Table of Contents

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Service Manual
Part No. 75861
November 2003
Refer to inside cover for serial number information
Rev A

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Table of Contents
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Summary of Contents for Genie Z-60/34

  • Page 1 Service Manual Part No. 75861 November 2003 Refer to inside cover for serial number information Rev A...
  • Page 2 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.
  • Page 3 Section 1 • Safety Rules 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.
  • Page 4 Be sure that your workshop or work area hazardous situation which, if not is properly ventilated and well lit. avoided, may result in property damage. Green—used to indicate operation or maintenance information. Genie Z-60/34 Part No. 75861...
  • Page 5: Table Of Contents

    Perform Engine Maintenance - Deutz Models ..........3 - 7 Perform Engine Maintenance - Ford Models ..........3 - 8 Check for Fuel Leaks ................... 3 - 8 Perform Function Tests ................3 - 9 Part No. 75861 Genie Z-60/34...
  • Page 6 Check the Lug Nut Torque (including the tires and wheels) ....... 3 - 22 Confirm the Proper Brake Configuration ............ 3 - 23 Check the Oil Level in the Drive Hubs ............3 - 23 B-10 Check and Adjust the Engine RPM ............3 - 24 Genie Z-60/34 Part No. 75861...
  • Page 7 Perform Engine Maintenance - Deutz Models ..........3 - 36 Grease the Platform Overload Mechanism (if equipped) ......3 - 36 Test the Platform Overload Mechanism (if equipped) ........ 3 - 37 Perform Engine Maintenance - Ford Models ..........3 - 39 Part No. 75861 Genie Z-60/34...
  • Page 8 Jib Boom Lift Cylinder ................4 - 11 Jib Boom / Platform Rotate Manifold Components (before serial number 4461 ................ 4 - 13 Jib Boom / Platform Rotate Manifold Components (after serial number 4460) ................4 - 14 Genie Z-60/34 Part No. 75861 viii...
  • Page 9 RPM Adjustment ..................4 - 32 Flex Plate ....................4 - 32 Engine Fault Codes - Ford Models ............4 - 33 Hydraulic Pumps Lift/Steer Pump ..................4 - 35 Drive Pump ....................4 - 35 Part No. 75861 Genie Z-60/34...
  • Page 10 8-13 Valve Coils, How to Test a Coil ..............4 - 58 Turntable Rotation Components Turntable Rotation Assembly ..............4 - 60 Axle Components 10-1 Hub and Bearings, 2WD Models ..............4 - 61 10-2 Oscillate Axle Cylinders ................4 - 62 Genie Z-60/34 Part No. 75861...
  • Page 11 Hydraulic Schematic, 2WD Models (before sn 4461) .......... 6 - 13 Hydraulic Schematic, 4WD Models (before sn 4461) .......... 6 - 14 Hydraulic Schematic, 2WD Models (after sn 4460) ..........6 - 15 Hydraulic Schematic, 4WD Models (after sn 4460) ..........6 - 16 Part No. 75861 Genie Z-60/34...
  • Page 12 November 2003 This page intentionally left blank. Genie Z-60/34 Part No. 75861...
  • Page 13: Machine Specifications

    Lug nut torque, lubricated 170 ft-lbs 230.4 Nm Tire ply rating Tire contact area 79 sq in 200.7 sq cm Overall tire diameter 41 in 104 cm Tire pressure (air-filled tires) 60 psi 4.13 bar Part No. 75861 Genie Z-60/34 2 - 1...
  • Page 14 8 to 12 seconds Platform level up 30 to 40 seconds Platform level down 15 to 25 seconds Continuous improvement of our products is a Genie policy. Product specifications are subject to change without notice. 2 - 2 Genie Z-60/34 Part No. 75861...
  • Page 15: Hydraulic Specifications

