Genie Z-60/34 Manuale utente

Part No. 75861

November 2003

Rev A

Service Manual

Refer to inside cover for serial number information

Genie Z-60/34 Part No. 75861

November 2003

Introduction

Important

Read, understand and obey the safety rules and

operating instructions in the Genie Z-60/34

Operator's Manual before attempting any

maintenance or repair procedure.

This manual provides detailed scheduled

maintenance information for the machine owner

and user. It also provides troubleshooting fault

codes and repair procedures for qualified service

professionals.

Basic mechanical, hydraulic and electrical skills

are required to perform most procedures.

However, several procedures require specialized

skills, tools, lifting equipment and a suitable

workshop. In these instances, we strongly

recommend that maintenance and repair be

performed at an authorized Genie dealer service

center.

Technical Publications

Genie Industries has endeavored to deliver the

highest degree of accuracy possible. However,

continuous improvement of our products is a Genie

policy. Therefore, product specifications are

subject to change without notice.

Readers are encouraged to notify Genie of errors

and send in suggestions for improvement. All

communications will be carefully considered for

future printings of this and all other manuals.

http://www.genielift.com

e-mail:[email protected]

Serial Number Information

Genie Industries offers the following Service

Manuals for these models:

Title Part No.

Z-60/34 Service Manual

(before serial number 4000) ................................. 52856

75861 Rev A November 2003

"Genie" and "Z" are registered trademarks of

Genie Industries in the USA and many other

countries.

Printed on recycled paper

Printed in U.S.A.

Part No. 75861 Genie Z-60/34

November 2003

iii

Safety Rules

Section 1 • Safety Rules

Danger

Failure to obey the instructions and safety rules in

this manual, and the Genie Z-60/34

Operator's Manual will result in death or serious

injury.

Many of the hazards identified in the operator's

manual are also safety hazards when maintenance

and repair procedures are performed.

Do Not Perform Maintenance

Unless:

You are trained and qualified to perform

maintenance on this machine.

You read, understand and obey:

- manufacturer’s instructions and safety rules

- employer’s safety rules and worksite

regulations

- applicable governmental regulations

You have the appropriate tools, lifting

equipment and a suitable workshop.

Genie Z-60/34 Part No. 75861

November 2003

SAFETY RULES

Section 1 •Safety Rules

Personal Safety

Any person working on or around a machine must

be aware of all known safety hazards. Personal

safety and the continued safe operation of the

machine should be your top priority.

Read each procedure thoroughly. This

manual and the decals on the machine

use signal words to identify the following:

Safety alert symbol—used to alert

personnel to potential personal

injury hazards. Obey all safety

messages that follow this symbol

to avoid possible injury or death.

Red—used to indicate the

presence of an imminently

hazardous situation which, if not

avoided, will result in death or

serious injury.

Orange—used to indicate the

presence of a potentially

hazardous situation which, if not

avoided, could result in death or

serious injury.

Yellow with safety alert symbol—

used to indicate the presence of a

potentially hazardous situation

which, if not avoided, may result in

minor or moderate injury.

Yellow without safety alert

symbol—used to indicate the

presence of a potentially

hazardous situation which, if not

avoided, may result in property

damage.

Green—used to indicate operation

or maintenance information.

Workplace Safety

Be sure to wear protective eye wear and

other protective clothing if the situation

warrants it.

Be aware of potential crushing hazards

such as moving parts, free swinging or

unsecured components when lifting or

placing loads. Always wear approved steel-toed

shoes.

Be sure to keep sparks, flames and

lighted tobacco away from flammable

and combustible materials like battery

gases and engine fuels. Always have an approved

fire extinguisher within easy reach.

Be sure that all tools and working areas

are properly maintained and ready for

use. Keep work surfaces clean and free

of debris that could get into machine components

and cause damage.

Be sure any forklift, overhead crane or

other lifting or supporting device is fully

capable of supporting and stabilizing the

weight to be lifted. Use only chains or straps that

are in good condition and of ample capacity.

Be sure that fasteners intended for one

time use (i.e., cotter pins and self-locking

nuts) are not reused. These components

may fail if they are used a second time.

Be sure to properly dispose of old oil or

other fluids. Use an approved container.

Please be environmentally safe.

