil Level in the Drive Hubs ....................................................... 3 - 16

B-9 Check and Adjust the Engine RPM ............................................................ 3 - 17

B-10 Test the Ground Control Override .............................................................. 3 - 18

B-11 Check the Directional Valve Linkage ......................................................... 3 - 18

B-12 Test the Platform Self-leveling ................................................................... 3 - 19

Part No. 110284 Z-51/30J

March 2006

TABLE OF CONTENTS

ix

Section 3 Rev Scheduled Maintenance Procedures, continued

B-13 Test the Engine Idle Select ........................................................................ 3 - 19

B-14 Test the Drive Brakes ................................................................................ 3 - 20

B-15 Test the Drive Speed - Stowed Position .................................................... 3 - 20

B-16 Test the Drive Speed - Raised or Extended Position ................................. 3 - 21

B-17 Test the Alarm Package (if equipped) ........................................................ 3 - 22

B-18 Perform Hydraulic Oil Analysis .................................................................. 3 - 23

B-19 Perform Engine Maintenance .................................................................... 3 - 23

B Checklist C Procedures

C-1 Perform Engine Maintenance .................................................................... 3 - 24

C-2 Grease the Platform Overload Mechanism (if equipped) ........................... 3 - 24

C-3 Test the Platform Overload Mechanism (if equipped) ................................ 3 - 25

B Checklist D Procedures

D-1 Check the Boom Wear Pads ..................................................................... 3 - 27

D-2 Check the Free-wheel Configuration .......................................................... 3 - 27

D-3 Replace the Drive Hub Oil ......................................................................... 3 - 29

D-4 Replace the Hydraulic Filters ..................................................................... 3 - 29

D-5 Perform Engine Maintenance .................................................................... 3 - 31

D-6 Calibrate the Platform Overload System (if equipped) ............................... 3 - 31

D-7 Check the Turntable Rotation Bearing Bolts .............................................. 3 - 33

D-8 Inspect for Turntable Bearing Wear ........................................................... 3 - 34

A Checklist E Procedures

E-1 Test or Replace the Hydraulic Oil .............................................................. 3 - 36

E-2 Perform Engine Maintenance .................................................................... 3 - 38

E-3 Perform Engine Maintenance .................................................................... 3 - 38

Z-51/30J Part No. 110284

September 2005

Section 4 Rev Repair Procedures

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

A Platform Controls

1-1 ALC-500 Circuit Board ................................................................................. 4 - 2

1-2 Joysticks ...................................................................................................... 4 - 3

A Platform Components

2-1 Platform Leveling Slave Cylinder ................................................................. 4 - 7

2-2 Platform Rotator ........................................................................................... 4 - 8

A Jib Boom Components

3-1 Jib Boom.................................................................................................... 4 - 10

3-2 Jib Boom Lift Cylinder ................................................................................ 4 - 11

A Primary Boom Components

4-1 Cable Track ............................................................................................... 4 - 13

4-2 Primary Boom ............................................................................................ 4 - 15

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

4-4 Primary Boom Extension Cylinder ............................................................. 4 - 19

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

A Secondary Boom Components

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

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

A Engines

6-1 RPM Adjustment ........................................................................................ 4 - 29

6-2 Flex Plate ................................................................................................... 4 - 29

A Hydraulic Pumps

7-1 Lift/Steer Pump .......................................................................................... 4 - 31

7-2 Drive Pump ................................................................................................ 4 - 32

x

TABLE OF CONTENTS

Part No. 110284 Z-51/30J

March 2006

Section 4 Rev Repair Procedures, continued

A Manifolds

8-1 Function Manifold Components ................................................................. 4 - 34

8-2 Valve Adjustments - Function Manifold ...................................................... 4 - 38

8-3 Jib Boom / Platform Rotate Manifold Components ..................................... 4 - 39

8-4 Turntable Rotation Manifold Components .................................................. 4 - 40

8-5 Directional Valve Manifold Components .................................................... 4 - 41

8-6 Traction Manifold Components .................................................................. 4 - 44

8-7 Valve Adjustments, Traction Manifold ........................................................ 4 - 46

8-8 Valve Coils ................................................................................................. 4 - 46

. A Turntable Rotation Components

9-1 Turntable Rotation Assembly ..................................................................... 4 - 48

A Axle Components

10-1 Oscillate Lock-out Cylinders ...................................................................... 4 - 49

Section 5 Rev Fault Codes

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

A Fault Codes - Control System ............................................................................... 5 - 2

Section 6 Rev Schematics

Introduction ........................................................................................................... 6 - 1

A Electrical Symbols Legend .................................................................................... 6 - 2

A Hydraulic Symbols Legend .................................................................................... 6 - 3

B Electrical Schematic .............................................................................................. 6 - 5

A Ground Control Box Terminal Strip Wiring Diagram .............................................. 6 - 7

A Ground Control Box Switch Panel Wiring Diagram ................................................ 6 - 8

A Platform Control Box Terminal Strip Wiring Diagram ............................................. 6 - 9

A Platform Control Box Switch Panel Wiring Diagram ............................................ 6 - 10

A Hydraulic Schematic ............................................................................................ 6 - 11

xi

TABLE OF CONTENTS

Z-51/30J Part No. 110284

September 2005

xvi


Part No. 110284 Z-51/30J 2 - 1

Section 2 • SpecificationsMarch 2006

REV B Specifications

Machine Specifications

Tires and wheels

Tire size 355/55 D625

Tire ply rating 14

Overall tire diameter 36.9 in93.7 cm

Wheel diameter 24.5 inches62.2 cm

Wheel width 11.75 inches29.8 cm

Wheel lugs 9 @ 5/8 -18

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

Fluid capacities

Fuel tank 17 gallons64.4 liters

Hydraulic tank 24 gallons91 liters

Hydraulic system 30 gallons(including tank) 113.6 liters

Drive hubs - Steer end 17 fl oz0.5 liters

Drive hubs with brake, 57:1, 24 fl ozNon-steer end 0.7 liters

Performance Specifications

Drive speed, maximum

Stowed position 5 mph8 km/h

40 ft/5.5 sec12.2 m/5.5 sec

Raised or extended position 0.6 mph1 km/h

40 ft/45 sec12.2 m/45 sec

Braking distance, maximum

High range on paved surface 3 to 6 ft0.9 to 1.8 m

Gradeability See Operator's Manual

Boom function speeds, maximumfrom platform controls

Jib boom up 48 to 52 seconds

Jib boom down 28 to 32 seconds

Primary boom up 36 to 40 seconds

Primary boom down 36 to 40 seconds

Secondary boom up 24 to 28 seconds

Secondary boom down 24 to 28 seconds

Primary boom extend 20 to 24 seconds

Primary boom retract 20 to 24 seconds

Turntable rotate, 355° 82 to 88 secondsprimary boom retracted

For operational specifications, refer to theOperator's Manual.

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

2 - 2 Z-51/30J Part No. 110284

Section 2 • Specifications September 2005

REV ASPECIFICATIONS

Hydraulic Specifications

Hydraulic Oil Specifications

Hydraulic oil type Chevron Rykon MV equivalentISO viscosity 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 have a minimum viscosity indexof 150. They should provide excellent antiwear,oxidation, corrosion inhibition, seal conditioning, andfoam and aeration suppression properties.

Optional fluids

Biodegradable Petro Canada Premium ECO 46Statoil 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

Use Chevron Aviation A hydraulicoil when in ambient temperaturesconsistently below 0°F / -18°C.

Use Shell Tellus T46 hydraulic oilwhen oil temperatures consistentlyexceed 205°F / 96°C.

Genie specifications requireadditional equipment and specialinstallation instructions for theapproved optional fluids. Consultthe Genie Industries ServiceDepartment before use.

Drive pump

Type: bi-directional, variabledisplacement piston pump

Flow rate @ 2500 rpm 32 gpm121 L/min

Drive pressure, maximum 3500 psi241 bar

Charge pump

Type: gear

Displacement 0.84 cu in13.76 cc

Flow rate @ 2500 rpm 9.1 gpm34.4 L/min

Charge pressure @ 2500 rpm 315 psi21.7 bar

Function pump

Type: gear

Displacement 0.67 cu in11 cc

Flow rate @ 2500 rpm 7.25 gpm27.4 L/min

Auxiliary pump

Type: gear, fixed displacement

Displacement per revolution 0.067 cu in1.1 cc

Auxiliary pump relief pressure 3200 psi220.6 bar

Part No. 110284 Z-51/30J 2 - 3

Section 2 • SpecificationsSeptember 2005

REV A

Function manifold

System relief valve pressure 3200 psi220.6 bar

Secondary boom down 2100 psirelief valve pressure 145 bar

Platform level relief valve pressure 2500 psi172 bar

Steer flow regulator 1.5 gpm5.7 L/min

Boom extend flow regulator 2 gpm7.6 L/min

Jib boom / platform rotate flow regulator 0.4 gpm1.5 L/min

Drive manifold

Hot oil relief pressure 250 psi17.2 bar

Steer end drive motors

Displacement 1.53 cu inper revolution 25 cc

Non-steer end drive motors

Displacement per revolution, variable 0.01 to 1.83 cu in(2 speed motor) 1.61 to 30 cc

Hydraulic filters

High pressure filter Beta 3 200

High pressure filter 100 psibypass pressure 6.89 bar

Medium pressure filter Beta 3 200

Medium pressure filter 50 psibypass pressure 3.4 bar

Hydraulic return filter 10 micron with 25 psi / 1.7 bar bypass

Manifold ComponentSpecifications

Plug torque

SAE No. 2 36 in-lbs / 4 Nm

SAE No. 4 10 ft-lbs / 13 Nm





Valve coil resistance specifications

Proportional directional solenoid valve, 10V DC 6 to 8Ω(schematic items BP, BU and BY)

3 position 4 way directional valve, 10V DC 6 to 8Ω(schematic items BF, BM and CG)

2 position 3 way solenoid valve, 10V DC 6 to 8Ω(schematic items CA, CC, G, AF and AG)

SPECIFICATIONS

2 - 4 Z-51/30J Part No. 110284


REV ASPECIFICATIONS

Oil viscosity requirements

-22°F to 86°F / -30°C to 30°C 5W-30(synthetic)

-4°F to 90°F / -20°C to 32°C 10W-40

Above 23°F / -5°C 20W-50

Engine oil should have minimum properties of APIclassification CC/SG or CD/SG grades.Units ship with 10W-40 CH-4

Oil temperature switch specifications

Torque 8-18 ft-lbs11-24 Nm

Temperature switch point 220° F104° C

Oil pressure switch specifications

Torque 8-18 ft-lbs11-24 Nm

Oil pressure switch point 15 psi1 bar

Fuel injection system

Injection pump make Bosch

Injector opening pressure 3046 psi210 bar

Fuel requirement diesel number 2-D

Alternator output 60A, 14V DC

Starter motor

Normal engine cranking speed 200 to 250 rpm

Current draw, normal load 140-200A

Battery

Type 12V DC, Group 34/78

Quantity 1

Cold cranking ampere 900A

Reserve capacity @ 25A rate 200 minutes

Fan belt deflection 3/8 to 1/2 inch9 to 12 mm

Deutz F3L 2011 Engine

Displacement 142.2 cu in2.33 liters

Number of cylinders 3

Bore and stroke 3.7 x 4.4 inches94 x 112 mm

Horsepower

Gross intermittent @ 2800 rpm 48Continuous @ 2800 rpm 46Horsepower @ 2500 rpm 40

Firing order 1 - 2 - 3

Low idle 1500 rpm

High idle 2500 rpm

Compression ratio 19:1

Compression pressure (approx.)Pressure (psi or bar) of lowest cylinder must beat least 75% of highest cylinder.

Governor centrifugal mechanical

Valve clearance, cold

Intake 0.012 in0.3 mm

Exhaust 0.020 in0.5 mm

Lubrication system

Oil pressure 40 to 60 psi(operating temp. @ 2000 rpm) 2.75 to 4.1 bar

Oil capacity 8.5 quarts(including filter) 8 liters

Part No. 110284 Z-51/30J 2 - 5


REV A

Machine Torque Specifications

Platform rotator

1-8 center bolt, GR 5 480 ft-lbs651 Nm

3/8 -16 bolts, GR 8 44 ft-lbs60 Nm

Turntable rotate assembly

Rotate bearing mounting bolts, lubricated 180 ft-lbs244 Nm

Drive motor/brake mounting bolts, dry 110 ft-lbs149 Nm

Drive motor/brake mounting bolts, lubricated 80 ft-lbs108 Nm

Drive motor and hubs

Drive hub mounting bolts, lubricated 180 ft-lbs244 Nm

Drive motor mounting bolts, lubricated 55 ft-lbs75 Nm

SPECIFICATIONS

2 - 6 Z-51/30J Part No. 110284


REV ASPECIFICATIONS

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.

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 / 25 Nm

-6 30 ft-lbs / 40 Nm

-8 40 ft-lbs / 55 Nm

-10 60 ft-lbs / 80 Nm

-12 85 ft-lbs / 115 Nm

-16 110 ft-lbs / 150 Nm

-20 140 ft-lbs / 190 Nm

-24 180 ft-lbs / 245 Nm

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.

The O-rings used in the ParkerSeal Lok® fittings and hose endsare custom-size O-rings. They arenot standard SAE size O-rings.They are available in the O-ringfield 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.

Part No. 110284 Z-51/30J 2 - 7


REV A SPECIFICATIONS

SIZE THREAD

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

f t -lbs N m f t -lbs N m f t -lbs N m f t -lbs N m f t -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

LUBEDDRYLUBED

SAE FASTENER TORQUE CHART

Grade 5

DRYLUBED

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

Grade 8

LUBED

1/4

LUBED DRY LUBED DRY

1 1/2

9/16

5/8

3/4

7/8

1

1 1/8

1 1/4

5/16

3/8

7/16

1/2

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 m

5 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 f t -lbs N m f t -lbs N m f t -lbs N m f t -lbs N m f t -lbs N m f t -lbs N m f t -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 4.6

DRYLUBED

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 8.8

DRY

10.9 12.98.84.6

2 - 8 Z-51/30J Part No. 110284



Part No. 110284 Z-51/30J 3 - 1

September 2005 Section 3 • Scheduled Maintenance Procedures

Scheduled Maintenance Procedures

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 perform each procedureas presented and scheduled maycause death, serious injury orsubstantial damage.

Immediately tag and remove from service adamaged or malfunctioning machine.

Repair any machine damage or malfunctionbefore operating machine.

Keep records on all inspections for three years.

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

· Machine parked on a firm, level surface

· Boom in stowed position

· Turntable rotated with the boom betweenthe non-steer wheels

· Turntable secured with the turntablerotation lock

· Key switch in the off position with thekey removed

· Wheels chocked

· All external AC power disconnectedfrom the machine

About This Section

This section contains detailed procedures for eachscheduled maintenance inspection.

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

Symbols Legend




With safety alert symbol—used toindicate the presence of apotentially hazardous situationwhich, if not avoided, may causeminor or moderate injury.



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

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

3 - 2 Z-51/30J Part No. 110284

September 2005Section 3 • Scheduled Maintenance Procedures

Maintenance Symbols Legend

The following symbols have beenused in this manual to helpcommunicate the intent of theinstructions. When one or more ofthe symbols appear at thebeginning of a maintenanceprocedure, it conveys the meaningbelow.

Indicates that tools will be required toperform this procedure.

Indicates that new parts will be requiredto perform this procedure.

Indicates that a cold engine will berequired to perform this procedure.

Indicates that a warm engine will berequired to perform this procedure.

Indicates that dealer service is requiredto perform this procedure.

Pre-delivery Preparation Report

The pre-delivery preparation report containschecklists for each type of scheduled inspection.

to use for each inspection. Store completed formsas required.

Maintenance Schedule

There are five types of maintenance inspectionsthat must be performed according to a schedule—daily, quarterly, six months, annual, and two years.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 which group(s)of procedures are required to perform a scheduledinspection.

Inspection Table or 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 years 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. Store completed formsfor three years.

SCHEDULED MAINTENANCE PROCEDURES

Part No. 110284 Z-51/30J 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-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 removed fromservice.

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 listed inthe responsibilities manual.

3 - 4 Z-51/30J Part No. 110284



Part No. 110284 Z-51/30J 3 - 5

March 2006 Section 3 • Scheduled Maintenance Procedures

Checklist A - Rev A Y N R

A-1 Pre-operationinspection

A-2 Functions tests

A-3 Engine maintenance

A-4 Filter condition indicator

A-5 Oscillate axle

Perform after 50 hours:

A-6 30 day service

Perform every 100 hours:

A-7 Fuel filter/separator

A-8 Rotation bearing

Instructions· Make copies of both pages to use

for each inspection.

· Select the appropriate checklist(s)for the 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.

· 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 service

R = repaired

Comments

Model

Serial number

Date

Hour meter

Machine owner


Inspector signature

Inspector title

Inspector company

Checklist B - Rev B Y N R

B-1 Battery

B-2 Electrical wiring

B-3 Key switch

B-4 Exhaust system

B-5 Oil cooler and fins

B-6 Tires and wheels

B-7 Brake configuration

B-8 Drive hub oil level

B-9 Engine RPM

B-10 Ground control override

B-11 Directional valve

B-12 Platform leveling

B-13 Engine idle select

B-14 Drive brakes

B-15 Drive speed -stowed position

B-16 Drive speed -raised position

B-17 Alarm package

B-18 Hydraulic oil analysis


B-19 Engine maintenance

Maintenance Inspection Report

3 - 6 Z-51/30J Part No. 110284

March 2006Section 3 • Scheduled Maintenance Procedures

Checklist C - Rev B Y N R

C-1 Engine maintenance

C-2 Grease platformoverload (if equipped)

C-3 Test platform overload(if equipped)

Checklist D - Rev B Y N R

D-1 Boom wear pads

D-2 Free-wheelconfiguration

D-3 Drive hub oil

D-4 Hydraulic filters

D-5 Engine maintenance

D-6 Calibrate platformoverload system(if equipped)

D-7 Turntable bearing bolts

D-8 Turntable bearing wear

MAINTENANCE INSPECTION REPORT

Checklist E - Rev A Y N R

E-1 Hydraulic oil


E-2 Engine maintenance

Perform every 12,000 hours:

E-3 Engine maintenance

Instructions· Make copies of both pages to use

for each inspection.

· Select the appropriate checklist(s)for the 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.

· 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 service

R = repaired

Comments

Model

Serial number

Date

Hour meter

Machine owner


Inspector signature

Inspector title

Inspector company

Part No. 110284 Z-51/30J 3 - 7


REV A

A-1Perform Pre-operationInspectionCompleting 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 apparently wrongwith a machine before the operator performs thefunction tests. The pre-operation inspection alsoserves to determine if routine maintenanceprocedures are required.

Complete information to perform this procedure isavailable in the Genie Z-51/30J Operator's Manualon your machine.

Checklist A Procedures

A-2Perform Function TestsCompleting 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 Genie Z-51/30J Operator's Manualon your machine.

3 - 8 Z-51/30J Part No. 110284


REV ACHECKLIST A PROCEDURES

A-3Perform Engine Maintenance

Engine specifications require thatthis procedure be performed dailyor every 10 hours, whichevercomes first.

Proper engine maintenance, following the enginemanufacturer's maintenance schedule, is essentialto good engine performance and service life. Failureto perform the maintenance procedures can lead topoor engine performance and component damage.

Required maintenance procedures and additionalengine information are available in theDeutz FL 2011 Operation Manual(Deutz part number 0297-9929).

Deutz FL 2011 Operation ManualGenie part number 84794

To access the engine:

1 Remove the safety pin from the engine pivotplate latch.

The engine pivot plate latch islocated under the engine turntablepivot plate at the counterweightend of the machine.

2 Open the engine pivot plate latch and swing theengine pivot plate out and away from themachine.

A-4Check the High PressureHydraulic Filter ConditionIndicatorMaintaining the high pressure hydraulic filter ingood condition is essential to good systemperformance and safe machine operation. The filtercondition indicator will show when the hydraulic flowis bypassing a clogged filter. If the filter is notfrequently checked and replaced, impurities willremain in the hydraulic system and causecomponent damage.