    Flow rate @ 2500 rpm mixable with Shell Donax TG (Dexron III) oils. 30.1 gpm Genie specifications require hydraulic oils which are 113.9 L/min designed to give maximum protection to hydraulic systems, have the ability to perform over a wide...
  • Page 16 65.5 bar bypass pressure 3.5 bar Jib boom / platform rotate 1.5 gpm Hydraulic tank circuit 10 micron with flow regulator 5. 7 L/min return line filter 25 psi / 1.7 bar bypass 2 - 4 Genie Z-60/34 Part No. 75861...
  • Page 17: Manifold Component Specifications

    Proportional solenoid valve, 12V DC 4 to 5Ω (schematic items AB, AC and AG) (before serial number 4461) Proportional solenoid valve, 12V DC 3 to 4Ω (schematic items HM, HO and HR) (after serial number 4460) Part No. 75861 Genie Z-60/34 2 - 5...
  • Page 18: Ford Lrg-425 Efi Engine Specifications

    18 Newtons Bolt torque 45 to 84 in-lbs through brush 5.08 to 9.5 Nm Brush mounting 15 to 20 ft-lbs bolt torque 20 to 27 Nm Maximum commutator 0.005 in run-out 0.127 mm 2 - 6 Genie Z-60/34 Part No. 75861...
  • Page 19 5 to 10 ft-lbs 7 to 14 Nm Engine coolant Capacity quarts 10.9 liters Coolant temperature switch Torque 8-18 ft-lbs 11-24 Nm Temperature switch point 230° F 112° C Alternator Output 95A, 14.5V DC Part No. 75861 Genie Z-60/34 2 - 7...
  • Page 20 Temperature below 60°F / 15.5°C (synthetic) 5W-30 -10°F to 90°F / -23°C to 32°C 10W-40 Temperature above -4°F / -34°C 15W-40 Engine oil should have properties of API classification CC/SE, CD/SE, CC/SF or CD/SF grades. 2 - 8 Genie Z-60/34 Part No. 75861...
  • Page 21: Machine Torque Specifications

    170 ft-lbs 231 Nm Drive motor mounting bolts, dry 25 ft-lbs 34 Nm Drive motor mounting bolts, lubricated 18 ft-lbs 25 Nm Turntable bearing Turntable bearing mounting bolts 210 ft-lbs 285 Nm Part No. 75861 Genie Z-60/34 2 - 9...
  • Page 22: Hydraulic Hose And Fitting Torque Specifications

    Your machine is equipped with Parker Seal-Lok ® The O-ring cannot be re-used if the fitting or fittings and hose ends. Genie specifications require hose end has been tightened beyond finger that fittings and hose ends be torqued to tight.
  • Page 23: Scheduled Maintenance Procedures

    · The red Emergency Stop button in the performing a series of steps. postion at both ground and platform controls · Wheels chocked · All external AC power supply disconnected from the machine Part No. 75861 Genie Z-60/34 3 - 1...
  • Page 24 Maintenance Inspection Report The maintenance inspection report contains checklists for each type of scheduled inspection. Make copies of the Maintenance Inspection Report to use for each inspection. Store completed forms for three years. 3 - 2 Genie Z-60/34 Part No. 75861...
  • Page 25: Pre-Delivery Preparation

    The Maltings, Wharf Road PO Box 97030 Grantham, Lincolnshire Redmond, WA 98073-9730 NG31- 6BH England (425) 881-1800 (44) 1476-584333 Part No. 75861 Genie Z-60/34 3 - 3 Copyright © 2002 by Genie Industries. Genie® is a registered trademark of Genie Industries. Rev A...
  • Page 26 Section 3 • Scheduled Maintenance Procedures November 2003 This page intentionally left blank. 3 - 4 Genie Z-60/34 Part No. 75861...
  • Page 27: Maintenance Inspection Report

    After repair, place a check in the “R” box. Legend Y = yes, acceptable N = no, remove from service R = repaired Comments Part No. 75861 Genie Z-60/34 3 - 5...
  • Page 28 After repair, place a check in the “R” box. Perform after 1500 hours: D-7 Drive hub oil Legend Y = yes, acceptable N = no, remove from service R = repaired Comments 3 - 6 Genie Z-60/34 Part No. 75861...
  • Page 29: Checklist A Procedures - Rev A