Be sure that your workshop or work area

is properly ventilated and well lit.

Part No. 75861 Genie Z-60/34

November 2003

Table of Contents

Introduction

ImportantInformation ..................................................................................................ii

Section 1 Safety Rules

General Safety Rules ................................................................................................. iii

Section 2 Specifications - Rev A

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

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

Manifold Component Specifications ...................................................................... 2 - 4

Ford LRG-425 EFI Engine Specifications.............................................................. 2 - 5

Deutz F3L-1011F Engine Specifications................................................................ 2 - 7

Machine Torque Specifications.............................................................................. 2 - 8

Hydraulic Hose and Fitting Torque Specifications ................................................. 2 - 9

Section 3 Scheduled Maintenance Procedures

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

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

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

Checklist A Procedures - Rev A

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

A-2 Perform Engine Maintenance - Deutz Models.............................................. 3 - 7

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

A-4 Check for Fuel Leaks................................................................................... 3 - 8

A-5 Perform Function Tests ............................................................................... 3 - 9

Genie Z-60/34 Part No. 75861

November 2003

TABLE OF CONTENTS

Section 3 Scheduled Maintenance Procedures, continued

A-6 Perform Drive Hub Maintenance.................................................................. 3 - 9

A-7 Check the High Pressure Hydraulic Filter Condition Indicator.................... 3 - 10

A-8 Test the Oscillate Axle (if equipped) .......................................................... 3 - 10

A-9 Perform 30 Day Service............................................................................. 3 - 11

A-10 Perform Engine Maintenance - Ford Models.............................................. 3 - 11

A-11 Replace the Fuel Filters - Ford Models ...................................................... 3 - 12

A-12 Inspect the Fuel Filter/Water Separator - Deutz Models ............................ 3 - 13

A-13 Grease the Turntable Rotation Bearing and Rotate Gear .......................... 3 - 15

A-14 Replace Drive Hub Oil ............................................................................... 3 - 15

A-15 Perform Engine Maintenance - Ford Models.............................................. 3 - 16

Checklist B Procedures - Rev A

B-1 Inspect the Battery..................................................................................... 3 - 17

B-2 Inspect the Electrical Wiring....................................................................... 3 - 18

B-3 Test the Key Switch ................................................................................... 3 - 19

B-4 Perform Engine Maintenance - Ford Models.............................................. 3 - 19

B-5 Check the Exhaust System........................................................................ 3 - 20

B-6 Check the Oil Cooler and Cooling Fins - Deutz Models ............................. 3 - 21

B-7 Check the Lug Nut Torque (including the tires and wheels) ....................... 3 - 22

B-8 Confirm the Proper Brake Configuration .................................................... 3 - 23

B-9 Check the Oil Level in the Drive Hubs ....................................................... 3 - 23

B-10 Check and Adjust the Engine RPM............................................................ 3 - 24

Part No. 75861 Genie Z-60/34

November 2003

TABLE OF CONTENTS

vii

Section 3 Scheduled Maintenance Procedures,continued

B-11 Test the Ground Control Override.............................................................. 3 - 25

B-12 Check the Directional Valve Linkage ......................................................... 3 - 26

B-13 Test the Platform Self-leveling ................................................................... 3 - 26

B-14 Test the Engine Idle Select ........................................................................ 3 - 27

B-15 Test the Fuel Select Operation - Ford Models ........................................... 3 - 28

B-16 Test the Drive Brakes ................................................................................ 3 - 29

B-17 Test the Drive Speed - Stowed Position .................................................... 3 - 30

B-18 Test the Drive Speed - Raised or Extended Position ................................. 3 - 30

B-19 Test the Alarm Package (if equipped)........................................................ 3 - 31

B-20 Perform Hydraulic Oil Analysis .................................................................. 3 - 32

B-21 Replace the Hydraulic Filters ..................................................................... 3 - 33

B-22 Perform Engine Maintenance - Deutz Models............................................ 3 - 34

B-23 Perform Engine Maintenance - Ford Models.............................................. 3 - 35

Checklist C Procedures - Rev A

C-1 Perform Engine Maintenance - Deutz Models............................................ 3 - 36

C-2 Grease the Platform Overload Mechanism (if equipped) ........................... 3 - 36

C-3 Test the Platform Overload Mechanism (if equipped) ................................ 3 - 37