1 Open the engine side turntable cover.

2 Start the engine from the ground controls.

3 Change the engine idle to high rpm (rabbitsymbol).

4 Visually inspect the filter condition indicator.

Result: The filter condition indicator should beoperating with the plunger in the green area.

Result: If the indicator displays the plunger inthe red area, this indicates that the hydraulicfilter is being bypassed and the filter should bereplaced. See D-4, Replace the HydraulicFilters.

Part No. 110284 Z-51/30J 3 - 9


REV A CHECKLIST A PROCEDURES

A-5Test the Oscillate Axle

Proper axle oscillation is essential to safe machineoperation. If the axle oscillation system is notoperating correctly, the stability of the machine iscompromised and it may tip over.

1 Start the engine from the platform controls.

2 Drive the right steer tire up onto a6 inch / 15 cm block or curb.

Result: The three remaining tires should stay infirm contact with the ground and the chassisshould remain level at all times.

3 Drive the left steer tire up onto a6 inch / 15 cm block or curb.

Result: The three remaining tires should stay infirm contact with the ground and the chassisshould remain level at all times.

4 Drive both steer tires up onto a6 inch / 15 cm block or curb.

Result: The non-steer tires should stay in firmcontact with the ground.

If the chassis does not remainlevel during test, refer to RepairProcedure 8-5, How to Set Up theDirectional Valve Linkage.

A-6Perform 30 Day Service

The 30 day maintenance procedure is a one timesequence of procedures to be performed after thefirst 30 days or 50 hours of usage, whichevercomes first. After this interval, refer to themaintenance checklist for continued scheduledmaintenance.

1 Perform the following maintenance procedures:

• A-8 Grease the Turntable Rotation Bearingand Rotate Gear

• B-6 Check the Lug Nut Torque(including tires and wheels)

• B-8 Check the Oil Level in the Drive Hubs

• C-1 Perform Engine Maintenance

• D-4 Replace the Hydraulic Filters

• D-7 Check the Turnable Rotation BearingBolts

3 - 10 Z-51/30J Part No. 110284


REV A

A-7Inspect the Fuel Filter/ WaterSeparator

Engine specifications require thatthis procedure be performed every100 hours.

Proper maintenance of the fuel filter/water separatoris essential for good engine performance. Failure toperform this procedure can lead to poor engineperformance and component damage.

Explosion and fire hazard. Enginefuels are combustible. Perform thisprocedure in an open, well-ventilated area away from heaters,sparks, flames and lightedtobacco. Always have an approvedfire extinguisher within easy reach.

Perform this procedure with theengine off.

1 Put on protective clothing and eye wear.




4 Locate the fuel filter/water separator next to theoil filter.

5 Loosen the drain plug located at the bottom ofthe filter. Allow the water to drain into a suitablecontainer until fuel starts to come out.Immediately tighten the drain plug.

Do not completely drain the filter.

a fuel filter/water separatorb drain valve

6 Clean up any fuel that may have spilled.

7 Start the engine from the ground controls andcheck the fuel filter/water separator for leaks.

Explosion and fire hazard. If a fuelleak is discovered, keep anyadditional personnel from enteringthe area and do not operate themachine. Repair the leakimmediately.

8 Swing the engine back to its original positionand close the engine pivot plate latch.

9 Install the engine pivot plate safety pin.

CHECKLIST A PROCEDURES

a

b

Part No. 110284 Z-51/30J 3 - 11


REV A

A-8Grease the Turntable RotationBearing and Rotate Gear

Genie specifications require thatthis procedure be performed every100 hours of operation. Performthis procedure more often if dustyconditions exist.

Frequent application of lubrication to the turntablebearing and rotate gear is essential to goodmachine performance and service life. Continueduse of an improperly greased bearing and gear willresult in component damage.

1 Open the ground controls side turntable coverand locate the grease fitting near the groundcontrol box.

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 Apply grease to each tooth of the drive gear,located under the turntable.

Grease Specification

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

CHECKLIST A PROCEDURES

3 - 12 Z-51/30J Part No. 110284


REV B

B-1Inspect the Battery

Proper battery condition is essential to good engineperformance and operational safety. Improper fluidlevels or damaged cables and connections canresult in engine component damage and hazardousconditions.

Electrocution hazard. Contact withhot or live circuits could result indeath or serious injury. Remove allrings, watches and other jewelry.

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

1 Put on protective clothing and eye wear.

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

3 Be sure that the battery retainer and cableconnections are tight.

The battery is a maintenance freebattery and does not require thereplenishing of electrolyte.

Adding terminal protectors and acorrosion preventative sealant willhelp eliminate corrosion on thebattery terminals and cables.

Checklist B Procedures

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.

Electrocution hazard. Contact withhot or live circuits could result indeath or serious injury. Remove allrings, watches and other jewelry.

1 Open the engine side turntable cover.




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

· Engine wiring harness

· Hydraulic manifold wiring

5 Open the ground controls side turntable cover.

Part No. 110284 Z-51/30J 3 - 13


REV B

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

· Ground control box wire harnesses

· Inside of the ground control box

· Hydraulic manifold wiring

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

· All wire harnesses connectors to theground control box

8 Start the engine from the ground controls andraise the secondary boom above the turntablecovers.

9 Remove the center turntable cover retainingfasteners. Remove the center turntable coverfrom the machine.

10 Inspect the turntable area for burnt, chafed andpinched cables.

11 Lower the boom to the stowed position and turnthe engine off.

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

· Cable track on the primary boom

· Cables on the primary, and jib booms

· Jib boom/Platform rotate manifold

· Inside of the platform control box

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

· All wire harnesses connectors to theplatform control box



16 Install the center turntable cover and tighten theretaining fasteners.

B-3Test the Key SwitchProper 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 cause ahazardous 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 ground control, start theengine and then turn the key switch to platformcontrol.

3 Check all machine function from the groundcontrols.

Result: All machine functions should notoperate.

4 Turn the key switch to ground control.

5 Check all machine function from the platformcontrols.

Result: All machine functions should notoperate.

6 Turn the key switch to the off position.

Result: The engine should stop and no functionsshould operate.

CHECKLIST B PROCEDURES

3 - 14 Z-51/30J Part No. 110284


REV B

B-4Check the Exhaust SystemMaintaining the exhaust system is essential togood engine performance and service life. Runningthe engine with a damaged or leaking exhaustsystem can cause component damage and unsafeoperating conditions.

Bodily injury hazard. Do notinspect while the engine is running.Remove the key to secure fromoperation.

Burn hazard. Beware of hot enginecomponents. Contact with hotengine components may result insevere burns.

1 Be sure that all nuts and bolts are tight.

2 Inspect all welds for cracks.

3 Inspect for exhaust leaks; i.e., carbon builduparound seams and joints.

B-5Check the Oil Cooler andCooling Fins

Maintaining the oil cooler in good condition isessential for good engine performance. Operating amachine with a damaged oil cooler may result inengine damage. Also, restricting air flow throughthe oil cooler will affect the performance of thecooling system.

Bodily injury hazard. Do notinspect while the engineis running. Remove the key tosecure from operation.

Burn hazard. Beware of hot enginecomponents. Contact with hotengine components may result insevere burns.

Oil cooler




3 Remove the fasteners from the engine sidecover, then remove the cover.


Part No. 110284 Z-51/30J 3 - 15


REV B

4 Inspect the oil cooler for leaks and physicaldamage.

a oil coolerb cylinder head cooling finsc fan blower fins

5 Clean the oil cooler of debris and foreignmaterial.

Cooling and fan blower fins

6 Inspect the fan blower fins for physical damage.

7 Clean the fan blower fins of debris and foreignmaterial.

8 Inspect the head cooling passages and fins forphysical damage or foreign material, using aflashlight.

9 Clean the cylinder head cooling passages ofdebris and foreign material.

10 Install the engine side cover.



B-6Check the Tires and Wheels(including lug nut torque)

Maintaining the tires and wheels, including properwheel fastener torque, is essential to safe operationand good performance. Tire and/or wheel failurecould result in a machine tip-over. Componentdamage may also result if problems are notdiscovered and repaired in a timely fashion.

The tires are foam-filled and do notneed air added to them.

1 Check all tire treads and sidewalls for cuts,cracks, punctures and unusual wear.

2 Check each wheel for damage, bends andcracked welds.

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


cba

3 - 16 Z-51/30J Part No. 110284


REV B

B-7Confirm the ProperBrake Configuration

Proper brake configuration is essential to safeoperation and good machine performance.Hydrostatic brakes and hydraulically-released,spring-applied individual wheel brakes can appearto operate normally when they are actually not fullyoperational.

1 Check each drive hub disconnect cap to be sureit is in the engaged position.

2 Be sure the free-wheel valve on the drive pumpis closed (clockwise).

a drive pumpb free-wheel valvec lift pumpd screwdriver

The free-wheel valve is located onthe side of the drive pump.

The free-wheel valve shouldalways remain closed.

B-8Check the Oil Levelin the Drive Hubs

Failure to maintain proper drive hub oil levels maycause the machine to perform poorly and continueduse may cause component damage.

1 Drive the machine to rotate the hub until theplugs are located one on top and the other 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.

4 Install the plug(s) into the drive hub.

5 Repeat this procedure for each drive hub.

6 Check the torque of the drive hub mountingbolts. Refer to Section 2, Specifications.


a

b

c

d

brake disengaged position

brake engaged position

a

Part No. 110284 Z-51/30J 3 - 17


REV B

B-9Check and Adjust theEngine RPM

Maintaining the engine rpm at the proper setting forboth low and high idle is essential to good engineperformance and service life. The machine will notoperate properly if the rpm is incorrect andcontinued use may cause component damage.

This procedure will require twopeople.




3 Connect a tachometer to the engine, and thenstart the engine from the ground controls.

Result: Low idle should be 1500 rpm.

Skip to step 5 if the low idle rpm is correct.

4 Loosen the low idle lock nut, then turn the lowidle adjustment screw clockwise to increase therpm or counterclockwise to decrease the rpm.Tighten the low idle lock nut and recheck therpm.

a solenoid bootb high idle adjustment nutc yoke lock nutd yokee low idle adjustment screwf low idle lock nut

5 Move the function enable toggle switch to thehigh idle (rabbit symbol) position at the groundcontrols.

Result: High idle should be 2500 rpm.

If high idle rpm is correct, disregard adjustmentstep 6.

6 Loosen the yoke lock nut, then turn the high idleadjustment nut and solenoid bootcounterclockwise to increase the rpm orclockwise to decrease the rpm. Tighten theyoke lock nut and recheck the rpm.

Be sure the solenoid fully retractswhen activating high idle.




f

e

c dba

3 - 18 Z-51/30J Part No. 110284


REV B

B-10Test the Ground ControlOverrideA properly functioning ground control override isessential to safe machine operation. The groundcontrol override function is intended to allow groundpersonnel to operate the machine from the groundcontrols whether or not 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 platform red Emergency Stop buttonto the off position.


3 At the ground controls, operate each boomfunction through a partial cycle.

Result: All boom functions should operate.

B-11Check the Directional ValveLinkage

Perform this test only on modelsequipped with an oscillating axle.

Proper axle oscillation is essential to safe machineoperation. If the directional valve linkage is notoperating correctly, the stability of the machine iscompromised and it may tip over.

1 Remove the drive chassis cover and the axlecovers from the non-steer end of the drivechassis.

2 Locate the directional valve inside of the non-steer axle and inspect the linkage for thefollowing:

· Lock nut is tight against yoke

· Yoke clevis pins are installed

· Cotter pins are installed through clevis pins

· Linkage is properly attached todirectional valve


Part No. 110284 Z-51/30J 3 - 19


REV B

B-12Test the Platform Self-leveling

Automatic platform self-leveling throughoutthe full cycle of boom raising and lowering isessential for safe machine operation. Theplatform is maintained at level by the platformleveling slave cylinder which operates in a closedloop hydraulic circuit with the master cylinderlocated at the base of the boom.A platform self-leveling failure creates an unsafeworking condition for platform andground personnel.

1 Start the engine from the ground controls andlower the boom into the stowed position.

2 Hold the function enable toggle switch to eitherside and adjust the platform to a level positionusing the platform level toggle switch.

3 Raise and lower the primary boom througha full cycle.

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

B-13Test the Engine Idle SelectA properly operating engine idle select switchis essential to good engine performance and safemachine operation. There are two settings.

Foot switch activated low idle (turtle symbol)allows the operator to control individual boomfunctions. Drive functions will operate at low idle,but at reduced performance.

Foot switch activated high idle (rabbit symbol)should be used for normal machine operation. Thisselection activates high idle only when the footswitch is pressed down.


2 Start the engine from the ground controls thenmove the function enable toggle switch to thehigh idle (rabbit symbol) position and hold in theon position.

Result: The engine should change to high idle.

3 Release the function enable toggle switch.

Result: The engine should return to low idle.

4 Turn the key switch to platform controls.

5 Move the engine idle control switch to footswitch activated high idle (rabbit symbol).

Result: The engine should not change tohigh idle.

6 Press down the foot switch.

Result: The engine should change to high idle.

6 Move the engine idle control switch to footswitch activated low idle (turtle symbol).

Result: The engine should change to low idle.


3 - 20 Z-51/30J Part No. 110284


REV B

B-14Test the Drive Brakes

Proper brake action is essential to safe machineoperation. The drive brake function should operatesmoothly, free of hesitation, jerking and unusualnoise. Hydrostatic brakes and hydraulically-released individual wheel brakes can appear tooperate normally when they are actually not fullyoperational.

Collision hazard. Be sure that themachine is not in free-wheel orpartial free-wheel configuration.Refer to B-7, Confirm the ProperBrake Configuration.

Select a test area that is firm, leveland free of obstructions.

1 Mark a test line on the ground for reference.


3 Move the engine idle control switch tofoot switch activated high idle (rabbit andfoot switch), then lower the boom into thestowed position.

4 Choose a point on the machine; i.e., contactpatch of a tire, as a visual reference for usewhen crossing the test line.

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

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

The brakes must be able to holdthe machine on any slope it is ableto climb.

B-15Test the Drive Speed -Stowed Position

Proper drive function movement is essential to safemachine operation. The drive function shouldrespond quickly and smoothly to operator control.Drive performance should also be free of hesitation,jerking and unusual noise over the entireproportionally controlled speed range.


1 Create start and finish lines by marking two lineson the ground 40 feet / 12.2 m apart.


3 Move the engine idle control switch tofoot switch activated high idle (rabbit and footswitch), then lower the boom into the stowedposition.

4 Choose a point on the machine; i.e., contactpatch of a tire, as a visual reference for usewhen crossing the start and finish lines.

5 Bring the machine to top drive speed beforereaching the start line. Begin timing when yourreference point on the machine crosses thestart line.

6 Continue at full speed and note the time whenthe machine reference point crosses the finishline. Refer to Section 2, Specifications.


Part No. 110284 Z-51/30J 3 - 21


REV B

B-16Test the Drive Speed -Raised or Extended Position

Proper drive function movement is essential to safemachine operation. The drive function shouldrespond quickly and smoothly to operator control.Drive performance should also be free of hesitation,jerking and unusual noise over the entireproportionally controlled speed range.


1 Create start and finish lines by marking two lineson the ground 40 feet / 12.2 m apart.


3 Move the engine idle select switch to foot switchactivated high idle (rabbit and foot switch).Press down the foot switch and raise theprimary boom above horizontal.



6 Continue at full speed and note the time whenthe machine reference point crosses the finishline.

7 Press down the foot switch and lower the boomto the stowed position.

8 Extend the boom 1 foot / 30 cm.



11 Continue at top speed and note the time whenthe machine reference point crosses the finishline. Refer to Section 2, Specifications.


3 - 22 Z-51/30J Part No. 110284


REV B

B-17Test the Alarm Package(if equipped)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 theturntable covers.

The alarms and beacon willoperate with the enginerunning or not running.

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

Result: The flashing beacon should be on andflashing.

2 Move the function enable switch to either sideand activate the primary boom toggle switch inthe down position, hold for a moment and thenrelease it.

Result: The descent alarm should sound whenthe switch is held down.

3 Move the function enable switch to either sideand activate the secondary boom toggle switchin the down position, hold for a moment andthen release it.


4 Move the function enable toggle switch to eitherside and activate the jib boom toggle switch inthe down position, hold for a moment and thenrelease it.


5 Turn the key switch to platform control.

Result: The flashing beacon should be onand flashing.

6 Press down the foot switch. Move the primaryboom control handle to the down position, holdfor a moment and then release it.

Result: The descent alarm should sound whenthe control handle is held down.

7 Press down the foot switch. Move thesecondary boom control handle to the downposition, hold for a moment and then release it.

Result: The descent alarm should sound whenthe control handle is held down.

8 Press down the foot switch. Activate the jibboom toggle switch in the down position, holdfor a moment and then release it.


9 Press down the foot switch. Move the drivecontrol handle off center, hold for a moment andthen release it. Move the drive control handle offcenter in the opposite direction, hold for amoment and then release it.

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


Part No. 110284 Z-51/30J 3 - 23


REV B

B-18Perform Hydraulic Oil Analysis

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

Before replacing the hydraulic oil,the oil may be tested by an oildistributor for specific levels ofcontamination to verify thatchanging the oil is necessary. Ifthe hydraulic oil is not replacedat the two year inspection, testthe oil quarterly. Replace the oilwhen it fails the test.See E-1, Test or Replace theHydraulic Oil.

B-19Perform Engine Maintenance

Deutz engine specifications requirethat this procedure be performedevery 400 hours.









3 - 24 Z-51/30J Part No. 110284


REV B

C-1Perform Engine Maintenance









Checklist C Procedures

C-2Grease the Platform OverloadMechanism (if equipped)

Genie specifications requirethat this procedure be performedevery 500 hours or 6 months,whichever comes first. Performthis procedure more often if dustyconditions 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.

Grease Specification

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

Part No. 110284 Z-51/30J 3 - 25


REV B

C-3Test the Platform OverloadSystem (if equipped)

Genie specifications require thatthis procedure be performed every500 hours or six months.

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

Perform this procedure with themachine on a firm, level surface.

1 Turn the key switch to platform control. Start theengine from the platform controls.

2 Level the platform.

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

4 Using a suitable lifting device, place anappropriate test weight equal to that of themaximum platform capacity in one of thelocations shown.

Result: The platform overload indicator lightshould be off at both the ground and platformcontrols.

5 Carefully move the test weight to eachremaining location.

Result: The platform overload indicator lightshould be off at both the ground and platformcontrols.

6 Add an additional 10 lbs / 4.5 kg of weight tooverload the platform.

Result: The alarm should be sounding.The platform overload indicator light should beflashing at both the ground and platformcontrols.

Result: If the alarm does not sound and theplatform overload indicator light does not comeon with the test weights in any of the platformlocations, the platform overload system needsto be calibrated. See D-6, Calibrate the PlatformOverload System (if equipped).

There may be an approximate 2second delay before the overloadindicator light turns on and thealarm sounds.

CHECKLIST C PROCEDURES

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REV B

7 Carefully move the test weights to eachremaining location in the platform.


Result: If the alarm does not sound and theplatform overload indicator light does not comeon with the test weights in any of the platformlocations, the platform overload system needsto be calibrated. See D-6, Calibrate the PlatformOverload System (if equipped).


8 Test all machine functions from the platformcontrols.

Result: All platform control functions should notoperate.


10 Test all machine functions from the groundcontrols.

Result: All ground control functions should notoperate.

Machine functions should stilloperate with auxiliary power at theground controls.

11 Lift the test weights off the platform floor using asuitable lifting device.

Result: The platform overload indicator light andalarm should turn off at both the ground andplatform controls.

There may be an approximate 2second delay before the overloadindicator light and alarm turn off.


Result: All ground control functions shouldoperate normally.

13 Turn the key switch to platform control.


Result: All platform control functions shouldoperate.

If the platform overload system isnot operating properly, see D-6,Calibrate the Platform OverloadSystem (if equipped).