    Failure Complete information to perform this procedure is to perform the maintenance procedures can lead to available in the Genie Z-60/34 Operator's Manual poor engine performance and component damage. on your machine. Required maintenance procedures and additional...
  • Page 30: Perform Engine Maintenance - Ford Models

    (Ford part number FPP 194-302). 2 Perform a visual inspection around the following areas. Ford LRG-425 EFI Operator Handbook Ford Models: Genie part number 77831 · LPG tank, hoses and fittings, solenoid shutoff valve, LPG regulator and throttle body. To access the engine: An LPG detector may be necessary to locate LPG leaks.
  • Page 31: Perform Function Tests

    10 hours of full load operation. Complete information to perform this procedure is available in the Genie Z-60/34 Operator's Manual Required maintenance procedures and additional on your machine. drive hub information is available in the Rexroth Operation Maintenance Service Manual (Rexroth part number GFT 7 T2 4030).
  • Page 32: Check The High Pressure Hydraulic Filter Condition Indicator

    Filters. Directional Valve Linkage. 4 Drive both steer tires up onto a 6 inch / 15.2 cm block or curb. Result: The non-steer tires should stay in firm contact with the ground. 3 - 10 Genie Z-60/34 Part No. 75861...
  • Page 33: Perform 30 Day Service

    • B-21 Replace the Hydraulic Filters • C-1 Perform Engine Maintenance - Ford LRG-425 EFI Operator Handbook Deutz Models Genie part number 77831 • D-2 Check the Turnable Rotation Bearing Bolts To access the engine: 1 Remove the two engine pivot plate retaining bolts.
  • Page 34: Replace The Fuel Filters - Ford Models

    1 Put on protective clothing and eye wear. 2 Open the tank side turntable cover and locate the fuel system components mounted to the tank plate. 3 - 12 Genie Z-60/34 Part No. 75861...
  • Page 35: Inspect The Fuel Filter/Water Separator - Deutz Models

    Swing the engine pivot plate out away from the machine and secure it from moving. Crushing hazard. Failure to secure the engine pivot plate from moving could result in death or serious injury. Part No. 75861 Genie Z-60/34 3 - 13...
  • Page 36 Explosion and fire hazard. If a fuel leak is discovered, keep any additional personnel from entering the area and do not operate the machine. Repair the leak immediately. 3 - 14 Genie Z-60/34 Part No. 75861...
  • Page 37: Grease The Turntable Rotation Bearing And Rotate Gear

    Replace Drive Hub Oil Bearing and Rotate Gear Rexroth drive hub specifications require that this procedure be Genie specifications require that performed after 150 hours. this procedure be performed initially after the first 50 hours of Replacing the drive hub oil is essential for good operation and every 100 hours machine performance and service life.
  • Page 38: Perform Engine Maintenance - Ford Models

    Required maintenance procedures and additional engine information are available in the Ford LRG-425 EFI Operator Handbook (Ford part number FPP 194-302). Ford LRG-425 EFI Operator Handbook Genie part number 77831 To access the engine: 1 Remove the two engine pivot plate retaining bolts.
  • Page 39: Checklist B Procedures - Rev A

    The battery is a maintenance free battery and does not require the replenishing of electrolyte. Adding terminal protectors and a corrosion preventative sealant will help eliminate corrosion on the battery terminals and cables. Part No. 75861 Genie Z-60/34 3 - 17...
  • Page 40: Inspect The Electrical Wiring

    Crushing hazard. Failure to install corroded and loose wires: the bolts into the engine pivot plate · Engine wiring harness to secure it from moving could result in death or serious injury. · Hydraulic manifold wiring 3 - 18 Genie Z-60/34 Part No. 75861...
  • Page 41: Test The Key Switch