C-4 Perform Engine Maintenance - Ford Models.............................................. 3 - 39

Genie Z-60/34 Part No. 75861

November 2003

Section 3 Scheduled Maintenance Procedures,continued

Checklist D Procedures - Rev A

D-1 Check the Boom Wear Pads ..................................................................... 3 - 40

D-2 Check the Turntable Rotation Bearing Bolts .............................................. 3 - 40

D-3 Check the Free-wheel Configuration.......................................................... 3 - 41

D-4 Check and Adjust the Air/LPG Mixture - Ford Models................................ 3 - 43

D-5 Perform Engine Maintenance - Deutz Models............................................ 3 - 44

D-6 Calibrate the Platform Overload System (if equipped) ............................... 3 - 44

D-7 Replace the Drive Hub Oil ......................................................................... 3 - 46

Checklist E Procedures - Rev A

E-1 Test or Replace the Hydraulic Oil .............................................................. 3 - 47

E-2 Change the Fuel Hoses - Ford Models ...................................................... 3 - 48

E-3 Perform Engine Maintenance - Deutz Models............................................ 3 - 50

E-4 Grease the Steer Axle Wheel Bearings, 2WD Models ............................... 3 - 50

Section 4 Repair Procedures

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

Platform Controls

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

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

Platform Components

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

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

Jib Boom Components

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

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

3-3 Jib Boom / Platform Rotate Manifold Components

(before serial number 4461........................................................................ 4 - 13

3-4 Jib Boom / Platform Rotate Manifold Components

(after serial number 4460).......................................................................... 4 - 14

viii

TABLE OF CONTENTS

Part No. 75861 Genie Z-60/34

November 2003

Section 4 Repair Procedures, continued

Primary Boom Components

4-1 Cable Track ............................................................................................... 4 - 15

4-2 Primary Boom............................................................................................ 4 - 17

4-3 Primary Boom Lift Cylinder ........................................................................ 4 - 20

4-4 Primary Boom Extension Cylinder ............................................................. 4 - 21

4-5 Platform Leveling Master Cylinder ............................................................. 4 - 23

Secondary Boom Components

5-1 Secondary Boom ....................................................................................... 4 - 25

5-2 Secondary Boom Lift Cylinders.................................................................. 4 - 30

Engines

6-1 RPM Adjustment........................................................................................ 4 - 32

6-2 Flex Plate................................................................................................... 4 - 32

6-3 Engine Fault Codes - Ford Models ............................................................ 4 - 33

Hydraulic Pumps

7-1 Lift/Steer Pump.......................................................................................... 4 - 35

7-2 Drive Pump................................................................................................ 4 - 35

TABLE OF CONTENTS

Genie Z-60/34 Part No. 75861

November 2003

TABLE OF CONTENTS

Section 4 Repair Procedures, continued

Manifolds

8-1 Function Manifold Components - View 1

(before serial number 4461)....................................................................... 4 - 37

8-2 Function Manifold Components - View 2

(before serial number 4461)....................................................................... 4 - 39

8-3 Function Manifold Components - (after serial number 4460) ..................... 4 - 41

8-4 Valve Adjustments - Function Manifold...................................................... 4 - 45

8-5 Turntable Rotation Manifold Components .................................................. 4 - 47

8-6 Brake/Two-Speed Manifold Components

(before serial number 4461)....................................................................... 4 - 48

8-7 Brake/Two-Speed Manifold Components

(after serial number 4460).......................................................................... 4 - 49

8-8 Directional Valve Manifold Components .................................................... 4 - 50

8-9 2WD Drive Manifold Components.............................................................. 4 - 52

8-10 Valve Adjustments, 2WD Drive Manifold ................................................... 4 - 54

8-11 4WD Drive Manifold Components.............................................................. 4 - 55

8-12 Valve Adjustments, 4WD Drive Manifold ................................................... 4 - 57

8-13 Valve Coils, How to Test a Coil.................................................................. 4 - 58

Turntable Rotation Components

9-1 Turntable Rotation Assembly..................................................................... 4 - 60

Axle Components

10-1 Hub and Bearings, 2WD Models................................................................ 4 - 61

10-2 Oscillate Axle Cylinders ............................................................................. 4 - 62

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