CHECKLIST C PROCEDURES

Part No. 110284 Z-51/30J 3 - 27


REV BChecklist D Procedures

D-1Check the Boom Wear Pads

Maintaining the boom wear pads in good conditionis essential to safe machine operation. Wear padsare placed on boom tube surfaces to provide a lowfriction, replaceable wear pad between movingparts. Improperly shimmed wear pads or continueduse of extremely worn wear pads may result incomponent damage and unsafe operatingconditions.

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

2 Extend and retract the primary boom through theentire range of motion to check for tight spotsthat may cause binding or scraping of the boom.

Always maintain squarenessbetween the outer and innerboom tubes.

Primary boom wearpad specifications New Minimum

Top, bottom and side wear pads 3/4 inch 5/8 inch(platform end of boom) 19 mm 15.9 mm

Side and bottom wear pads 5/8 inch 1/2 inch(pivot end of boom) 15.9 mm 12.7 mm

Top wear pads 3/4 inch 5/8 inch(pivot end of boom) 19 mm 15.9 mm

D-2Check the Free-wheelConfiguration

Proper use of the free-wheel configuration isessential to safe machine operation. Thefree-wheel configuration is used primarily for towing.A machine configured to free-wheel without operatorknowledge may cause death or serious injury andproperty damage.

Collision hazard. Select a work sitethat is firm and level.

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

Non-steer wheels:

1 Chock the steer wheels to prevent the machinefrom rolling.

2 Center a lifting jack of ample capacity(20,000 lbs / 10,000 kg) under the drive chassisbetween the non-steer tires.

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

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

disengaged position

engaged position

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REV B

5 Manually rotate each non-steer wheel.

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

6 Re-engage the drive hubs by turning overthe hub disconnect caps. Rotate each wheel tocheck for engagement. Lift the machine andremove the jack stands.

Collision hazard. Failure tore-engage the drive hubs couldresult in death or serious injury andproperty damage.

Steer wheels:

7 Chock the non-steer wheels to prevent themachine from rolling.

8 Center a lifting jack of ample capacity(20,000 lbs / 10,000 kg) under the drive chassisbetween the steer tires.

9 Lift the wheels off the ground and then placejack stands under the drive chassis for support.

10 Disengage the drive hubs by turning over thedrive hub disconnect caps on eachsteer wheel hub.

11 Manually rotate each steer wheel.

Result: Each steer wheel should rotate withminimum effort.

12 Re-engage the drive hubs by turning overthe hub disconnect caps. Rotate each wheel tocheck for engagement. Raise the machine andremove the jack stands.

Collision hazard. Failure tore-engage the drive hubs couldresult in death or serious injury andproperty damage.

13 Be sure the free-wheel valve on the drive pumpis closed (clockwise).

a drive pumpb free-wheel valvec lift pumpd screwdriver

The free-wheel valve is located onthe side of the drive pump.

The free-wheel valve shouldalways remain closed.

CHECKLIST D PROCEDURES

disengaged position

engaged position

a b

c

d

Part No. 110284 Z-51/30J 3 - 29


REV B

a

D-3Replace 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 and continueduse may cause component damage.

1 Select the drive hub to be serviced. Then drivethe machine until one of the two plugs is at thelowest point.

2 Remove both plugs and drain the oil.

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 hole.Install the plugs.

5 Repeat steps 1 through 4 for all the other drivehubs.

D-4Replace the Hydraulic Filters

Genie requires that this procedurebe performed yearly or every 1000hours, whichever comes first.Perform this procedure more oftenif dusty conditions exist.

Replacement of the hydraulic filters is essential forgood machine performance and service life. A dirtyor clogged filter may cause the machine to performpoorly and continued use may cause componentdamage. Extremely dirty conditions may requirethat the filters be replaced more often.

Bodily injury hazard. Beware of hotoil. Contact with hot oil may causesevere burns.


Hydraulic return filter

1 Open the ground controls side turntable coverand locate the hydraulic return filter housing ontop of the hydraulic tank.

2 Remove the cap from the filter housing.

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

4 Remove the filter element from the filterhousing.


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REV B

5 Install the new filter element into the filterhousing.

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

7 Rotate the filter element clockwise to lock it inplace.

8 Install the filter housing cap.

9 Use a permanent ink marker to write the dateand number of hours from the hour meter on theoil filter housing.

Medium and high pressure filters

The medium pressure filter is forthe charge pump and the highpressure filter is for all machinefunctions except the drive circuitand oscillating axle circuit.

10 Open the engine side turntable cover and locatethe medium and high pressure filters.

The medium pressure filter ismounted near the pump. The highpressure filter, with filter conditionindicator, is mounted to thebulkhead.

11 Place a suitable container under each filter.

12 Remove the filter housings by using a wrench onthe nut provided on the bottom of the housings.

13 Remove the filter elements from the housings.

14 Inspect the housing seals and replace them ifnecessary.

15 Install the new filter elements into the housingsand tighten them securely.

The medium and high pressurefilters use the same elements.

16 Clean up any oil that may have spilled during theinstallation procedure.

17 Use a permanent ink marker to write the dateand number of hours from the hour meter on theoil filter housings.


19 Inspect the filter housings and relatedcomponents to be sure that there are no leaks.


Part No. 110284 Z-51/30J 3 - 31


REV B

D-5Perform Engine Maintenance









D-6Calibrate the Platform OverloadSystem (if equipped)

Genie specifications require thatthis procedure be performed every1000 hours of operation or yearly.

Yearly calibration of the platform overload systemis essential 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.

Perform this procedure with themachine on a firm, level surface.

1 Level the platform.

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

3 Using a suitable lifting device, place anappropriate test weight equal to that of themaximum platform capacity at the center of theplatform floor.


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REV B

Determine the limit switch trigger point:

4 Gently move the platform up and down by hand,so it bounces approximately 2.5 to 5 cm. Allowthe platform to settle.

Result: The overload indicator light and thealarm is on. Slowly tighten the load springadjustment nut by turning it clockwise just untilthe overload indicator light and alarm turns off.

The platform will need to be movedup and down and allowed to settlein between adjustments.


Result: The overload indicator light andalarm is off. Slowly loosen the load springadjustment nut by turning it counterclockwisejust until the overload indicator light and alarmturn on.


The platform will need to be movedup and down and allowed to settlein between adjustments.


Confirm the setting:

5 Turn the key switch to platform control. Start theengine from the platform controls.

6 Lift the test weight off the platform floor using asuitable lifting device.

7 Place the test weight back onto the center of theplatform floor using a suitable lifting device.

Result: The alarm should be off. The platformoverload indicator light should be off at both theground and platform controls.

There may be an approximate 2second delay before the overloadindicator light and alarm turn off.

8 Add an additional 10 lb / 4.5 kg test weight tothe original test weight to overload the platform.




Result: All platform control functions should notoperate.



Result: All ground control functions should notoperate.

If the platform overload system isnot operating properly, repeatsteps 1 through 4.

Part No. 110284 Z-51/30J 3 - 33


REV B

D-7Check 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 primary boom and place a safetychock on the lift cylinder rods. Carefully lowerthe boom onto the lift cylinder safety chock.

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

The lift cylinder safety chock isavailable through the GenieService Parts Department.

2 Turn the engine off.






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

Bolt torque sequence


8 Raise the primary boom and remove the safetychock.

9 Lower the boom to the stowed position.

10 Remove drive chassis covers from both thesteer end and the non-steer end of the machine.

11 Remove the lower chassis cover mountingfasteners from inside of the drive chassis (ifequipped).

12 Remove the lower chassis cover to access thelower turntable bearing bolts under the drivechassis.

13 Check to ensure that each lower bearingmounting bolt under the drive chassis is torquedin sequence to specification. Refer to Section 2,Specifications.

Bolt torque sequence

15

1013618

311

8

16

2

914 5 17

412

7

1

Counterweight

115

7

12

4

5

14

9216

8

3

11

6

1310

Counterweight

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REV B

a

b

c

d


D-8Inspect for Turntable BearingWear

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.

Perform this procedure with themachine on a firm, level surfaceand the boom in the stowedposition.

1 Grease the turntable bearing. See A-8, Greasethe Turntable Bearing and Rotate Gear.

2 Torque the turntable bearing bolts tospecification. See D-7, Check the TurntableRotation Bearing Bolts.

3 Start the machine from the ground controls andraise the primary and secondary booms to fullheight. Do not extend the primary boom.

4 Place a dial indicator between the drive chassisand the turntable at a point that is directlyunder, or inline with, the boom and no more than1 inch / 2.5 cm from the bearing.

To obtain an accuratemeasurement, place the dialindicator no more than 1 inch /2.5 cm from the turntable rotationbearing.

a turntableb dial indicatorc drive chassisd turntable rotation bearing

5 At the dial indicator, adjust it to "zero" theindicator.

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 "zero" position.

Part No. 110284 Z-51/30J 3 - 35


REV B

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.


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REV A

1 Locate the two hydraulic tank valves at thehydraulic tank through the access holeunderneath the turntable. Close the valves.

Component damage hazard. Theengine must not be started with thehydraulic tank shut-off valves inthe closed position or componentdamage will occur. If the tankvalves are closed, remove the keyfrom the key switch and tag themachine to inform personnel of thecondition.

3 Remove the drain plug from the hydraulic tankand completely drain the tank into a container ofsuitable capacity. Refer to Section 2,Specifications.

4 Tag, disconnect and plug the two suction hosesand supply hose for the auxiliary pump from thehydraulic tank. Cap the fittings on the tank.

The hoses can be accessedthrough the access hole under theturntable.

5 Disconnect and plug the return filter hydraulichose at the return filter. Cap the fitting on thefilter housing.

E-1Test or Replace the HydraulicOil

Replacement or testing of the hydraulic oil isessential for good machine performance andservice life. Dirty oil and a clogged suction straineror hydraulic filters may cause the machine toperform poorly and continued use may causecomponent damage. Extremely dirty conditionsmay require oil changes to be performed moreoften.

Before replacing the hydraulic oil,the oil may be tested by an oildistributor for specific levels ofcontamination to verify thatchanging the oil is necessary. Ifthe hydraulic oil is not replacedat the two year inspection, testthe oil quarterly. Replace the oilwhen it fails the test.

Perform this procedure with theboom in the stowed position.

Checklist E Procedures

open closed

Part No. 110284 Z-51/30J 3 - 37


REV A

6 Remove the ground controls side turntablecover.

7 Support the hydraulic tank with an appropriatelifting device.

8 Remove the hydraulic tank mounting fasteners.

9 Remove the hydraulic tank from the machine.

Crushing hazard. The hydraulictank could become unbalancedand fall if not properly supportedwhen removed from the machine.

10 Remove the hydraulic return filter housingmounting fasteners. Remove the hydraulicreturn filter housing from the hydraulic tank.

11 Remove the suction strainers from the tank andclean them using a mild solvent.

12 Rinse out the inside of the tank using a mildsolvent.

13 Install the suction strainers into the hydraulictank

14 Install the drain plug using a thread sealant onthe threads.

15 Install the hydraulic return filter housing onto thehydraulic tank.

16 Install the hydraulic tank onto the machine.

17 Install the two suction hoses to the suctionstrainers.

18 Install the supply hose for the auxiliary powerunit and the return filter hose.

19 Open the two hydraulic tank valves at thehydraulic tank.

20 Fill the tank with the proper hydraulic oil for yourmachine until the level is within the top2 inches / 5 cm of the sight gauge. Do notoverfill. Refer to Section 2, Specifications.

21 Clean up any oil that may have spilled.

22 Prime the pump. Refer to Repair Procedure 7-2,How to Prime the Pump.

CHECKLIST E PROCEDURES

3 - 38 Z-51/30J Part No. 110284


REV A

E-2Perform Engine Maintenance









E-3Perform Engine Maintenance

Deutz engine specifications requirethat this procedure be performedevery 12,000 hours.








CHECKLIST E PROCEDURES

Part No. 110284 Z-51/30J 4 - 1

September 2005 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 Genie Z-51/30JOperator’s Manual on your machine.

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:



· Turntable rotated with the boom between the non-steer wheels

· Turntable secured with the turntable rotation lock

· Key switch in the off position with the key removed

· 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. To re-assemble,perform the disassembly steps in reverse order.

Symbols Legend




With safety alert symbol—used toindicate the presence of apotentially hazardous situationwhich, if not avoided, may causeminor or moderate injury.



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-51/30J Part No. 110284

September 2005Section 4 • Repair Procedures

REV A

The platform control box contains one printedcircuit board. The ALC-500 circuit board inside theplatform control box controls all proportionalmachine functions from the platform. The joystickcontrollers at the platform controls utilize HallEffect technology and require no adjustment. Theoperating parameters of the joysticks are stored inmemory at the ECM circuit board at the platformcontrols. If a joystick error occurs or if a joystick isreplaced, it will need to be calibrated before thatparticular machine function will operate. See 1-2,How to Calibrate a Joystick.

Each joystick controller should operate smoothlyand provide proportional speed control over itsentire range of motion.

a ALC-500 circuit boardb drive/steer joystick controllerc secondary boom up/down

joystick controllerd primary boom up/down and

turntable rotate left/rightjoystick controller

1-1ALC-500 Circuit Board

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

When the ALC-500 circuit board isreplaced, the joystick controllerswill need to be calibrated. See 1-2,How to Calibrate a Joystick.

How to Remove the ALC-500Circuit Board1 Push in the red Emergency Stop button to the off

position at both the ground and platform controls.

2 Remove the platform control box lid retainingfasteners. Open the control box lid.

3 Locate the ALC-500 circuit board mounted to theinside of the platform control box.

Electrocution hazard. Contact withelectrically charged circuits couldresult in death or serious injury.Remove all rings, watches andother jewelry.

Platform Controls

bcd

a

Part No. 110284 Z-51/30J 4 - 3


REV A

1-2Joysticks

How to Calibrate a JoystickThe joysticks on this machine utilize digital HallEffect technology for proportional control. If ajoystick is disconnected or replaced, it must becalibrated before that particular machine functionwill operate.

The joystick must be calibratedbefore the threshold, max-out orramp rate can be set.



2 Turn the key switch to platform control. Do notstart the engine.

3 Select a joystick to calibrate.

4 Move the joystick full stroke in either directionand hold for 5 seconds.

5 Return the joystick to the neutral position, pausefor a moment, then move the joystick full strokein the opposite direction. Hold for 5 seconds andreturn the joystick to the neutral position.

Result: The alarm should sound indicatingsuccessful joystick calibration.

6 Repeat this procedure for each joystickcontrolled machine function including the thumbrocker steer switch.

No machine fuction should operatewhile performing the joystickcalibration procedure.

4 Attach a grounded wrist strap to the groundscrew inside the platform control box.

Component damage hazard.Electrostatic discharge (ESD) candamage printed circuit boardcomponents. Maintain firm contactwith a metal part of the machinethat is grounded at all times whenhandling printed circuit boards ORuse a grounded wrist strap.

5 Carefully disconnect the wire connectors fromthe circuit board.

6 Remove the ALC-500 circuit board mountingfasteners.

7 Carefully remove the ALC-500 circuit board fromthe platform control box.

PLATFORM CONTROLS

4 - 4 Z-51/30J Part No. 110284


REV APLATFORM CONTROLS

How to Adjust the JoystickMax-out SettingThe max-out setting of a joystick controls themaximum speed of a joystick-controlled machinefunction. Whenever a hydraulic cylinder, drivemotor or hydraulic pump is replaced, the max-outsetting should be adjusted to maintain optimumperformance. The max-out settings on the joystickcan be changed to compensate for hydraulic pumpwear to maintain peak performance from themachine.




3 Push in the platform controls red EmergencyStop button to the off position.

4 Do not press down the foot switch.

5 Move and hold the drive enable toggle switch inthe right position and pull out the redEmergency Stop button to the on position.

6 When the alarm sounds, release the driveenable toggle switch.

7 Momentarily activate the drive enable toggleswitch in the right direction 4 times.

Result: There should be a pause and the alarmshould sound 4 times indicating that themachine is in max-out calibration mode.

8 Start the engine from the platform controls andpress down the foot switch.

9 Start a timer and activate the machine functionthat needs to be adjusted. Record the time ittakes for that function to complete a full cycle(ie; boom up).

10 Compare the machine function time withspecifications and determine whether thefunction time needs to increase or decrease.

Refer to Section 2, Specificationsfor function speeds.

11 While the joystick is activated, adjust the max-out setting to achieve the proper function cycletime. Momentarily move the drive enable toggleswitch in the right direction to increase the timeor momentarily move the drive enable toggleswitch in the left direction to decrease the time.

Each time the drive enable toggleswitch is momentarily moved, thetime will change in 2% increments.

12 Repeat steps 9 through 11 for each joystickcontrolled machine function.

13 Return the joystick to the neutral position andwait for approximately 10 seconds.

Result: The alarm should sound indicating thatthe settings have been saved in memory.

Do not operate any machinefunction during the 10 secondwaiting time.

Part No. 110284 Z-51/30J 4 - 5


REV A PLATFORM CONTROLS

How to Adjust the JoystickRamp Rate SettingThe ramp rate setting of a joystick controls the timeat which it takes for the joystick to reach maximumoutput, when moved out of the neutral position. Theramp rate settings of a joystick can be changed tocompensate for hydraulic pump wear to maintainpeak performance from the machine.









Result: There should be a pause and the alarmshould sound 6 times indicating that themachine is in ramp rate calibration mode.


9 Start a timer and simultaneously move thejoystick in either direction full stroke. Note howlong it takes the function to reach maximumspeed. This is the ramp rate.

10 Compare the function ramp rate time with thetable below and determine whether the ramprate time needs to increase or decrease.

11 While the joystick is activated, set the ramprate. Momentarily move the drive enable toggleswitch in the right direction to increase the timeor momentarily move the drive enable toggleswitch in the left direction to decrease the time.

Each time the drive enable toggleswitch is momentarily moved, thetime will change in 10%increments.

12 Repeat steps 9 through 11 for each joystickcontrolled machine function.




Ramp rate (factory settings)

Primary boom up/downaccelerate 4 secondsdecelerate 0.5 second

Secondary boom up/downaccelerate 2 secondsdecelerate 0.5 second

Turntable rotateaccelerate 2 secondsdecelerate 0.5 second

Driveaccelerate 3 secondsdecelerate to neutral 0.5 seconddecelerate, change of direction 0.5 seconddecelerate, coasting 0.75 seconddecelerate, braking 1 seconddecelerate, shift from low to high speed 1 seconddecelerate, shift from high to low speed 2 seconds

4 - 6 Z-51/30J Part No. 110284


REV APLATFORM CONTROLS

How to Adjust the JoystickThreshold SettingThe threshold setting of a joystick is the minimumoutput at which a function proportional valve canopen and allow the function to operate.









Result: There should be a pause and the alarmshould sound 8 times indicating that themachine is in threshold calibration mode.


9 Select a boom function joystick to set thethreshold.

10 Slowly move the joystick off center in eitherdirection just until the function begins to move.

11 Slowly move the joystick back to the neutralposition. Just before the function stops moving,move the drive enable toggle switch to eitherside to set the threshold.

Result: The alarm should sound indicating asuccessful calibration.

12 Repeat steps 9 through 11 for each boomjoystick controlled machine function (boom up/down, boom extend/retract and turntable rotate).




Part No. 110284 Z-51/30J 4 - 7


REV APlatform Components

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 boom motion. It operates in aclosed-circuit hydraulic loop with the mastercylinder. The slave cylinder is equipped withcounterbalance valves to prevent movement inthe event of a hydraulic line failure.

How to Remove the PlatformLeveling Slave Cylinder

Before cylinder removal isconsidered, bleed the slavecylinder to be sure there is noair in the closed loop.

When removing a hose assemblyor fitting, the O-ring on the fittingand/or hose end must be replacedand then torqued to specificationduring installation.Refer to Section 2, Hydraulic Hoseand Fitting Torque Specifications.

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

2 Raise the primary boom slightly and placeblocks under the platform for support.

3 Lower the primary boom until the platform isresting on the blocks just enough to support theplatform.

Do not rest the entire weight of theboom on the blocks.