    (Ford part number FPP 194-302). Result: All machine functions should not operate. Ford LRG-425 EFI Operator Handbook Genie part number 77831 4 Turn the key switch to ground control. 5 Check all machine function from the platform controls. To access the engine:...
  • Page 42: Check The Exhaust System

    Crushing hazard. Failure to secure the engine pivot plate from moving could result in death or serious injury. All models: 2 Be sure that all nuts and bolts are tight. 3 Inspect all welds for cracks. 3 - 20 Genie Z-60/34 Part No. 75861...
  • Page 43: Check The Oil Cooler And Cooling Fins - Deutz Models

    6 Clean the fan blower fins of debris and foreign Crushing hazard. Failure to secure material. the engine pivot plate from moving could result in death or serious injury. Part No. 75861 Genie Z-60/34 3 - 21...
  • Page 44: Check The Lug Nut Torque (Including The Tires And Wheels)

    2 Check each wheel for damage, bends and cracked welds. 3 Check each lug nut for proper torque. Refer to Section 2, Specifications. 4 Check the pressure in each air-filled tire. Refer to Section 2, Specifications. 3 - 22 Genie Z-60/34 Part No. 75861...
  • Page 45: Confirm The Proper Brake Configuration

    4 Apply pipe thread sealant to the plug(s), and then install the plug(s) in the drive hub. 5 Repeat this procedure for each drive hub. Part No. 75861 Genie Z-60/34 3 - 23...
  • Page 46: Check And Adjust The Engine Rpm

    Ford models: The engine rpm is controlled by the ECM and can only be adjusted by re-programming the ECM. If rpm adjustment or service is required, please contact Genie Industries Service Department OR your local Ford dealer. Deutz models: solenoid boot...
  • Page 47: Test The Ground Control Override

    2 Start the engine from the ground controls. 3 At the ground controls, operate each boom function through a partial cycle. Result: All boom functions should operate. Part No. 75861 Genie Z-60/34 3 - 25...
  • Page 48: Check The Directional Valve Linkage

    Result: The platform should remain level at · Linkage is properly attached to all times to within ±5 degrees. directional valve directional valve clevis pin with cotter pin (hidden) yoke lock nut 3 - 26 Genie Z-60/34 Part No. 75861...
  • Page 49: Test The Engine Idle Select

    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. Part No. 75861 Genie Z-60/34 3 - 27...
  • Page 50: Test The Fuel Select Operation - Ford Models

    (rabbit and foot switch symbol). 2 Start the engine from the platform controls and allow it to run at low idle. 3 - 28 Genie Z-60/34 Part No. 75861...
  • Page 51: Test The Drive Brakes

    2 Start the engine from the platform controls. 3 Move the engine idle control switch to foot switch activated high idle (rabbit and foot switch), then lower the boom into the stowed position. Part No. 75861 Genie Z-60/34 3 - 29...
  • Page 52: Test The Drive Speed - Stowed Position

    6 Continue at full speed and note the time when the machine reference point crosses the finish line. Refer to Section 2, Specifications. 3 - 30 Genie Z-60/34 Part No. 75861...
  • Page 53: Test The Alarm Package (If Equipped)

    2 Hold the function enable switch to either side and activate the boom toggle switch in the down position, hold for a moment and then release it. Result: The descent alarm should sound when the toggle switch is held down. Part No. 75861 Genie Z-60/34 3 - 31...
  • Page 54: Perform Hydraulic Oil Analysis

    Replace the oil when it fails the test. See E-1, Test or Replace the Hydraulic Oil. 3 - 32 Genie Z-60/34 Part No. 75861...
  • Page 55: Replace The Hydraulic Filters

    5 Install the new filter and tighten it securely by hand. Clean up any oil that may have spilled during the installation procedure. Genie requires that this procedure 6 Use a permanent ink marker to write the date be performed quarterly or every and number of hours from the hour meter on the 250 hours, whichever comes first.
  • Page 56: Perform Engine Maintenance - Deutz Models