4 Tag, disconnect and plug the hydraulic hosesfrom the slave cylinder at the unions andconnect them together using a connector.Connect the hoses from the cylinder togetherusing a connector.

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.

5 Remove the pin retaining fastener from the slavecylinder rod-end pivot pin. Do not remove thepin.

6 Remove the external snap rings from the slavecylinder barrel-end pivot pin. Do not remove thepin.

7 Place a block under the slave cylinder forsupport. Protect the cylinder rod from damage.

8 Use a soft metal drift to drive the rod-end pivotpin out.

Crushing hazard. The platformcould fall when the slave cylinderrod-end pivot pin is removed if notproperly supported.

Component damage hazard. Theslave cylinder rod may becomedamaged if it is allowed to fall ifnot properly supported by the liftingdevice.

9 Use a soft metal drift and drive the barrel-endpin out.

10 Carefully pull the cylinder out of the primaryboom.

4 - 8 Z-51/30J Part No. 110284


REV APLATFORM COMPONENTS

How to Bleed the Slave CylinderDo not start the engine. Useauxiliary power for this procedure.

1 Raise the primary 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.

2-2Platform Rotator

How to Bleed the PlatformRotator

This procedure will require twopeople. Do not start the engine.Use auxiliary power for thisprocedure.

1 Move the function enable toggle switch to eitherside and activate the platform rotate toggleswitch to the right then the left through twoplatform rotation cycles, then hold the switch tothe right position until the platform is fullyrotated to the right.

2 Place a suitable container underneath theplatform rotator.

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


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 bleedscrew. Close the bleed screw.

Crushing hazard. Keep clear of theplatform during rotation.

Part No. 110284 Z-51/30J 4 - 9


REV A PLATFORM COMPONENTS

5 Open the bottom bleed screw on the rotator, butdo not remove it.


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 bleedscrew. Close the bleed screw.

Crushing hazard. Keep clear of theplatform during rotation.

7 Clean up any hydraulic oil that may have spilled.

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

4 - 10 Z-51/30J Part No. 110284


REV A

3-1Jib Boom

How to Remove the Jib BoomPerform this procedure with theboom in the stowed position.


1 Remove the platform.

2 Disconnect the electrical connector from the jibboom/platform rotate select valve manifoldmounted to the platform support.

3 Tag, disconnect and plug all of the hydraulichoses from the jib boom/platform rotate selectvalve manifold. Cap the fittings on the manifoldand pull the hoses out through the platformrotator.


4 Remove the platform mounting weldment.

5 Attach a lifting strap from an overhead crane tothe platform rotator for support.

6 Remove the pin retaining fastener from the jibboom lift cylinder rod-end pivot pin. Do notremove the pin.

7 Remove the pin retaining fasteners from bothplatform rotator pivot pins. Do not remove thepins.

8 Use a soft metal drift to remove the leveling armpivot pin and let the leveling arms hang down.

9 Use a soft metal drift to remove the platformrotator pivot pin and remove the platform rotatorfrom the machine.

10 Slide both of the jib boom leveling arms off ofthe jib boom cylinder rod-end pivot pin.

11 Remove the hose and cable cover from the sideof the jib boom. Remove the hose and cableseparators.

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

13 Support the barrel end of the jib boom liftcylinder with a suitable lifting device.

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


Jib Boom Components

Part No. 110284 Z-51/30J 4 - 11


REV A JIB BOOM COMPONENTS

15 Remove the pin retaining fastener from the jibboom lift cylinder barrel-end pivot pin.

16 Use a soft metal drift to remove the pin and letthe cylinder hang down.

Crushing hazard. The jib boomcould fall when when the barrel-endpivot pin is removed if not properlysupported by the overhead crane.

17 Remove the pin retaining fastener from the jibboom pivot pin. Use a soft metal drift to removethe pin, then remove the jib boom from thebellcrank.

Crushing hazard. The jib boomcould become unbalanced and fallwhen removed from the machine ifnot properly attached to theoverhead crane.

18 Attach a lifting strap from an overhead crane tothe lug on the rod end of the jib boom liftcylinder.

19 Use a soft metal drift to remove the jib boom liftcylinder rod-end pivot pin, then remove the jibboom lift cylinder from the bellcrank.

Crushing hazard. The jib boom liftcylinder could become unbalancedand fall when removed from themachine if not properly attached tothe overhead crane.

3-2Jib Boom Lift Cylinder

How to Remove the Jib BoomLift Cylinder



1 Raise the jib boom slightly and place blocksunder the platform mounting weldment. Thenlower the jib boom until the platform is restingon the blocks just enough to support theplatform.

Do not rest the entire weight of theboom on the blocks.

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


4 - 12 Z-51/30J Part No. 110284


REV A

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 jib boom liftcylinder rod-end pivot pin half way out. Thenlower one of the leveling arms to the ground.Tap the pin the other direction and lower theopposite leveling arm. Do not remove the pin.

5 Support the jib boom lift cylinder with a suitablelifting device.

6 Remove the pin retaining fastener from the jibboom lift cylinder barrel-end pivot pin. Use asoft metal drift to remove the barrel-end pin andlet the cylinder hang down.

Crushing hazard. The jib boomcould fall when the barrel-end pivotpin is removed if not properlysupported by the overhead crane.

7 Attach a lifting strap from an overhead crane tothe lug on the rod end of the jib boom liftcylinder.

8 Use a soft metal drift to remove the jib boom liftcylinder rod-end pin. Remove the jib boom liftcylinder from the machine.

Crushing hazard. The jib boom liftcylinder could become unbalancedand fall when removed from themachine if not properly attached tothe overhead crane.

JIB BOOM COMPONENTS

Part No. 110284 Z-51/30J 4 - 13


REV A

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 Remove the Cable TrackWhen removing a hose assemblyor fitting, the O-ring on the fittingand/or hose end must be replacedand then torqued to specificationduring installation.Refer to Section 2, Hydraulic Hoseand Fitting Torque Specifications.

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

2 Disconnect the cables from the platform controlbox.

3 Remove the hose and cable cover from the sideof the jib boom. Remove the hose and cableseparators.

4 Remove the hose clamp on the primary boombellcrank.

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

Primary Boom Components

6 Tag, disconnect and plug the hydraulic hosesfrom the "V1" and "V2" ports on thecounterbalance valve manifold located on theplatform rotator. Cap the fittings on themanifold.


7 Tag and disconnect the hydraulic hoses fromthe platform leveling slave cylinder at the unionand connect them together using a connector.Connect the hoses from the cylinder togetherusing a connector.


8 Tag, disconnect and plug the hydraulic hosesfrom the jib boom/platform rotate manifold. Capthe fittings on the manifold.


4 - 14 Z-51/30J Part No. 110284


REV APRIMARY BOOM COMPONENTS

9 Tag, disconnect and plug the platform rotatorhydraulic hoses at the union located above theprimary boom lift cylinder. Cap the fittings onthe unions.


10 Tag, disconnect and plug the hydraulic hosesfrom the platform leveling master cylinder. Capthe fittings on the cylinder.


11 Raise the boom to a horizontal position.

12 Place blocks between the upper and lower cabletracks and secure the upper and lower trackstogether.

Crushing hazard. If the upper andlower cable tracks are not properlysecured together, the cable trackcould become unbalanced and fallwhen removed from the machine.

13 Attach a lifting strap from an overhead 5 ton /5,000 kg capacity crane to the platform end ofthe primary boom for support. Do not lift it.

14 Remove all hose and cable clamps from theunderside of the primary boom.

15 Support the rod end of the primary boom liftcylinder with a suitable lifting device.

16 Remove the pin retaining fasteners from theprimary boom lift cylinder rod-end pivot pin. Donot remove the pin.

17 Raise the primary boom slightly with theoverhead crane to relieve the pressure on theprimary boom lift cylinder rod-end pivot pin.

18 Use a soft metal drift to remove the primaryboom lift cylinder rod-end pivot pin.

Crushing hazard. The primaryboom lift cylinder could becomeunbalanced and fall if not properlysupported by the lifting device.

19 Lower the rod end of the primary boom liftcylinder approximately 12 inches / 30 cm.

20 Pull all of the hoses and cables out and awayfrom the mounting ears for the rod end of theprimary boom lift cylinder.

21 Raise the rod end of the primary boom liftcylinder back into position and install the rod-end pivot pin. Install the pin retaining fasteners.

22 Attach a strap from an overhead crane to thecable track.

23 Remove the mounting fasteners from the uppercable track at the platform end of the extensionboom.

Part No. 110284 Z-51/30J 4 - 15


REV A

24 Remove the cable track mounting fasteners thatattach the lower cable track to the primaryboom.

25 Remove the cable track from the machine andplace it on a structure capable of supporting it.

Crushing hazard. The cable trackcould become unbalanced and fallif not properly attached to theoverhead crane.

Component damage hazard.Cables and hoses can be damagedif they are kinked or pinched.

How to Repair the Primary BoomCable Track

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

A 7 link repair section of cabletrack is available throughthe Genie Industries Service PartsDepartment.

a link separation pointb lower clip

1 Use a slotted screwdriver to pry down on thelower clip.

2 To remove a single link, open the lower clipand then use a screw driver to pry the link to theside.

3 Repeat steps 1 and 2 for each link.

4-2Primary Boom

How to Remove the PrimaryBoom

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.




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

3 Remove the cable track. See 4-1, How toRemove the Cable Track.


5 Remove the hose and cable cover from theupper pivot.

PRIMARY BOOM COMPONENTS

a

b

4 - 16 Z-51/30J Part No. 110284


REV A

6 Remove the pin retaining fastener from themaster cylinder barrel-end pivot pin. Use a softmetal drift to remove the pin. Then lower thecylinder and let it hang down.

Component damage hazard.When lowering the master cylinderdown, be sure not to damage themaster cylinder hoses or fittings.

7 Locate the primary boom drive speed limitswitch inside of the upper pivot.

8 Remove the primary boom drive speed limitswitch mounting fasteners. Do not disconnectthe wiring.

9 Locate the primary extension boom drive speedlimit switch inside of the extension boom.

10 Remove the primary extension boom drivespeed limit switch mounting fasteners. Do notdisconnect the wiring.

11 Pull the limit switch and the wiring out of theextension tube and move it out of the way.

12 Tag, disconnect and plug the primary boomextension cylinder hydraulic hoses. Cap thefittings on the cylinder.


13 Remove the hose clamp at the pivot end of theboom.

14 Attach a 5 ton / 5,000 kg overhead crane to thecenter point of the primary boom.

15 Attach a similar lifting device to the primaryboom lift cylinder.

16 Place support blocks under the primary boom liftcylinder.

17 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 boom liftcylinder and primary boom will fallif not properly supported.

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

19 Remove the pin retaining fasteners from theprimary boom pivot pin.

20 Remove the primary boom pivot pin with a softmetal drift, then carefully remove the primaryboom from the machine and place it on astructure capable of supporting it.

Crushing hazard. The primaryboom could become unbalancedand fall when removed from themachine if not properly attached tothe overhead crane.


Part No. 110284 Z-51/30J 4 - 17


REV A PRIMARY BOOM COMPONENTS

How to Disassemble the PrimaryBoom

Complete disassembly of theboom is only necessaryif the outer or inner boom tubemust be replaced. The extensioncylinder can be removed withoutcompletely disassembling theboom. See 4-4, How to Removethe Primary Boom ExtensionCylinder.

1 Remove the primary boom. See How to Removethe Primary Boom.

2 Place blocks under the barrel end of the primaryboom extension cylinder for support.

3 Remove the pin retaining fastener from theextension cylinder barrel-end pivot pin at thepivot end of the primary boom. Use a soft metaldrift to remove the pin.

4 Remove and label the location of the wear padsfrom the platform end of the primary boom.

Pay careful attention to thelocation and amount of shims usedwith each wear pad.

5 Support and slide the extension tube andextension cylinder assembly out of the boomtube.

Crushing hazard. The primaryboom extension tube couldbecome unbalanced and fall whenremoved from the primary boomtube if not properly supported.

During removal, the overheadcrane strap will need to becarefully adjusted for properbalancing.

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

7 Support and slide the extension cylinder out ofthe base end of the extension tube. Place theextension cylinder on blocks for support.

Crushing hazard. The extensioncylinder could become unbalancedand fall when removed fromprimary boom extension tube if notproperly supported.

During removal, the overheadcrane strap will need to becarefully adjusted for properbalancing.

4 - 18 Z-51/30J Part No. 110284


REV APRIMARY BOOM COMPONENTS

4-3Primary Boom Lift Cylinder

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

How to Remove the PrimaryBoom Lift Cylinder




2 Raise the secondary boom until the primaryboom lift cylinder barrel-end pivot pin is abovethe turntable covers.

3 Attach a 5 ton / 5000 kg overhead crane to theprimary boom for support.

4 Raise the primary boom with the overhead craneslightly to take the pressure off the primaryboom lift cylinder pivot pins.

5 Support the rod end and the barrel end of theprimary boom lift cylinder with a secondoverhead crane or similar lifting device.

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


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 will fall if not properlysupported when the primary boomrod-end pivot pin is removed.

8 Place a support block across both turntablecovers under the primary boom lift cylinder.

9 Lower the rod end of the lift cylinder onto theblock. Protect the cylinder rod from damage.

Crushing hazard. The primaryboom lift cylinder could fall if notproperly supported.

10 Remove the primary boom lift cylinder barrel-endpivot pin retaining fasteners. Do not remove thepin.

11 Use a slide hammer to remove the barrel-endpivot pin. Carefully remove the primary boom liftcylinder from the machine.

Crushing hazard. The lift cylindercould become unbalanced and fallif not properly supported andsecured to the lifting device.

Part No. 110284 Z-51/30J 4 - 19


REV A PRIMARY BOOM COMPONENTS

4-4Primary Boom ExtensionCylinder

The primary boom extension cylinder extends andretracts the primary boom extension tube.Theprimary boom extension cylinder is equipped withcounterbalance valves to prevent movement in theevent of a hydraulic line failure.

How to Remove the PrimaryBoom Extension Cylinder




2 Extend the primary boom until the primary boomextension cylinder rod-end pivot pin isaccessible in the primary boom extension tube.

3 Remove the hose and cable guard from theupper pivot.

4 Tag, disconnect and plug the primary boomextension cylinder hydraulic hoses. Cap thefittings on the cylinder.


5 At the platform end of the boom, remove theexternal snap rings from the extension cylinderrod-end pivot pin. Use a soft metal drift toremove the pin.

6 Remove the barrel-end pivot pin retainingfasteners.

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

8 Support and slide the extension cylinder out ofthe upper pivot.

Crushing hazard. The extensioncylinder could fall when removedfrom the extension boom if notproperly supported.

Component damage hazard. Becareful not to damage thecounterbalance valves on theprimary boom extension cylinderwhen removing the cylinder fromthe primary boom.

Component damage hazard. Hosesand cables can be damaged if theprimary boom extension cylinder isdragged across them.

Note the length of the cylinder afterremoval. The cylinder must be atthe same length for installation.

4 - 20 Z-51/30J Part No. 110284


REV A

4-5Platform LevelingMaster Cylinder

The master cylinder acts as a pump for the slavecylinder. It’s part of the closed circuit hydraulic loopthat keeps the platform level through the entirerange of boom motion. The master cylinder islocated at the base of the primary boom.

How to Remove the PlatformLeveling Master Cylinder


1 Raise the secondary boom until both the rod-endand barrel-end pivot pins on the master cylinderare accessible.

2 Tag, disconnect and plug the master cylinderhydraulic hoses. Cap the fittings on the cylinder.



3 Attach overhead crane or similar lifting device tothe master cylinder.

4 Remove the pin retaining fasteners from themaster cylinder barrel-end pivot pin.

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

6 Remove the pin retaining fastener from the rod-end pivot pin.

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

8 Remove the master cylinder from the machine.

Crushing hazard. The mastercylinder could become unbalancedand fall if not properly attached tothe overhead crane.

Part No. 110284 Z-51/30J 4 - 21



4 - 22 Z-51/30J Part No. 110284


REV ASecondary Boom Components

j

a b c

d

e

i

g

f

h

Secondary Boom components

a upper secondary boom(number 1 arm)

b upper tension link(number 2 arm)

c lower tension link(number 3 arm)

d mid-pivote compression linkf secondary boom lift cylinder (2)g lower secondary boom

(number 4 arm)h turntable pivoti boom restj upper pivot

Part No. 110284 Z-51/30J 4 - 23


REV A 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.

Follow the disassembly steps to the point requiredto complete the repair. Then re-assemble thesecondary boom by following the disassemblysteps in reverse order.



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

3 Remove the primary boom. See 3-2, How toRemove the Primary Boom.

4 Remove the master cylinder. See 4-5, How toRemove the Master Cylinder.

5 Attach a lifting strap from an overhead crane toto the lug on the rod end of the primary boom liftcylinder. Then raise the primary boom liftcylinder with the crane, to a vertical position.

6 Tag, disconnect and plug the hydraulic hoses atthe primary boom lift cylinder. Cap the fittingson the cylinder.

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.

7 Remove the pin retaining fastener from theprimary boom lift cylinder barrel-end pivot pin.

8 Use a slide hammer to remove the pin. Removethe primary boom lift cylinder from the machine.

Crushing hazard. The primaryboom lift cylinder could becomeunbalanced and fall if not properlysupported by the overhead crane.

9 Tag, disconnect and plug the hydraulic hoseson both of the secondary boom lift cylinders.Cap the fittings on the cylinders.


4 - 24 Z-51/30J Part No. 110284


REV A

10 Remove the pin retaining fasteners from bothsides of the secondary boom lift cylinder rod-end pivot pin and barrel-end pivot pin. Do notremove the pins.

11 Attach a strap from an overhead crane to the lugon the rod end of one of the secondary boom liftcylinders for support. Do not apply any liftingpressure.

12 Use a soft metal drift to drive the barrel-endpivot pin half way out. Lower the barrel end ofthe secondary boom lift cylinder and let it hangdown.

13 Use a soft metal drift to drive the rod-end pivotpin half way out.

14 Remove the secondary boom lift cylinder fromthe machine.

15 Repeat steps 11 through 14 for the othersecondary boom lift cylinder.

Crushing hazard. The secondaryboom lift cylinder could becomeunbalanced and fall when removedfrom the machine if not properlyattached to the overhead crane.

Component damage hazard. Whenremoving a secondary boom liftcylinder from the machine, becareful not to damage thecounterbalance valve at the barrelend of the cylinder.

16 Attach a lifting strap from an overhead crane tothe upper pivot for support. Do not lift it.

17 Attach a lifting strap from a second overheadcrane to the number 1 arm at the mid-pointbetween the upper pivot and mid-pivot.

18 Remove the pin retaining fasteners from thenumber 1 arm pivot pins at the mid-pivot andthe upper pivot. Do not remove the pins.

19 Use a soft metal drift to drive both pins out.

20 Remove the number 1 arm from the machine.

Crushing hazard. The number 1arm could become unbalanced andfall when removed from themachine if not properly attached tothe overhead crane.

Crushing hazard. The upper pivotcould fall when the number 1 armis removed from the machine if notproperly supported by the overheadcrane.

21 Using the overhead crane attached to the upperpivot, raise the secondary boom assemblyapproximately 30 inches / 76 cm.

22 Insert a 4 x 4 x 11 inch / 10 x 10 x 28 cm blockbetween the number 2 arm and the boom rest.Then lower the secondary boom assembly ontothe block.

Crushing hazard. The secondaryboom assembly could fall if notproperly supported by the4 x 4 x 11 inch / 10 x 10 x28 cm block.

SECONDARY BOOM COMPONENTS

Part No. 110284 Z-51/30J 4 - 25


REV A

23 Pull all of the cables and hoses out through theupper pivot.

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

24 Remove the hose and cable covers from the topof the number 2 arm.

25 Pull all of the hoses and cables out of the upperpivot and out through the mid-pivot. Lay thehoses and cables on the ground.


26 Remove the pin retaining fastener from thenumber 2 arm pivot pin at the upper pivot. Use asoft metal drift to remove the pin.

27 Remove the upper pivot from the machine.

Crushing hazard. The upper pivotcould become unbalanced and fallwhen removed from the machine ifnot properly attached to theoverhead crane.

28 Attach the lifting strap from an overhead craneto the number 2 arm at the upper pivot end.

29 Raise the number 2 arm slightly and remove the4 x 4 x 11 inch / 10 x 10 x 28 cm block.

30 Lower the number 2 arm onto the boom rest pad.

31 Insert a 4 x 4 x 81/2 inch / 10 x 10 x 22 cmblock between the number 3 arm and thenumber 4 arm at the mid-pivot end.

32 Attach a lifting strap from the overhead crane tothe mid-pivot for support. Do not lift it.

33 Remove the pin retaining fasteners from thenumber 2, 3 and 4 arm pivot pins at themid-pivot. Do not remove the pins.

34 Use a soft metal drift to drive each pin out. Thenremove the mid-pivot from the secondary boomassembly.

Crushing hazard. The mid-pivotcould become unbalanced and fallwhen removed from the secondaryboom assembly if not properlysupported by the overhead crane.

35 Attach the lifting strap from an overhead craneto the center point of the number 2 arm forsupport. Do not lift it.

36 Remove the pin retaining fasteners from bothcompression link pivot pins. Do not remove thepins.

37 Use a soft metal drift to remove the lowercompression link pivot pin at the number 3 arm.

38 Support the compression link with an appropriatelifting device.


4 - 26 Z-51/30J Part No. 110284


REV A

43 Open the ground controls side turntable cover.

44 Remove the fuel tank filler cap.

45 Using an approved hand-operated pump, drainthe fuel tank into a container of suitablecapacity. Refer to Section 2, Specifications.

Explosion and fire hazard. Enginefuels are combustible. Perform thisprocedure in an open, well-ventilated area away from heaters,sparks, flames and lightedtobacco. Always have an approvedfire extinguisher within easy reach.

Explosion and fire hazard. Whentransferring fuel, connect agrounding wire between themachine and pump or contrainer.

Be sure to only use a hand-operated pump suitable for usewith gasoline and diesel fuel.

46 Tag, disconnect and plug the fuel hoses fromthe fuel tank. Clean up any fuel that may havespilled.

47 Remove the fuel tank mounting fasteners.Carefully remove the fuel tank from themachine.

Component damage hazard. Thefuel tank is plastic and maybecome damaged if allowed to fall.

Clean the fuel tank and inspect forcracks and other damage beforeinstalling it onto the machine.

39 Use a soft metal drift to remove the uppercompression link pivot pin from the number 2arm. Remove the compression link from themachine.

Crushing hazard. The number 2arm could fall when thecompression link is disconnectedfrom the number 2 arm if notproperly supported by the overheadcrane.

Crushing hazard. The compressionlink may fall if not properlysupported when removed from thesecondary boom assembly.


Crushing hazard. The number 2arm could become unbalanced andfall when removed from thesecondary boom assembly if notproperly supported by the overheadcrane.

41 Remove the upper and lower hose and cablecovers from the number 3 arm.

42 Pull all of the cables and hoses from the number3 arm and lay them over the turntablecounterweight.



Part No. 110284 Z-51/30J 4 - 27


REV A

57 Remove the pin retaining fasteners from thenumber 4 arm at the turntable riser. Do notremove the pin.

58 Attach a lifting strap from the overhead crane tothe center point of the number 4 arm. Do notlift it.

59 Use a slide hammer to remove the number 4arm from the turntable riser through the groundcontrols side bulkhead.


Crushing hazard. The number 4arm could become unbalanced andfall when removed from themachine if not properly supportedby the overhead crane.


48 Remove the retaining fastener from the groundcontrol box and function manifold pivot plate.

49 Lower the ground control box and functionmanifold pivot plate to access the number 3 armpivot pin.

50 Attach the lifting strap from the overhead craneto the centerpoint of the number 3 arm forsupport. Do not lift it.

51 Remove the mounting fasteners from the coverlocated in the boom storage area to access thenumber 3 and number 4 arm pivot pin retainingfasteners at the turntable riser.

52 Remove the pin retaining fasteners from thenumber 3 arm at the turntable riser. Do notremove the pin.

53 Use a slide hammer to remove the number 3arm pivot pin from the turntable pivot throughthe access hole behind the ground control box.


Crushing hazard. The number 3arm could become unbalanced andfall when removed from themachine if not properly supportedby the overhead crane.

55 Remove the upper and lower hose and cablecovers from the number 3 arm.

56 Remove the secondary boom drive speed limitswitch mounting fasteners from the number 4arm at the mid-pivot end. Do not disconnect thewiring.

4 - 28 Z-51/30J Part No. 110284


REV A

5-2Secondary Boom Lift Cylinders

There are two secondary boom lift cylindersincorporated in the structure of the secondary boomassembly. These cylinders operate in parallel andrequire hydraulic pressure to extend and retract.Each secondary boom lift cylinder is equipped witha counterbalance valve to prevent movement in theevent of a hydraulic line failure.

How to Remove a SecondaryBoom Lift Cylinder



1 Lower the secondary boom to the stowedposition.

2 Raise the primary boom so that it is above thesecondary boom lift cylinder rod-end pivot pin.


3 Tag, disconnect and plug the hydraulic hoseson the secondary boom lift cylinder.


4 Remove the pin retaining fasteners from thesecondary boom lift cylinder rod-end pivot pinand barrel-end pivot pin. Do not remove thepins.

5 Attach a strap from an overhead crane to the lugon the rod end of the secondary boom liftcylinder for support. Do not apply any liftingpressure.

6 Use a soft metal drift to drive the barrel-endpivot pin half way out. Lower the barrel end ofthe secondary boom lift cylinder and let it hangdown.

7 Use a soft metal drift to drive the rod-end pivotpin half way out.

8 Remove the secondary boom lift cylinder fromthe machine.

Crushing hazard. The secondaryboom lift cylinder could becomeunbalanced and fall when removedfrom the machine if not properlyattached to the overhead crane.

Component damage hazard. Whenremoving a secondary boom liftcylinder from the machine, becareful not to damage thecounterbalance valve at the barrelend of the cylinder.

Part No. 110284 Z-51/30J 4 - 29


REV A

6-1RPM Adjustment

Refer to Maintenance Procedure B-9, Check andAdjust the Engine RPM.

6-2Flex Plate

The flex plate acts as a coupler between the engineand the pump. It is bolted to the engine flywheeland has a splined center to drive the pump.

How to Remove the Flex Plate1 Disconnect the positive battery cable from the

battery.


2 Disconnect the electrical connectors at theelectrical proportional controller, located on thedrive pump.

3 Support the drive pump with an appropriatelifting device. Then remove all of the bellhousing to engine mounting bolts. Leave thepump connected to the bell housing.

4 Carefully pull the pump and bell housing awayfrom the engine and secure it from moving.

Component damage hazard. Hosescan be damaged if they are kinkedor pinched.

5 Remove the flex plate mounting fasteners,then remove the flex plate from the engineflywheel.

How to Install the Flex Plate1 Install the flex plate onto the engine flywheel

with the raised spline towards the pump.

2 Torque the flex plate mounting bolts in sequenceto 28 ft-lbs / 38 Nm.

3 Torque the flex plate mounting bolts in sequenceto 40 ft-lbs / 54 Nm.

Engines

1

2

3

4 5

6

4 - 30 Z-51/30J Part No. 110284


REV AENGINES

4 Install the pump coupler onto the pump shaftwith the set screw toward the pump. Leave theappropriate gap between coupler and pump endplate for your engine.

a pumpb pump shaftc pump couplerd flex plate with raised splinee engine flywheelf 7/16 inch / 11 mm gap

5 Apply Loctite® removable thread sealant to thepump coupler set screw. Torque the set screwto 61 ft-lbs / 83 Nm.

6 Install the pump and bell housing assembly.Torque the bell housing mounting bolts labeled"C" in sequence to 28 ft-lbs / 38 Nm.

Component damage hazard. Wheninstalling the pump, do not forcethe pump coupler into the flexplateor damage to the pump shaft sealmay occur.

Component damage hazard. Donot force the drive pump duringinstallation or the flex plate teethmay become damaged.

7 Torque the bell housing mounting bolts labeled"C" in sequence to 40 ft-lbs / 54 Nm.

a b c d e

f

10

6 1

8

4

11

7 5

92

12

3

C

C C

C

C

C

C

CC

C

C

C

Part No. 110284 Z-51/30J 4 - 31


REV AHydraulic Pumps

7-1Lift/Steer Pump

How to Remove theLift/Steer Pump




2 Tag, disconnect and plug the lift/steer pumphydraulic hoses. Cap the fittings on the pump.


3 Remove the pump mounting bolts. Carefullyremove the pump.

Component damage hazard. Besure to open the two hydraulic tankvalves and prime the pump afterinstalling the pump.

open closed

4 - 32 Z-51/30J Part No. 110284


REV AHYDRAULIC PUMPS

7-2Drive Pump

The drive pump is a bi-directional variabledisplacement piston pump. The pump output iscontrolled by the electrical proportional controller,located on the pump. The only adjustment that canbe made to the pump is the neutral or nulladjustment. Any internal service to the pumpshould only be performed at an authorized servicecenter. Call Genie Industries Service Department tolocate your local authorized service center.

How to Remove the Drive PumpComponent damage hazard. Thework area and surfaces where thisprocedure will be performed mustbe clean and free of debris thatcould get into the hydraulic systemand cause severe componentdamage. Dealer service isrecommended.


1 Disconnect the electrical connectors at theelectrical proportional controller located on thedrive pump.



3 Tag and disconnect and plug the hydraulichoses from the drive and lift/steer pumps. Capthe fittings on the pumps.


4 Support the pump with a lifting device andremove the two drive pump mounting fasteners.

open closed

Part No. 110284 Z-51/30J 4 - 33


REV A

a

5 Carefully pull the drive pump out until the pumpcoupler separates from the flex plate.

6 Remove the drive pump from the machine.

Component damage hazard. Thehydraulic pump may becomeunbalanced and fall if not properlysupported.

Component damage hazard. Wheninstalling the pump, do not forcethe pump coupler into the flexplateor damage to the pump shaft sealmay occur.

Component damage hazard. Besure to open the two hydraulic tankvalves and prime the pump afterinstalling the pump.

HYDRAULIC PUMPS

How to Prime the Pump1 Connect a 0 to 600 psi / 0 to 41 bar pressure

gauge to the test port on the drive pump.

2 Remove the safety pin (if equipped) from theengine pivot plate latch.



4 Hold the manual fuel shutoff valve clockwise tothe closed position.

a manual fuel shutoff valve

5 Have another person crank the engine with thestarter motor for 15 seconds, wait 15 seconds,then crank the engine an additional 15 secondsor until the pressure reaches 320 psi / 22 bar.

6 Release the manual fuel shutoff valve.

7 Start the engine from the ground controls andcheck for hydraulic leaks.

4 - 34 Z-51/30J Part No. 110284


REV A

8-1Function Manifold Components

The function manifold is located next to the hydraulic tank underneath the ground controls side cover.

Index SchematicNo. Description Item Function Torque

1 Solenoid valve, 3 position 4 way ...... BM ........ Platform level up/down ................................ 25 ft-lbs / 34 Nm

2 Solenoid valve, 3 position 4 way ...... CG ........ Platform rotate left/right andjib boom up/down ........................................ 25 ft-lbs / 34 Nm

3 Flow regulator valve,2 gpm / 7.6 L/min ............................... BZ ......... Boom extend/retract circuit .......................... 20 ft-lbs / 27 Nm

4 Solenoid valve, 2 position 3 way ...... CA ........ Primary boom extend .................................. 20 ft-lbs / 27 Nm

5 Proportional directionalsolenoid valve, 3 position 4 way ....... BY ......... Primary boom up/down .................... 16-20 ft-lbs / 22-27 Nm

6 Differential sensing valve160 psi / 11 bar ................................. BG ........ Meters flow to functions ............................... 25 ft-lbs / 34 Nm

7 Proportional directionalsolenoid valve, 3 position 4 way ....... BP ......... Turntable rotate left/right .................. 16-20 ft-lbs / 22-27 Nm

8 Proportional directionalsolenoid valve, 3 position 4 way ....... BU ........ Secondary boom up/down ............... 16-20 ft-lbs / 22-27 Nm

9 Solenoid valve, 3 position 4 way ...... BF ......... Steer left/right ............................................... 25 ft-lbs / 34 Nm

10 Relief valve, 2100 psi / 145 bar ........ BV ......... Secondary boom down ............................... 20 ft-lbs / 27 Nm

11 Orifice, 0.046 inch / 1.17 mm ............ CF ......... Secondary boom down circuit

12 Check valve, 5psi / 0.3 bar ................ BT ......... Differential sensing circuit,secondary boom down ..................... 12-14 ft-lbs / 16-19 Nm

13 Check valve, 5psi / 0.3 bar ................ BW ........ Secondary boom circuit ............................... 25 ft-lbs / 34 Nm

14 Check valve, 5psi / 0.3 bar ................ BS ......... Differential sensing circuit,secondary boom up .......................... 12-14 ft-lbs / 16-19 Nm

15 Priority flow regulator valve,1.5 gpm / 5.7 L/min ............................ BB ......... Steer circuit .................................................. 25 ft-lbs / 34 Nm

16 Relief valve, 3200 psi / 220.6 bar ..... BA ......... System relief ................................................ 20 ft-lbs / 27 Nm

17 Shuttle valve ...................................... BO ........ Turntable rotate circuit ...................... 12-14 ft-lbs / 16-19 Nm

18 Check valve, 5psi / 0.3 bar ................ BQ ........ Differential sensing circuit,turntable rotate ................................. 12-14 ft-lbs / 16-19 Nm

19 Check valve, 5psi / 0.3 bar ................ CB ........ Differential sensing circuit,primary boom retract ........................ 12-14 ft-lbs / 16-19 Nm

20 Check valve, 5psi / 0.3 bar ................ BC ........ Differential sensing circuit,platform rotate left andjib boom up .................................................. 25 ft-lbs / 34 Nm

This list continues. Please turn the page.

Manifolds

Part No. 110284 Z-51/30J 4 - 35


REV A MANIFOLDS

31

9

17

1 2 4 7

11

12

15

182023 22 21

26

28

29

30

32

34

35

27

25

13

10

24

33

3

19

14

16

865

4 - 36 Z-51/30J Part No. 110284


REV A

Function Manifold Components, continued


21 Check valve, 5 psi / 0.3 bar ............... BD ........ Differential sensing circuit,platform rotate right andjib boom down ............................................. 25 ft-lbs / 34 Nm

22 Flow regulator valve,0.1 gpm / 0.38 L/min .......................... BX ......... Primary boom load sense circuit ................. 20 ft-lbs / 27 Nm

23 Counterbalance valve,3000 psi / 207 bar ............................. CD ........ Primary boom down circuit ............... 30-35 ft-lbs / 45-50 Nm

24 Pressure compensator valve,80 psi / 5.5 bar ................................... BR ........ Turntable rotate circuit ................................. 25 ft-lbs / 34 Nm

25 Shuttle valve ...................................... CE ........ Differential sensing circuit,primary boom up/down ..................... 12-14 ft-lbs / 16-19 Nm

26 Flow regulator valve,0.4 gpm / 1.5 L/min ............................ BE ......... Jib boom and platform

rotate circuit ................................................. 20 ft-lbs / 27 Nm

27 Needle valve ..................................... BN ........ Platform level flow control ........................... 20 ft-lbs / 27 Nm

28 Relief valve, 2500 psi / 172 bar ........ BH ........ Platform level circuit .................................... 20 ft-lbs / 27 Nm

29 Check valve, 5psi / 0.3 bar ................ BK ......... Differential sensing circuit,platform level up ............................... 12-14 ft-lbs / 16-19 Nm

30 Check valve, 5psi / 0.3 bar ................ BL ......... Differential sensing circuit,platform level down .......................... 12-14 ft-lbs / 16-19 Nm

31 Solenoid valve, 2 position 3 way ...... CC ........ Primary boom retract ................................... 20 ft-lbs / 27 Nm

32 Shuttle valve ...................................... BI .......... Platform level circuit ......................... 12-14 ft-lbs / 16-19 Nm

33 Check valve, dual pilot operated,135 psi / 9.3 bar ................................. BJ ......... Platform level circuit .................................... 20 ft-lbs / 27 Nm

MANIFOLDS

Part No. 110284 Z-51/30J 4 - 37


REV A MANIFOLDS

29

9

15

1 2 4 7

11

13

161821 20 19

24

26

27

28

30

32

33

25

23

10

22

31

3

17

12

14

865

4 - 38 Z-51/30J Part No. 110284


REV AMANIFOLDS

8-2Valve Adjustments -Function Manifold

How to Adjust the SystemRelief Valve


1 Connect a 0 to 5000 psi / 0 to 350 bar pressuregauge to the TEST1 port on the function manifold.


3 Hold the function enable switch to the high rpmposition and activate and hold the primary boomretract switch with the boom fully retracted.

4 Observe the pressure reading on the pressuregauge. Refer to Section 2, Specifications.

5 Turn the engine off. Use a wrench to hold therelief valve and remove the cap (item BA).

6 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.

7 Repeat steps 2 through 5 and recheck reliefvalve pressure.

8 Remove the pressure gauge.

How to Adjust the SecondaryBoom Down Relief Valve


1 Connect a 0 to 5000 psi / 0 to 350 bar pressuregauge to the TEST1 port on the function manifold.


3 Hold the function enable switch to the high rpmposition and activate and hold the secondaryboom down switch with the secondary boomfully lowered.

4 Observe the pressure reading on the pressuregauge. Refer to Section 2, Specifications.

5 Turn the engine off. Use a wrench to hold therelief valve and remove the cap (item BV).

6 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.

7 Repeat steps 2 through 5 and recheck reliefvalve pressure.

8 Remove the pressure gauge.

Part No. 110284 Z-51/30J 4 - 39


REV A

8-3Jib Boom / Platform Rotate Manifold Components

The jib boom / platform rotate manifold is mounted to the platform support.


1 Solenoid valve, 2 position 3 way ..... G ........... Platform rotate/jib boom select ........... 8-10 ft-lbs / 11-14 Nm

MANIFOLDS

1

4 - 40 Z-51/30J Part No. 110284


REV A

8-4Turntable Rotation Manifold Components

The turntable rotation manifold is mounted to the turntable rotation motor located in the boom storagecompartment.

Index SchematicNo. Description Item Function

1 Counterbalance valve ...................... L ............ Turntable rotate right

2 Counterbalance valve ...................... J ............ Turntable rotate left

MANIFOLDS

1 2

Part No. 110284 Z-51/30J 4 - 41


REV A

8-5Directional Valve Manifold Components

The directional valve manifold is mounted inside the drive chassis at the non-steer end.

IndexNo. Description Function Torque

1 Cap ................................................................... Breather ............................................ 20-25 ft-lbs / 27-33 Nm

2 Spool valve ...................................................... Directional control

MANIFOLDS

1

2

4 - 42 Z-51/30J Part No. 110284


REV A

How to Set Up the DirectionalValve Linkage

Adjustment of the directional valvelinkage is only necessary when thelinkage or valve has beenreplaced.

1 Lower the boom to the stowed position.

2 Use a "bubble type" level to be sure the floor iscompletely level.

Tip-over hazard. Failure to performthis procedure on a level floorcould compromise the stability ofthe machine resulting in themachine tipping over.

3 Check the tire pressure in all four tires and addair if needed to meet specification.

4 Remove the drive chassis cover and the non-steer axle covers.

5 Place a "bubble type" level across the drivechassis non-steer end. Check to be sure thedrive chassis is completely level.

6 To level the drive chassis, start the engine andloosen the lock nuts on both sides of theurethane cushions.

7 Push up or pull down on the threaded rod untilthe machine is completely level.

MANIFOLDS

8 Verify that the ground and drive chassis arecompletely level.

9 Tighten the nuts on both sides of the urethanecushions until they are snug. Tighten thelocknuts.

10 Check to be sure the drive chassis iscompletely level.

11 Measure the distance between the drive chassisand the non-steer axle on both sides (from theinside of the drive chassis).

If the distance is not equal and theadjustment to the linkage wascompleted with the ground anddrive chassis level, repeat steps 6through 10 OR consult GenieIndustries Service Department.

Part No. 110284 Z-51/30J 4 - 43


REV A


4 - 44 Z-51/30J Part No. 110284


REV A

8-6Traction Manifold Components

The traction manifold is mounted inside the drive chassis at the non-steer end.


1 Flow divider/combiner valve ............. U ........... Controls flow to non-steer enddrive motors in forwardand reverse ....................................... 25-30 ft-lbs / 34-41 Nm

2 Bi-directional flow control valve,2 gpm / 7.6 L/min ............................... Z ........... Non-steer end drive motor circuit ..... 25-30 ft-lbs / 34-41 Nm

3 Bi-directional flow control valve,1 gpm / 3.8 L/min ............................... X ........... Steer end drive motor circuit ............ 25-30 ft-lbs / 34-41 Nm

4 Directional control valve ................... AV ......... 2 speed motor shift circuit/High speed bypass ........................... 10-12 ft-lbs / 14-16 Nm

5 Diagnostic fitting ............................................... Testing

6 Shuttle valve, 3 position 3 way ......... R ........... Charge pressure circuit thatdirects hot oil out of low pressureside of drive pump and allowslow pressure flow path forbrake release and 2-speedmotor shift ......................................... 15-18 ft-lbs / 20-24 Nm

7 Relief valve, 250 psi / 17.2 bar ......... AD ........ Charge pressure circuit .................... 10-12 ft-lbs / 14-16 Nm

8 Solenoid valve, 2 position 3 way ...... AG ........ 2-speed motor shift ........................... 10-12 ft-lbs / 14-16 Nm

9 Orifice, 0.030 inch / 0.76 mm ............ AE ......... Brake and 2-speed motor shift circuit

10 Solenoid valve, 2 position 3 way ...... AF ......... Braking ............................................. 10-12 ft-lbs / 14-16 Nm

11 Check valve ....................................... AH ........ 2 speed motor shift circuit ................. 10-12 ft-lbs / 14-16 Nm

12 Orifice, 0.025 inch / 0.64 mm ............ AI .......... 2 speed motor shift circuit

13 Flow divider/combiner valve ............. V ........... Controls flow to flowdivider/combiner valves 1 and 17 .... 25-30 ft-lbs / 34-41 Nm

14 Check valve ....................................... AC ........ Steer end drive motor circuit ............ 10-12 ft-lbs / 14-16 Nm

15 Orifice, 0.052 in / 1.32 mm ................ Y ........... Drive circuit

16 Check valve ....................................... T ........... Steer end drive motor circuit ............ 10-12 ft-lbs / 14-16 Nm

17 Flow divider/combiner valve ............. W .......... Controls flow to steer enddrive motors in forwardand reverse ....................................... 25-30 ft-lbs / 34-41 Nm

18 Check valve ....................................... S ........... Non-steer end drive motor circuit ..... 10-12 ft-lbs / 14-16 Nm

19 Check valve ....................................... AA ......... Non-steer end drive motor circuit ..... 10-12 ft-lbs / 14-16 Nm

MANIFOLDS

Part No. 110284 Z-51/30J 4 - 45


REV A

1 32 4 5 6 7 8 9

17

18

19

10

11

12

13

14

15

16

4 - 46 Z-51/30J Part No. 110284


REV AMANIFOLDS

8-7Valve Adjustments,Traction Manifold

How to Adjust the ChargePressure Relief Valve1 Connect a 0 to 600 psi / 0 to 50 bar pressure

gauge to the test port on the drive pump.

2 Hold the charge pressure relief valve at thetraction manifold and remove the cap (item AD).

3 Turn the internal hex socket clockwise fully untilit stops. Install the cap.

4 Start the engine and move and hold the functionenable/rpm select toggle switch to the high rpm(rabbit symbol) position. Note the reading on thepressure gauge.

5 Turn the engine off.

6 Remove the pressure gauge from the drivepump. Connect the gauge to the test portlocated on the traction manifold.

7 Hold the charge pressure relief valve andremove the cap (item AD).

8 Start the engine and move and hold the functionenable/rpm select toggle switch to the high rpm(rabbit symbol) position.

9 Adjust the internal hex socket until the pressurereading on the gauge is 40 psi / 2.8 bar lessthan the pressure reading on the pump. Turn itclockwise to increase the pressure orcounterclockwise to decrease the pressure.Install the valve cap.

10 Turn the engine off and remove the pressuregauge.

8-8Valve 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 to betested.

2 Test the coil resistance.

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 Resistance Specification

Proportional directional solenoid valve, 10V DC 6 to 8Ω(schematic items BP, BU and BY)

3 position 4 way directional valve, 10V DC 6 to 8Ω(schematic items BF, BM and CG)

2 position 3 way solenoid valve, 10V DC 6 to 8Ω(schematic items CA, CC, G, AF and AG)

Part No. 110284 Z-51/30J 4 - 47


REV A

How to Test a Coil DiodeProperly functioning coil diodes protect theelectrical circuit by suppressing voltage spikes.Voltage spikes naturally occur within a functioncircuit following the interruption of electrical currentto a coil. Faulty diodes can fail to protect theelectrical system, resulting in a tripped circuitbreaker 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.

Resistor, 10Genie part number 27287

The battery should read 9V DC ormore when measured across theterminals.

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.

The multimeter, when set to readDC current, should be capable ofreading up to 800 mA.

4 Connect the negative lead to the other terminalon the coil.

5 Momentarily connect the positive lead from themultimeter to the positive terminal on the 9V DCbattery. Note and record the current 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.

9V

BATTERY

10

RESISTOR

MULTI

METER

COIL

+

-

+

-

d

b

b

a

c

c

4 - 48 Z-51/30J Part No. 110284


REV A





6 Tag, disconnect and plug the hydraulic hosesfrom the turntable rotation motor manifold. Capthe fittings on the manifold.


7 Attach a lifting strap from and overhead crane orother suitable lifting device to the turntablerotator assembly.

8 Remove the turntable rotation assemblymounting fasteners.

9 Carefully remove the turntable rotation assemblyfrom the machine.

Tip-over hazard. The machinecould tip over when the turntablerotation assembly is removed if theturntable rotation lock is not in thelocked position.

Crushing hazard. The turntablerotation assembly could becomeunbalanced and fall when removedfrom the machine if not properlysupported by the overhead crane.

Turntable Rotation Components

9-1Turntable Rotation Assembly

How to Remove the TurntableRotation Assembly


1 Raise the secondary boom until the upper pivotis above the turntable covers. Turn the machineoff.

2 Secure the turntable from rotating with theturntable rotation lock.

Tip-over hazard. The machinecould tip over when the turntablerotation assembly is removed if theturntable rotation lock is not in thelocked position.

Unlocked position

Locked position

Part No. 110284 Z-51/30J 4 - 49


REV AAxle Components

10-1Oscillating AxleLock-out Cylinders

The oscillating axle cylinders extend and retractbetween the drive chassis and the oscillating axle.The cylinders are equipped with counterbalancevalves to prevent movement in the event of ahydraulic line failure. The valves are not adjustable.

How to Remove an OscillatingAxle Cylinder

Perform this procedure on a firm,level surface with the boom inthe stowed position.


1 Tag, disconnect and plug the oscillating axlecylinder hydraulic hoses. Cap the fittings on theoscillate cylinder.


2 Remove the pin retaining fasteners from therod-end pivot pin. Use a soft metal drift toremove the pin.

3 Attach a lifting strap from an overhead crane tothe barrel end of the oscillating cylinder.

4 Remove the pin retaining fasteners from thebarrel-end pivot pin. Use a soft metal drift toremove the pin.

Crushing hazard. The oscillatecylinder may become unbalancedand fall when removed from themachine if not properly attached tothe overhead crane.

5 Remove the oscillate cylinder from the machine.

4 - 50 Z-51/30J Part No. 110284


AXLE COMPONENTS


Part No. 110284 Z-51/30J 5 - 1

September 2005 Section 5 • Fault Codes

Before Troubleshooting:

Read, understand and obey the safety rules andoperating instructions printed in theGenie Z-51/30J Operator’s Manual.

Be sure that all necessary tools and testequipment are available and ready for use.

Read each appropiate fault code thoroughly.Attempting shortcuts may produce hazardousconditions.

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.



Perform all troubleshooting on afirm level surface.

Two persons will be required tosafely perform sometroubleshooting 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:



· Turntable rotated with the boom betweenthe non-steer wheels

· Turntable secured with the turntablerotation lock

· Key switch in the off position with thekey removed

· Wheels chocked


5 - 2 Z-51/30J Part No. 110284

September 2005Section 5 • Fault Codes

REV AFAULT CODES

Fault Codes - Control System

How to Retrieve Control SystemFault Codes

At least one fault code is presentwhen the alarm at the platformcontrols produces two short beepsevery 30 seconds for 10 minutes.

Perform this procedure with theengine off, the key switch turned toplatform controls and the redEmergency Stop button pulled outto the on position at both theground and platform controls.

1 Open the platform control box lid.


2 Locate the red and yellow fault LEDs on theALC-500 circuit board inside the platform controlbox. Do not touch the circuit board.

Component damage hazard.Electrostatic discharge (ESD) candamage printed circuit boardcomponents. If the circuit boarddoes need to be handled, maintainfirm contact with a metal part ofthe machine that is grounded at alltimes when handling the printedcircuit board OR use a groundedwrist strap.

3 Determine the error source: The red LEDindicates the error source and will flash twoseparate codes. The first code will indicate thefirst digit of the two digit code, flashing once persecond. It will then pause for 1.5 seconds andflash the second digit once per 0.5 second.

When the red LED is flashing thecode, the yellow LED will be onsolid.

4 Determine the error type: The yellow LEDindidates the error type and will flash twoseparate codes. The first code will indicate thefirst digit of the two digit code, flashing once persecond. It will then pause for 1.5 seconds andflash the second digit once per 0.5 second.

When the yellow LED is flashingthe code, the red LED will be onsolid.

5 Use the fault code table on the following pagesto aid in troubleshooting the machine bypinpointing the area or component affected.

Part No. 110284 Z-51/30J 5 - 3


REV A

Error Source Error TypeID Name ID Name

Condition Solution11121516

Value at 5VValue too highValue too lowValue at 0V

Limited speed anddirection frozen atzero and neutral.Alarm soundsindicating fault.

Power upcontroller withproblem corrected.

17 Not calibratedJoystick speed anddirection frozen atzero and neutral.

Calibrate joystick.

21 Boom 1 Joystick(primary boom up/down)

18 Just calibratedInitiate 1-second beepof alarm.

Self-clearing.(transient)

22 Boom 1 directionalvalves

21 Fault



1215

Value too highValue too low



17 Not calibratedCalibrate valvethresholds.

23 Boom 1 flowcontrol valve

18 Just calibrated

Normal functionexcept threshold forone or both directionsis zero.


11121516





Calibrate joystick.

31 Boom 2 Joystick(secondary boomup/down orprimary boomextend/retract)

18 Just calibratedInitiate 1 second beepof alarm.


32 Boom 2 directionalvalves

21 Fault



Continued on next page

FAULT CODES

5 - 4 Z-51/30J Part No. 110284


REV A


Condition Solution

1215





33 Boom 2 flowcontrol valve

18 Just calibrated



11121516





Calibrate joystick.

41 Turntable rotatejoystick



42 Turntable rotatedirectional valves

21 Fault



1215





43 Turntable rotateflow control valve

18 Just calibrated



44 Drive enableoverride switches 21 Fault

Enable overridedirection is frozen atneutral.


FAULT CODES

Part No. 110284 Z-51/30J 5 - 5


REV A


Condition Solution11121516





Calibrate joystick

51 Drive joystick



1215




17 Not calibratedCalibrate valvethresholds

53 Drive flow valve(EDC)

18 Just calibrated



54 Drive brake valve

21 Fault



55 High speed drivemotor Valve 21 Fault

Motor speed frozen inthe low state. Alarmsounds indicatingfault.


11121516





Calibrate Joystick

61 Steer joystick



62 Steer directionalvalves

21 Fault



FAULT CODES

5 - 6 Z-51/30J Part No. 110284



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-51/30J 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.An illustration legend precedes each group ofdrawings.

Electrical Schematics


Hydraulic Schematics


General Repair Process

Malfunctiondiscovered

Identifysymptoms

Troubleshoot

Performrepair

Return toservice problem

solved

problemstill exists

Inspectand test

Part No. 110284 Z-51/30J 6 - 1

Section 6 • SchematicsSeptember 2005

September 2005Section 6 • Schematics

6 - 2 Z-51/30J Part No. 110284

Electrical Symbols Legend

Connectionno terminal

P3

Horn buttonnormally open

T-circuitsconnect

FB

Flashing beacon

Diode

Circuits crossingno connection

Quick disconnectterminal

BLK

WHT

T-circuits connectat terminal

WHT #21 TB21

Battery

+

-

Circuit breakerwith amperage

15A

CB1

Horn or alarm

H1 Emergency Stopbutton normally

closed

P1

Coilsolenoid or relay

Key switch(before serial number 22051)

KS1

GROUND

PLATFORM

Power relay

PR1

Toggle switch SPDT

TS2

START

ENG

INE

Toggle switch DPDT

TS6

UP

DO

WN

PLATFOR

MLEVEL

Gauge sending unit

HM

Hour meter

N.O.OTS2

Oil temperatureswitch

normally open

N.O.CTS1

Coolant temperatureswitch

normally open

Oil pressure switchnormally closed

N.C.OPS1

BLK

FS1

Foot switch

PumpAux

Auxiliary pump

FAN

Hydraulic oilcooling fan

G1

Gauge

Tilt sensorLED

L3

Limit switch

N.C.H.ON.O.H.C

LS3

Fusewith amperage

25A

F1

510

Resistor withohm value

Starting aid:glow plug orflame ignitor

Control relay contactnormally open

CR4N.O.

Coil

Fuel or RPMsolenoid

PU

LL

IN

HO

LD

CA B

Key switch(after serial number 22050)

KS1

REV A

September 2005 Section 6 • Schematics

Hydraulic Symbols Legend

Part No. 110284 Z-51/30J 6 - 3

Pumpfixed displacement

Motorbi-directional

Check valve

2 position, 3 way, shuttle valve

Double actingcylinder

Priorityflow regulator valve

Differentialsensing valve

Solenoid operatedproportional valve

Brake

Pilot operated 3 position,3 way, shuttle valve

Filter withbypass valverelief setting

25 psi(1.7 bar)

Motor2-speed,

bi-directional

Pumpbi-directional,

variable displacement

E

Pump prime mover(engine or motor)

Directional valve(mechanically activated)

o

Relief valvewith pressure setting

200 psi(13.8 bar)

Orifice with size

.035"(0.89 mm)

Solenoid operated 3 position,4 way, directional valve

Directional valvepilot operated

2 position, 2 way

Flow divider/combiner valvewith pressure balancing orifice

and flow percentages

50% 50%

Counterbalance valvewith pressure and pilot ratio

(206.8 bar)3000 psi

3:1

Solenoid operated 2 position,3 way, directional valve

2 position, 2 waysolenoid valve

Solenoid operated3 position, 4 way,

proportional directional valve

REV A


6 - 4 Z-51/30J Part No. 110284

Electrical Schematic

1

2

3

4

5

6

7

8

A B C D E F G H I J K L M N

March 2006Section 6 • Schematics

6 - 5 Z-51/30J Part No. 110284

REV B

C1

33

PL

AB

L/R

DP

13

4T

TS

WH

HO

RN

RE

LA

Y

LE

VE

LS

EN

SO

R

HO

RN

15A

+

-

RD

P2

0B

AT

RD

TB20

C1

07

AF

WH

C4

1R

PM

OR

/BK

CR5

C4

6H

RN

BK

/RD

NO

CB1

RD

RD

CB2

15A

TB41

C4

6H

RN

BK

/RD

TB23

KS1

PLAT

GND

P1

RD

P3

HORN

TB134

P2

2B

AT

BK

BK-(FS)C9P-1 BK

P2

GE

NE

RA

TO

RO

PT

ION

FL

AS

HIN

GB

EA

CO

NS

OP

TIO

N

HO

UR

ME

TE

R

PO

WE

RR

EL

AY

IGN

ITIO

N/S

TA

RT

RE

LA

Y

STA

RT

ER

MO

TO

R

AU

XIL

IAR

YP

UM

P

AU

XIL

IAR

YP

OW

ER

RE

LA

Y

TS2

GROUND

AUX. ON

KEY PWR.

BATTERY

TACHOMETER

IGN./FUEL ON

ENG. FAULT

KEY BYPASS

START INPUT

START RELAY

4

PUMP

PR1

C2

7A

UX

RD

PR1

NO

C2

8T

TA

RD

/BK

CR1CR1NO

R3

3S

TR

BK

TB21

TB25

CR2NO

8

7

6

5

10

9

CR2

TS51

C2

8T

TA

RD

/BK

TB27

RD

TS1

RD

TS52

BK

1

2

TB33

3IGNITION/STARTMODULE

C2

1IG

NW

H

FB1

C3

3S

TR

BK

C4

5G

EN

GR

/WH

TS47

P24FS WH

C9P-3RD-(FS)

FS1

BR

N

TS54

TS4

BRN

RD

BK

P24FS WH

P26ESTP BK

OIL

TE

MP

ER

AT

UR

EL

ED

C9P-2

REGULATOR

IND.

ALTERNATOR

BAT.+

STA.

BAT.-

EXCT.

FU

EL

SO

LE

NO

ID

TB24

TB26

C2

6T

SR

WH

/RD

C2

5P

SR

WH

/BK

L42

L43

OIL

PRES.

OIL

TEMP.

SW2NC

SW3NO

OIL

PR

ES

SU

RE

SW

ITC

H

OIL

TE

MP

ER

AT

UR

ES

WIT

CH

OIL

PR

ES

SU

RE

LE

D

TB34

TS56

C3

4S

AB

K/W

H

TS6

PR3

NO

CR4

CR4

NO

HIG

HR

PM

SO

LE

NO

ID

HIG

HID

LE

RE

LA

Y

TIL

TA

LA

RM

P2

2B

AT

BK

W

GL

OW

PL

UG

WH-(FS)

H1

RD

WH

BR

NB

K

BK

C3

P-9

H2+

_

C41RPM OR/BK

RD

P25FS RD

P26ESTP BK

C1

P-2

C1

P-1

C2

7A

UX

RD

C7

P-1

C1

P-7

C1

P-8

C2

P-7

C1

P-9

C3

5R

PM

BK

/RD

C4

1R

PM

OR

/BK

C28TTA RD/BKC28TTA RD/BK

C28TTA RD/BK

C41RPM OR/BK

EN

GIN

ES

PE

ED

C1

B-9

C5

-18

C1

B-8

C5

-12

C1

B-7

C4

5G

EN

GR

/WH

C5

-22

C5

-14

C5

-16

C5

-11C6

-9

C3

4S

AB

K/W

H

C5

-5

C21IGN WH

C2

1IG

N2

WH

C3

B-9

C5

-2

C5-3

C7

B-4

C5

-17

C2

B-7

B112V DC

D1

C33MF

+

M2

M3

PR2PR2

NO

Q3

S8

U1

U32

C3

5R

PM

BK

/RD

BK

/RD

C6

-34

P1

34

FB

RD

C2

B-3

L30 L30

L29L29

FUSE 10A (ONLY FOR WORKLIGHTS)

C3

P-4

C3

B-4

DL

ITE

WH

C2

P-1

1

C2

P-1

2C

2P

-10

C2

P-9

PBOX GND

RD

RD

NO

CR23CR23

DR

IVE

LIG

HT

OP

TIO

N

WO

RK

LIG

HT

OP

TIO

N

C6

-38

C6

-39

TS48

RD

RD

C7

B-1

FUSE 10A

P20BAT RD

A B

C

HIG

HR

PM

SU

PR

ES

SIO

ND

IOD

E

4

6

12 8

7

5

C1

B-1

D3

D4

C7

P-2

P2

3B

AT

WH

C7

B-2

D2

D40

1 3

C2

P-5

C1

32

PL

IB

L/W

H

C1

34

PW

RG

NC

2B

-5

C1

B-1

2

TB22

C4

B-1

C1

B-2

P134 RD

5

BR

N

U33

PR3

C5

-23 C

6-2

7

TB35

GR/BK

ALT

ER

NA

TO

R

AU

XIL

IAR

YP

OW

ER

AU

XIL

IAR

YP

OW

ER

EN

GIN

ES

TA

RT

EN

GIN

ES

TA

RT

GL

OW

PL

UG

GL

OW

PL

UG

LO

WR

PM

HIG

HR

PM

LO

WR

PM

FU

NC

TIO

NE

NA

BL

E

GE

NE

RA

TO

R

WO

RK

LIG

HT

S

DR

IVE

LIG

HT

S

C1B & C1P = GRAYC2B & C2P = BLACKC3B & C3P = GREENC4B & C4P = BROWN

NOTE:

1. All switches and contacts are shown with the boomin the stowed position and the keyswitch off.

5 Add D40 only if unit has L4 and L48.

4 CE and platform overload option

H6 L45

L4

D39

4

LS18

C1

P-1

2

LO

AD

SE

NS

EM

OD

UL

E

FUSE70A


1

2

3

4

5

6

7

8

N M L K J I H G F E D C B A

Part No. 110284 Z-51/30J 6 - 6

March 2006 Section 6 • Schematics

REV B

NOTES:1. ALL LIMIT SWITCHES SHOWNWITH BOOM IN STOWED POSITIONEXCEPT AS NOTED.

SWITCH SHOWN WITH BOOMROTATED PAST EITHER NON-STEERWHEEL.

2

C1B & C1P - GRAYC2B & C2P - BLACKC3B & C3P - GREENC4B & C4P - BROWN

WH

P26ESTP BK

C41RPM OR/BK

C28TTA RD/BK

BRN

RD

RD

BK

P24FS WH

WH

-4

BO

OM

RE

TR

AC

T

CR33

PL

AT

FO

RM

RO

TA

TE

RIG

HT

/JIB

BO

OM

DO

WN

PL

AT

FO

RM

RO

TA

TE

LE

FT

/JIB

BO

OM

UP

C6

-19

DE

SC

EN

TA

LA

RM

OP

TIO

N

JIB

BO

OM

VA

LV

E

H3

C2

2-2C

5-2

5

C2

3-2

PL

AT

FO

RM

LE

VE

LD

OW

N

PL

AT

FO

RM

LE

VE

LU

P

BO

OM

EX

TE

ND

C2

1-2

C2

0-2

C1

6-2

C1

7-2

C1

29

DA

BK

C1

8JD

GR

/BK

C2

2-1

C2

3-1

C1

7JU

GR

C6

-18

C6

-17

C1

5P

LD

OR

/BK

C1

4P

LU

OR

C2

1-1

C2

0-1

C8

PB

RB

K/W

H

C1

6-1

C1

7-1

C7

PB

EB

K

C6

-15

C6

-14

C6

-8

C6

-7

C6

-20

BK

-5 C6

-13

LS

4-

SE

CO

ND

AR

YB

OO

MU

PD

RIV

EL

IMIT

SW

ITC

H

LS

1-

PR

IMA

RY

BO

OM

EX

TE

ND

DR

IVE

LIM

ITS

WIT

CH

LS

2-

PR

IMA

RY

BO

OM

UP

DR

IVE

LIM

ITS

WIT

CH

LS

3-

DR

IVE

EN

AB

LE

LIM

ITS

WIT

CH

SE

CO

ND

AR

YB

OO

MU

P

SE

CO

ND

AR

YB

OO

MS

EL

EC

TR

EL

AY

SE

CO

ND

AR

YB

OO

MD

OW

N

C1

8-2

C1

9-2

PR

IMA

RY

BO

OM

UP

PR

IMA

RY

BO

OM

SE

LE

CT

RE

LA

Y

PR

IMA

RY

BO

OM

DO

WN

TU

RN

TA

BL

ER

OTA

TE

SE

LE

CT

RE

LA

Y

TU

RN

TA

BL

ER

OTA

TE

RIG

HT

TU

RN

TA

BL

ER

OTA

TE

LE

FT

C1

3-2

C1

4-2

C1

2-2

C1

5-2

BK LS3

C6

-10

C6

-11

C1

0-1

WH

-6

RD

C11

-3B

K-7

C1

0-2

14

R11

SB

DB

L/B

K

R1

0S

BU

BL

C1

8-1

C1

9-1

LS2

22

21

C1

0-4

WH

-5

BK

-6

13

2

8587a 87

8630

CR37

R4

TR

LW

H

R5

TR

RW

H/B

K

R2

PB

DR

D/B

K

C1

3-1

C1

4-1

C1

2-1

C1

5-1

R1

PB

UR

D

8587a 87

8630

C6

-2

C6

-5

C6

-4

C6

-1

CR32

8587a 87

8630

BR

AK

ER

EL

EA

SE

VA

LV

E

TR

AV

EL

AL

AR

MO

PT

ION

MO

TO

RS

TR

OK

E

ST

EE

RL

EF

T

ST

EE

RR

IGH

T

C2

4-2

C2

5-2

C2

8-2

C2

6-2

DR

IVE

ED

CR

EV

ER

SE

DR

IVE

ED

CF

OR

WA

RD

GR

OU

ND

BR

N

BR

N

BK

RD

C3

7S

CW

BL

/BK

C3

6S

CC

BL

C2

4-1

C2

5-1

C2

9M

SR

D/W

H

C3

2B

RK

WH

/RD

C3

2TA

WH

/RD

C2

8-1

C2

6-1

H4

C6

-37

C6

-36

C6

-29

C6

-32

C6

-33

C3

1R

EV

WH

/BK

C3

0F

WD

WH

RD

BK

U4

C5

-20

C5

-21

TB5

C5

TR

RW

H/B

K

JIB

BO

OM

VA

LV

E GR

/BK

-44

J3 J1 J1

C1

29

DA

GR

/BK

C1

9JS

VG

R/W

H

C1

5P

LD

OR

/BK

C1

4P

LU

OR

C8

PB

RB

K/W

H

C7

PB

EB

K

P2

2L

SB

K

TB18

TB17

C4

B-5

C4

B-7

TB14

C4

B-6

TB15

C4

B-2

C4

B-3

TB7

TB8

C3

B-8

C3

B-7

C2

B-6

TB44

C1

7JU

GR

TS57

TS58

C4

P-7

C19JSV GR/WH

C4

P-5

C1

8JD

GR

/BK

C4

P-2

C4

P-3

TS59 TS63

C4

P-6

C2

P-6

C3

P-8

C3

P-7

C1

6P

DR

EO

R/R

D

C1

2S

BF

BL

/WH

C11

SB

DB

L/B

K

C3

PB

FR

D/W

H

C1

0S

BU

BL

C2

PB

DR

D/B

K

C1

PB

UR

D

LS1

C1

0-3

WH

-6

21

WH

-7

22

LS4

C11

-2

C6

-16

22BK

-4

C4

B-4

TB10

TB12

TB11

C3

B-1

0

C3

B-1

1

C11

-4

21

OR BK

-6

C6

-40 C11

-1

TB3

C3

B-1

2

C3

B-3

C3

B-2

C3

B-1

TB2

TB6

TB1

C3

B-5

14

BK

C2

B-2

C40LSS OR

TS60

U13 JOYSTICK CONTROL CARD

C2

P-2

C4

P-4

CELIFT/DRIVEOPTION

4 3

C3

P-1

0

C3

P-1

1

12

13

TS61 TS62

6R14

J2

C3

P-1

2

C3

P-2

C3

P-3

C3

P-1

8 7 6

C3

P-5

10

WH

CR13

TS7TS8

BRN

TS9

CR13

NC

TS13

6

P2

4F

SW

H

P2

6E

ST

PB

K

CR30NO

3 4

CR27NC

P2

4F

SW

H

BR

N

BR

N OR

YE

L

12

10 9 3

1 2 3 4 5

PW

R

GN

D

OU

T

JC1

SECONDARY BOOM UP/DOWN

P26ESTP BK

BR

N1

2

7 21

GN

D

RD

OR

BK

2

11 1

543 6 7

PW

R

XO

UT

YO

UT

PRIMARY BOOM UP/DOWN &TURNTABLE ROTATE

JC2

J1

C4

1R

PM

OR

/BK

J1

C3

7S

CW

BL

/BK

C2

9M

SR

D/W

H

C6

TR

FW

H/R

D

C3

6S

CC

BL

C3

1R

EV

WH

/BK

C3

2B

RK

WH

/RD

C3

0F

WD

WH

BA

TG

ND

C3

B-6

C1

B-1

0

C1

B-1

1

TB32

C1

B-3

C1

B-6

C1

B-5

C1

B-4

C7

B-3

C3

P-6

C1

P-1

0

C1

P-1

1

18

119 17

C1

P-3

C1

P-6

20

19

C1

P-5

C2

P-3

C1

P-4

C7

P-3

15

16 5

C28TTA RD/BK

RK

OU

T

L1

7

WH

BR

N

OR

BL

BL

14

5

13 4

GN

D21 3 4 5 6

PW

R

YO

UT

DR

IVE

MO

DE

CD

E3

BL

/RD

CD

E2

BL

/BK

6 7

16 8

CD

E1

BL

P24FS WH

P26ESTP BK

DRIVE & STEERING

JC3

TS15

15

TS14

WH

BK

RD

/WH

DO

WN

UP

JIB

BO

OM

RIG

HT

LE

FT

DR

IVE

EN

AB

LE

LE

FT

RIG

HT

BO

OM

EX

TE

ND

RE

TR

AC

T

PL

AT

FO

RM

LE

VE

LU

P

DO

WN

PL

AT

FO

RM

RO

TA

TE

RIG

HT

LE

FT

PL

AT

FO

RM

RO

TA

TE

DO

WN

UP

JIB

BO

OM

PL

AT

FO

RM

LE

VE

LU

P

DO

WN

BO

OM

EX

TE

ND

RE

TR

AC

T SE

CO

ND

AR

YB

OO

MU

P

DO

WN

PR

IMA

RY

BO

OM

UP

DO

WN

TU

RN

TA

BL

ER

OTA

TE

RIG

HT

LE

FT

D314

20R4

7.5


March 2006 Section 6 • Schematics

Ground Control Box Terminal Strip Wiring Diagram


Ground Control Box Terminal Strip Wiring Diagram

1

2

3

4

5

6

7

8



6 - 7 Z-51/30J Part No. 110284

REV A

NOTE: DASHED LINES INDICATE OPTION WIRES30

85

87

86

87A

30 = COMMON (12V DC IN)87A = NC87 = NO85 = COIL NEGATIVE86 = COIL POSITIVE

DC

PR

IMA

RY

BO

OM

UP

1 2 3 4 5 6 7 8 10

PR

IMA

RY

BO

OM

DO

WN

PR

IMA

RY

BO

OM

FU

NC

TIO

NC

ON

TR

OL

TU

RN

TA

BL

ER

OTA

TE

RIG

HT

TU

RN

TA

BL

ER

OTA

TE

FU

NC

TIO

NC

TR

L

PR

IMA

RY

BO

OM

EX

TE

ND

PR

IMA

RY

BO

OM

RE

TR

AC

T

SE

CO

ND

AR

YB

OO

MU

P

+1

2V

OLT

PO

WE

R

PL

AT

FO

RM

RO

TA

TE

RIG

HT

/JIB

DO

WN

PL

AT

FO

RM

RO

TA

TE

LE

FT

/JIB

UP

PL

AT

FO

RM

LE

VE

LD

OW

N

PL

AT

FO

RM

LE

VE

LU

P

SE

CO

ND

AR

YB

OO

MF

UN

CT

ION

CT

RL

SE

CO

ND

AR

YB

OO

MD

OW

N

2011 15

17

18

14

12

AU

XIL

IAR

YP

UM

P

OIL

TE

MP

ER

AT

UR

ES

WIT

CH

OIL

PR

ES

SU

RE

SW

ITC

H

KE

YS

WIT

CH

PO

WE

R

IGN

ITIO

NP

OW

ER

21

25

27

26

23

24

HIG

HR

PM

STA

RT

EN

GIN

E

BR

AK

E

39

35

38

33

34

32

ALT

ER

NA

TO

RP

UL

SE

PIC

KU

P4

1

44

42

BA

CR

32

#8

6R

D

C3

B-1

RD

C3

B-2

RD

/BK

C3

B-3

RD

/WH

CR

33

#8

6W

H/B

K

C3

B-5

WH

/BK

C3

B-6

WH

/RD

C6

-7B

K

C3

B-7

BK

C6

-8B

K/W

H

C3

B-8

BK

/WH

CR

37

#8

6B

L

C3

B-1

0B

L

C3

B-1

1B

L/B

K

CR

37

#3

0B

L/W

H

C3

B-1

2B

L/W

H

C6

-14

OR

C6

-15

OR

/BK

C6

-17

GR

C4

B-5

GR

C6

-18

GR

/BK

C4

B-6

GR

/BK

C1

B-1

RD

C7

B-4

RD

C5

-3W

H

C3

2-4

BK

C7

B-2

WH

C1

B-6

WH

/RD

C6

-32

WH

/RD

C1

B-7

BK

C5

-22

BK

/WH

C2

B-3

OR

/BK

C5

-2O

R/B

K

C2

B-6

GR

/BK

RD

-TS

61

RD

/BK

-TS

61

WH

/BK

-TS

62

BK

-TS

63

BK

/WH

-TS

63

BL

-TS

60

BL

/BK

-TS

60

BL

/WH

-TS

60

OR

-TS

59

OR

/BK

-TS

59

GR

-TS

57

GR

/BK

-TS

57

RD

-CB

1

BK

/RD

-TS

54

RD

/WH

-TS

61

WH

/RD

-TS

62

CR

33

#3

0W

H/R

D

C1B

C4B

C5

BATGND BRN

ENGINE HARNESS

FUNCTION HARNESS

WH

-23

B

RD

-27

B

GROUND CONTROL HARNESS

E.H.

F.H.

OR

/BK

-IS

2

TE

RM

INA

LB

AS

E(T

B)

1 2 3 4 5 6 7 8 10

11 15

17

18

14

12

20

24

26

27

25

23

21

38

39

34

35

32

33

44

42

41

GROUNDCONTROLHARNESS(TO SWITCHPANEL)

1 2 3 4 5 6 7 8 9 10

1 2 3 4 5 6 7 8 9 10

STA

RT

RE

LA

Y

TA

CH

OM

ET

ER

STA

RT

INP

UT

AU

XP

WR

UN

IT

GR

OU

ND

BA

TT

ER

Y

TO

KE

YS

W(D

IES

EL

ON

LY)

JU

MP

TO

7(G

AS

ON

LY)

IGN

OR

FU

EL

ON

TE

MP

OR

PR

ES

SF

AU

LT

13

47

10

92

12

/24

Vo

ltIG

NIT

ON

/STA

RT

MO

DU

LE

P/N

56

05

7

Ge

nie

Ind

ustr

ies

TO

RE

MO

VE

:

Pu

sh

ge

ntly

an

dlif

t

(SP

AR

E)

BK

-R1

OR

/BK

-41

A

BK

-33

B

RD

-27

B

BR

N-I

S5

WH

-23

B

WH

-R2

RD

-CR

1

CR

32

#3

0R

D/W

H

C4

B-2

OR

C4

B-3

OR

/BK

C6

-27

RD

WH

-IS

7

WH

-KS

RD

-TS

51

BK

-33

TS

52

OR

/BK

-41

A

WH

-IS

7

RD

-IS

4

OR

/BK

-IS

2

BK

-IS

1

WH

-IS

9

C5

-5B

K

C7B3 BRN

I.S.M. I.S.M. I.S.M. I.S.M.

C6

C4B

C5

C7B

WH

/RD

-AL

AR

MC

6-3

3

BK-ALARMBK-ALARMBK

C6

-33

WH

/RD

-AL

AR

M

C5

-19

BK

-AL

AR

M

WH

/RD

-32

A

BK

-AL

AR

M

BK

BK

WH/RD-ALARM

JIB

DO

WN

DE

SC

EN

TA

LA

RM

BR

NB

RN

GROUND BOLT

RD

-IS

6

RD

-IS

4

FUNCTIONS ENGINE19/18 CABLES

C5C6 C2B C1BC3BC4B

12V DC TO PLAT

C7B

CB

1P

OW

ER

OIL

TE

MP

ER

AT

UR

ES

WIT

CH

WH

/RD

-L4

3(-

)

C3BC3B C3B C3B C3B

C2B

C2

B-1

BL

/RD

(SP

AR

E)

(SP

AR

E)

(SP

AR

E)

BL

/RD

-TS

53

BL

/WH

-L2

(-)

OIL

PR

ES

SU

RE

SW

ITC

H

BK

/RD

-CR

4

CR2POWERRELAY

CR1IGNITIONSTARTRELAY

BR

N

WH-21C

RD

-24

B

BRN

C3B

+1

2V

OLT

TO

PL

AT

FO

RM

22

22

C7B-3

C5-18 BK/RD

WH

BK/RD-35C

C16DRE OR/RDC6-16 C4B-4

C1

9JS

VG

R/W

HT

S5

7C

4B

-7G

R/W

H

C3B-4

C4B C4BC4B

C36STCC BLC6-36 C1B-10

C37STC BL/BKC6-37 C1B-11

C30FWD WHC1B-4 C5-21

C31REV WH/BKC1B-5 C5-20

C28TTA RD/BK C5-24C1B-2C29MS RD/WHC6-29 C1B-3

C40LS1 ORC6-40 C2B-2

GL

OW

PL

UG

GL

OW

PL

UG

C5

-22

BK

/WH

C1

B-8

BK

/WH

WH

-25

D&

26

D

C1

B-9

BK

/RD

C6

-20

BK

BK

/WH

-TS

56

WH

/BK

-L4

2(-

)

C5-11 WH

BK

-KS

I

CR4HIGH RPMSOLENOIDRELAY

BRN

R4

3D

LIT

E1

RD

R4

3D

LIT

E2

RD

P20DLITE RD

C4

3D

LIT

EG

R

WH

-IS

10

C2

B-4

OR

/RD

C5

-14

WH

/RD

C5

-14

WH

/RD

C45 GEN GR/WH C5-12C2B-7

RD

-CR

2

RD

-CB

1

RD

-CB

2C

R2

3R

D

RD

-20

CD

RIV

EL

IGH

TS

WH

-HM

WH

-CR

2

WH

-IS

7

C5

-16

WH

/RD

C5

-16

WH

/RD

GR

/BK

-TS

58

BK

-AL

AR

M

RELAY HARNESS

I.S.M.

BRN

WH

-23

BW

H-I

S7

WH

-23

B

BK

-33

BB

K-I

S3

BK

-IS

3

CR23DRIVE LIGHTOPTION RELAY

F1910A FUSE

C6-13 BK

BK-22B

RD

CR32PRIMARYBOOMRELAY

CR33TURNTABLEROTATERELAY

CR37SECONDARYBOOMRELAY

BRN

BRN

BR

N

RD

/WH

-3B

RD

-1B

C6

-2R

D/B

K

C6

-1R

D

C6

-5W

H/B

K

C6

-10

BL

C6

-4W

H

C6

-11

BL

/BK

WH

/RD

-6B

WH

/BK

-5B

BL

/WH

-12

BBL-10BBR

N

13

4K

SP

OW

ER

13

4A

KS

PO

WE

R

RD

KS

1C

5-1

7W

H

C3

B-4

WH

C6

-34

RD

BRN GND

GR/BK H6

RD TS52

RD TS51

BK C7B-1

BK 22B

RD H6

U33

C3

2

13

45

67

81

2

RD

H6

H6

RD

C3

2-1

RD

13

4B

GR

/BK

C3

2-8

GR

/BK

L4

5

GR

/BK

C4

B-1

C6

-38

C6

-39

CR5HORNRELAY

C3

B-9

BK

/RD

13

4A

13

4

C6

-9B

K/R

D

C3

+

BR

NB

RN

C3

+

RD

H6

RD

C3

2-1

RD

13

4B

GR

/BK

C3

2-8

GR

/BK

L4

5

GR

/BK

C4

B-1

BRN GND

GR/BK H6

RD TS52

RD TS51

BK 22B

BK/WH C1B-12

RD H6

C3

2

13

45

67

81

2

U33W

H-2

5D

&2

6D

WH

-IS

10

WH

/RD

-L4

3-

WH

/BK

-L4

2-

1 2 3 4 5 6 7 8 9 10

1 2 3 4 5 6 7 8 9 10

STA

RT

RE

LA

Y

TA

CH

OM

ET

ER

STA

RT

INP

UT

AU

XP

WR

UN

IT

GR

OU

ND

BA

TT

ER

Y

TO

KE

YS

W(D

IES

EL

ON

LY)

JU

MP

TO

7(G

AS

ON

LY)

IGN

OR

FU

EL

ON

TE

MP

OR

PR

ES

SF

AU

LT

13

47

10

92

12

/24

Vo

ltIG

NIT

ON

/STA

RT

MO

DU

LE

P/N

56

05

7

Ge

nie

Ind

ustr

ies

TO

RE

MO

VE

:

Pu

sh

ge

ntly

an

dlif

t

BK

-R1

OR

/BK

-41

A

BK

-33

B

RD

-27

B

BR

N-I

S5

WH

-R2

RD

-CR

1

I.S.M. I.S.M. I.S.M. I.S.M.I.S.M.

BK

-IS

1

RD

-IS

6

RD

-27

B

OR

/BK

-41

A

RD

-IS

4

OR

/BK

-IS

2

BK

-33

BB

K-I

S3

BK

-IS

3

RD

-IS

4

BRN

BRN-GND

C6 C6

(SP

AR

E)

(SP

AR

E)

BK

-CR

5

Ground Control Box Switch Panel Wiring Diagram

1

2

3

4

5

6

7

8


Part No. 110284 Z-51/30J 6 - 8


REV A

P1 RED EMERGENCY STOP BUTTON

KS1 KEY SWITCH

TS51 AUXILIARY POWER TOGGLE SWITCH

TS52 ENGINE START TOGGLE SWITCH

TS54 FUNCTION ENABLE TOGGLE SWITCH

TS56 GLOW PLUG TOGGLE SWITCH (OPTION)

TS57 PLATFORM ROTATE TOGGLE SWITCH

TS58 JIB BOOM UP/DOWN TOGGLE SWITCH

TS59 PLATFORM LEVEL TOGGLE SWITCH

TS63 PRIMARY BOOM EXTEND/RETRACT TOGGLE SWITCH

TS61 PRIMARY BOOM UP/DOWN TOGGLE SWITCH

TS62 TURNTABLE ROTATE TOGGLE SWITCH

LABEL DESCRIPTION

TS60 SECONDARY BOOM UP/DOWN TOGGLE SWITCH

CB1 CIRCUIT BREAKER, ENGINE, 15A

CB2 CIRCUIT BREAKER, CONTROLS, 15A

HM HOUR METER

R4 SPEED LIMITING VARIABLE RESISTOR 20 OHMS

L42 OIL PRESSURE LED

CR1 IGNITION / START RELAY

CR2 IG ITION POWER RELAYN

CR4 HIGH IDLE RELAY

CR5 HORN RELAY

L43 OIL TEMPERATURE LED

HIGH IDLE RELAY

L45 PLATFORM OVERLOAD

HO

UR

ME

TE

R

BA

SE

BO

XH

AR

NE

SS

(TO

TE

RM

INA

LS

TR

IP)

BK

/RD

-35

A

RD

-20

B

RD

RD

C2

3-7

RD

RD

-20

A

BK

-33

A

RD R

DR

D

RD

RD

RD

RD

RD

RD

RD

RDRD

RDRDRD

RDRDRD

RD

RDRD

BRN

WH

-21

BR

N

RD

RD

RD

RD

GR

/BK

-18

GR

/BK

-18

A

RD

RD

GR

GR

GRGR

GR/BK

GR

-17

GR

-17

A

C1

9JS

VG

R/W

HC

4B

-7G

R/W

H

RD

GR/BK

RD

GR/BK

RD

GR

/BK

OR

-14

A

RD

OR

/BK

-15

A

RDRD

BL

/WH

-12

A

BL

/BK

-11

A

RD

BL

-10

A

RD

RD

RDRD

RD

WH

/RD

-6

WH

-4

WH

/BK

-5

WH

/RD

-6A

WH

-4A

WH

/BK

-5A

RDRD

RDRD

RDRD

RDRD RD

RD

RD

RD

RD

BK

/WH

-8A

BK

-7A

RD

-1A

RD

RD

/WH

-3A

RD

/BK

-2A

RD

BK/WH-8

BK-7

RD

RD

WH-23WH-23

WH

/RD

-26

A

WH

/BK

-25

A

WH-23

RD

13

4A

RD

-27

RD

-27

A

WH

TS

59

PL

AT

FO

RM

LE

VE

L

TS

57

PL

AT

FO

RM

RO

TA

TE

CB

2C

IRC

UIT

BR

EA

KE

RC

ON

TR

OL

S1

5A

CB

1C

IRC

UIT

BR

EA

KE

RE

NG

INE

15

A

TS

54

FU

NC

TIO

NE

NA

BL

E

TS

52

STA

RT

EN

GIN

E

TS

60

SE

CO

ND

AR

YB

OO

MU

P/D

OW

N

TS

58

JIB

BO

OM

UP

/DO

WN

TS

62

TU

RN

TA

BL

ER

OTA

TE

TS

63

PR

IMA

RY

BO

OM

EX

TE

ND

/R

ET

RA

CT

TS

61

PR

IMA

RY

BO

OM

UP

/DO

WN

L4

3O

ILT

EM

PL

ED

R4

FU

NC

TIO

NS

PE

ED

CO

NT

RO

LV

AR

IAB

LE

RE

SIS

TE

R,

20

TS

51

AU

XIL

IAR

YP

OW

ER

P1

EM

ER

GE

NC

YS

TO

PS

WIT

CH

L4

2O

ILP

RE

SS

UR

EL

ED

GR

/BK

-44

A

RD

RD

RD

1

2

NC

1

2

NC

-+

RD

-24

A

TS

56

GL

OW

PL

UG

(OP

TIO

N)

-+

BK

/WH

-34

A

RD

WH-CR4

BK-22A

WH

-23

A

GR

/BK

H6

RD

C3

2-6

RD

L4

5P

LA

TF

OR

MO

VE

RL

OA

DL

ED

(CE

mo

de

ls)

-+

KS

1

G-BOX

P-BOX

RD

14

6

DA

LE

RH

-25

25

W7

.5o

hm

1%

R1

4S

EC

ON

DA

RY

BO

OM

UP

/DO

WN

SP

EE

DR

ES

IST

OR

R14 SECONDARY BOOM SPEED RESISTOR 7.5 OHMS

Ground Control Box Switch Panel Wiring Diagram


Platform Control Box Wiring Diagram


Platform Control Box Wiring Diagram

1

2

3

4

5

6

7

8



6 - 9 Z-51/30J Part No. 110284

REV A

TILTALARM

WH

C1

9JS

V

RE

D-T

ILT

RE

D-T

ILT

C2

P-5

BR

NB

RN

C3P

JIB

F.S.

C7P

JIB BK JIB BK JIB

C3P

C7PBATGRN C7P-3

C1P

PLATFORM CONTROLHARNESS

(TO SWITCH PANEL)

H1

12V DC BATTERYSUPPY

C1

P(G

Y)

19/18 CONTROL CABLE

C7P C9

FOOT SWITCH

JIB

9

1

J1

JC

3-3

OR

DR

EA

BL

/WH

JC

3-2

BR

N

DR

EB

BL

/BK

C1

3L

ED

BL

/RD

C2

9M

SR

D/W

H

JC

2-5

BK

JC

1-5

YE

L

JC

2-3

OR

JC

3-4

BL

*

JC

2-2

BR

N

JC

3-5

WH

JC

1-3

OR

JC

2-4

RD

JC

1-2

BR

N

J2

1

11

1

P2

4F

SW

H

P24FS WH

P2

6E

ST

PB

K

J3

3

C2

P(B

K)

C3

P(G

R)

C4

P(B

R)

C28TTA RD/BK C1P-2

BR

N

C2

9M

SR

D/W

HC

1P

-3

C3

2B

RK

WH

/RD

C1

P-6

C5

TR

RW

H/B

KC

3P

-5

C3

6S

TC

CB

KC

1P

-10

C3

PB

FR

D/W

HC

3P

-3

C3

7S

TC

BL

/BK

C1

P-11

C2

PB

DR

D/B

KC

3P

-2

C3

1R

EV

WH

/BK

C1

P-5

C1

PB

UR

DC

3P

-1

C3

0F

WD

WH

C1

P-4

C4

1R

PM

OR

/BK

C2

P-3

C1

2S

BF

BL

/WH

C3

P-1

2

C4

0L

SS

OR

C2

P-2

C11

SB

DB

L/B

KC

3P

-11

C1

6D

RE

OR

/RD

C4

P-4

C1

0S

BU

BL

C3

P-1

0

C6

TR

FW

H/R

DC

3P

-6

C2

8T

TA

RD

/BK

H1

C2P

C2

7A

UX

RD

C1

P-1

C3

3S

TR

BK

C1

P-7

C3

5H

SB

K/R

DC

1P

-9

C4P

C4

4JD

AL

AR

MG

R/B

KC

2P

-6

C4

5G

EN

GR

/WH

C2

P-7

P2

4F

SW

HC

9-2

P2

5F

SR

DC

9-3

P2

6B

AT

BK

C9

-1

C7

PB

EB

KC

3P

-7

C8

PB

RB

K/W

HC

3P

-8

C9

HR

NB

K/R

DC

3P

-9

C1

4P

LU

OR

C4

P-2

C1

5P

LD

OR

/BK

C4

P-3

C1

7JU

GR

C4

P-5

C1

8JD

GR

/BK

C4

P-6

C1

9JS

VG

R/W

HC

4P

-7

P2

2B

AT

BK

C7

P-1

P2

3S

WB

AT

WH

C7

P-2

U13ALC-500

CR30 CR27

P2

4F

SW

HC

9P

-2

C4

0L

SS

OR

C2

P-2

C3

2B

RK

WH

/RD

C1

P-6

C3

2B

RK

WH

/RD

J2

-19

C4

0L

SS

OR

J2

-4

CE LIFT/DRIVE OPTION

TS

7

CW

LIT

ER

DC

2P

-11

CW

LIT

ER

DC

2P

-12

CD

LIT

EG

R

WLITE BRN C2P-10

WLITE BRN C2P-9

BRN

BRNBRN

BR

N

Y

RD

-P2

RD

-H1

RE

D-

LS

18

LS18CE OPTION

ONLYOPT.

H1

J3

J2

J1

U13

C1P - C4P

C7P

ALC-500 CONTROL BOARD

CONTROL BOARD POWER CONNECTOR

CONTROL BOARD OUTPUT CONNECTOR

CONTROL BOARD INPUT CONNECTOR

TILT ALARM

12V DC PLATFORM POWER CONNECTOR

48 PIN CONNECTOR BLOCK

DESCRIPTIONITEM

FOOT SWITCH CONNECTORC9

CR27 CONTROL RELAY (CE OPTION)

CR30 CONTROL RELAY (CE OPTION)

LS18 LOAD SENSE LIMIT SWITCH

RD

/BK

-L4

8(-)

GR

/BK

C4

P-1

GR

/BK

-L4

TS

1W

H

Platform Control Box Switch Panel Wiring Diagram

1

2

3

4

5

6

7

8


Part No. 110284 Z-51/30J 6 - 10


REV A

P2EMERGENCY

STOPTS4HIGH/LOW

RPM

TS2ENGINESTART

TS15DRIVE

ENABLE

L1DRIVE

ENABLELED

DRIVESPEED

TS14HIGH/LOW(2WD/4WD)

TS13PRIMARY BOOM

EXTEND/RETRACT

TS8JIB BOOM

TS7PLATFORMROTATE

TS9PLATFORM

LEVEL

P3HORN TS1

AUXILIARYPUMP

C9

HR

NB

K/R

DC

3P

-9

RD

C1

4P

LU

OR

C4

P-2

C1

5P

LD

OR

/BK

C4

P-3

C1

8P

RR

GR

/BK

C4

P-6

C1

9JS

VG

R/W

HC

4P

-7

C1

7P

RL

GR

C4

P-5

C2

7A

UX

RD

C1

P-1

P2

5F

SR

DC

9-3

C3

3S

TR

BK

C1

P-7

BK

C9

P-1

WH

C7

P-2

RD

WH

GR/BK

RD

GR

RD

WH-24

RD RD RD

TS47GENERATOR

(OPTION)

C8

PB

RB

K/W

HC

3P

-8

BL

/RD

-DE

3J1

-16

C4

5G

EN

GR

/WH

C2

P-7

RD

BL

-DE

1J1

-6

GR/WH

RD

C7

PB

EB

KC

3P

-7

GR

/WH

RD

C2

9M

SR

D/W

HJ1

-8

TS6GLOWPLUG

(OPTION)

C3

4S

AB

K/W

HC

1P

-8WHWH

White wire replacedby CR27 and CR30on CE models

GR

/BK

-44

C2

P-6

RD

NOTE:DASHED LINES INDICATE OPTION WIRES

C3

5R

PM

BK

/RD

C1

P-9

2

1

NC

2

1

NC

BL

/BK

-DE

2J1

-7

4

2

1

3

5

6

7

OR

J1

-13

BR

NJ1

-14

WH

J1

-4

BL

J1

-5

OR

J1

-9

BR

NJ1

-10

YE

LJ1

-3

OR

J1

-11

BR

NJ1

-12

BK

J1

-2

RD

J1

-1

JC3DRIVE

FORWARD/REVERSE& STEER

LEFT/RIGHT

JC1SECONDARY BOOM

UP/DOWN

CR13JIB BOOMRELAY

WH

-JIB

C1

9JS

VG

R/W

H

P2

4F

SW

H

BR

N

WH

-JIB

P2

4F

SW

HC

9-2

RD

BK

BK

BK

BK

BK

BK

34 NO

PLATFORM CONTROLHARNESS

(TO CONTROL BOX)

BL

J1

-5

+

TS48DRIVE LIGHTS/WORK LIGHTS

(OPTION)

RD

RD

PD

LIT

ER

D

CW

LIT

ER

DC

2P

-11

CW

LIT

ER

DC

2P

-12

F18FUSE 10A

C3

P-4

DL

ITE

WH

2

1

3

5

4

6

7

2

1

3

5

4

6

7JC2

PRIMARY BOOM UP/DOWN& TURNTABLE ROTATE

LEFT/RIGHT

GE

NE

RA

TO

RO

PT

ION

2

1

NC

BK

J3

-3

BK

C7

P-1

RD

LS

18

L48TILT ALARM LED

+

L4PLATFORMOVERLOAD

LED

+

GR

/BK

H1

(D3

9)

BK

RD

RD

RD

RD

RD

/BK

H1

Platform Control Box Switch Panel Wiring Diagram


1

2

3

4

5

6

7

8


Hydraulic Schematic


Part No. 110284 Z-51/30J 6 - 11

REV A

OSC

2.0GPM

0.1GPM

PR2 PR1

PR1PR2

L R

RE

FUNCTION MANIFOLD

JIB SELECT

MANIFOLD

LEFTREAR

RIGHTREAR

LEFTFRONT

RIGHTFRONT

TRACTION MANIFOLDRB

RFB

RFA

LFB

LFA

TEST

T2

T

67% 33%

0.052 inch

250PSI

0.030 inch

50%

50%

RA

LB

LA

2SPD

BRK

50%

50%

2.0

GP

M

1.0

GP

M

0.025 inch

2100 PSISET @2.5 GPMAT TEST

0.046 inch

2500PSI SET.6 GPM@ TEST2

3200 PSISET @ 7 GPM@ TEST1

0.4GPM

1.5GPM

T1

PRESS

102PSI

TEST1

3200 PSI

25 PSI

TEST 2

T

AUX P2P1S2S1SW2SW1PL2PL1PR2PR1 RETEXT

V1V2

J1 J2

3500 PSI

51PSI

315 PSI

V1

0.030 inch

V2

PRIMARY BOOMLIFT CYLINDER

TURNTABLE ROTATE

SLAVE

PLATFORM ROTATE

0.4 GPM

MASTER

0.4 GPM

JIB BOOM

STEER CYLINDERS

OSCILLATE AXLE CYLINDERS

APU

TANK

7

PUMP

FUNCTION

DRIVE PUMP

M

E

PRIMARY BOOMEXTENSION CYLINDER

ST1 ST2

RATIO PRESSURE

1000 PSI

3300 PSI

3800 PSI

3:1

3626 PSI

3:1

3:1

4.25:1

4.5:1 3500 PSI

3:1 3500 PSI

3:1 1500 PSI

COUNTERBALANCE VALVES

AB

PLATFORM LEVEL

MEDIUMPRESSURE

FILTER

7

5.0:1 1000 PSI

1.5:1 3800 PSI

E R

E R

E R

E R E R

B

A

SECONDARY BOOMELEVATE CYLINDERS

3:1 3000 PSI

0.1 GPM

0.60 GPM

HIGHPRESSURE

FILTER

BZ

BX

CA

CB

CC

CD

CE

BY

BW

BU

BS BT

CFBV

BO

BP

BQ BRBN

BM

BLBK

BJ

BI

BH

BDBC

CG

BEBB

BF

BG

BA

AJ AK

Q

P

CD

E F

H I

J L

M N

C D

O

R

W

T

V

Y

X

AC

AD

ABAI

AH

AA

Z

U

S

AF AG

AE

C D

G

E F

H I

J L

K

M

NO

P Q

AKAJ

3.2 / 2.4 GPM 4.1 (regen) / 2.1 GPM

LEFT RIGHT

A

B

P

T

E R E R

B

A

A

BA

B

A

B

Hydraulic Schematic


Genie North America

Genie Australia Pty Ltd.

Genie China

Genie Malaysia

Genie Japan

Genie Korea

Genie Africa

Genie Latin America

Phone

Toll Free

Fax

Phone +

Fax +

Phone +

Fax +

Phone +

Fax +

Phone +

Fax +

Phone +

Fax +

Phone +

Fax +

Phone +

Fax +

425.881.1800

USA and Canada

800.536.1800

425.883.3475

61 7 3375 1660

61 7 3375 1002

86 21 53852570

86 21 53852569

60 4 228 1235

60 4 226 6872

81 3 3453 6082

81 3 3453 6083

82 2 558 7267

82 2 558 3910

27 11 455 0373

27 11 455 0355

55 11 4055 2499

55 11 4043 1661 Dis

trib

ute

dB

y:

California Proposition 65

WARNINGThe exhaust from this product contains chemicals

known to the State of California to cause cancer,

birth defects or other reproductive harm.

Genie Holland

Genie Scandinavia

Genie France

Genie Iberica

Genie Germany

Genie U.K.

Genie Mexico City

Phone +

Fax +

Phone +

Fax +

Phone +

Fax +

Phone +

Fax +

Phone +

Fax +

Phone +

Fax +

Phone +

Fax +

31 70 51 78836

31 70 51 13993

46 31 3409612

33 (0)2 37 26 09 99

33 (0)2 37 26 09 98

34 93 579 5042

34 93 579 5059

49 (0)4202 88520

49 (0)4202 8852-20

44 (0)1476 584333

44 (0)1476 584334

52 55 5666 5242

52 55 5666 3241

46 31 3409613

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ServiceManual - Ramirenttuotteet.ramirent.fi/sites/tuotteet.ramirent/files/product... · ServiceManual Refertoinsidecoverforadditionalserialnumberinformation ICPower (fromserialnumber100)