    Deutz FL 1011F Operation Manual (Deutz part number 0297 9683). Deutz FL 1011F Operation Manual Genie part number 52883 To access the engine: 1 Remove the two engine pivot plate retaining bolts. Swing the engine pivot plate out away from the machine and secure it from moving.
  • Page 57: Perform Engine Maintenance - Ford Models

    Ford LRG-425 EFI Operator Handbook (Ford part number FPP 194-302). Ford LRG-425 EFI Operator Handbook Genie part number 77831 To access the engine: 1 Remove the two engine pivot plate retaining bolts. Swing the engine pivot plate out away from the machine and secure it from moving.
  • Page 58: Checklist C Procedures - Rev A

    Perform Engine Maintenance - Grease the Platform Overload Deutz Models Mechanism (if equipped) Deutz engine specifications require Genie specifications require that this procedure be performed that this procedure be performed every 500 hours. every 500 hours or 6 months, whichever comes first. Perform...
  • Page 59 Test the Platform Overload maximum platform capacity in one of the System (if equipped) locations shown. Genie specifications require that this procedure be performed every 500 hours or six months. Testing the platform overload system regularly is essential to safe machine operation. Continued use...
  • Page 60 8 Test all machine functions from the platform controls. Result: All platform control functions should not operate. 9 Turn the key switch to ground control. 3 - 38 Genie Z-60/34 Part No. 75861...
  • Page 61: C-4 Perform Engine Maintenance - Ford Models

    (Ford part number FPP 194-302). Result: All ground control functions should operate normally. Ford LRG-425 EFI Operator Handbook Genie part number 77831 13 Turn the key switch to platform control. 14 Test all machine functions from the platform controls.
  • Page 62: Checklist D Procedures - Rev A

    Always maintain squareness between the outer and inner boom tubes. Wear pad specifications All wear pads inch 14.3 mm Bolt torque sequence 3 - 40 Genie Z-60/34 Part No. 75861...
  • Page 63: Check The Free-Wheel Configuration

    3 Lift the wheels off the ground and then place blocks under the drive chassis for support. Crushing hazard. The chassis will fall if not properly supported. Part No. 75861 Genie Z-60/34 3 - 41...
  • Page 64 8 Center a lifting jack of ample capacity under the drive chassis between the steer wheels. 9 Lift the wheels off the ground and then place blocks under the drive chassis for support. 3 - 42 Genie Z-60/34 Part No. 75861...
  • Page 65: Check And Adjust The Air/Lpg Mixture - Ford Models

    Preliminary setting: turn low idle adjustment screw clockwise all the 3 Loosen the lock nut on the high idle mixture way in. Turn low idle adjustment adjustment screw. screw counterclockwise 2 turns. Part No. 75861 Genie Z-60/34 3 - 43...
  • Page 66: Perform Engine Maintenance - Deutz Models

    Perform Engine Maintenance - How to Calibrate the Platform Deutz Models Overload System (if equipped) Deutz engine specifications require Genie specifications require that that this procedure be performed this procedure be performed every every 1000 hours. 1000 hours of operation or yearly.
  • Page 67 The platform will need to be moved up and down and allowed to settle 9 Test all machine functions from the platform in between adjustments. controls. Result: All platform control functions should not operate. Part No. 75861 Genie Z-60/34 3 - 45...
  • Page 68: Replace The Drive Hub Oil

    Refer to Section 2, Specifications. 5 Apply pipe thread sealant to the plugs. Install the plugs. 6 Repeat steps 1 through 5 for all the other drive hubs. 3 - 46 Genie Z-60/34 Part No. 75861...
  • Page 69: Checklist E Procedures - Rev A

    12 Rinse out the inside of the tank using a mild solvent. 2 Ford models: Open the clamps from the LPG tank straps and remove the LPG tank from the machine (if equipped). Part No. 75861 Genie Z-60/34 3 - 47...
  • Page 70 Diesel models: 4 Remove and replace all of the fuel line hoses and clamps according to the following illustration: 3 - 48 Genie Z-60/34 Part No. 75861...
  • Page 71 Repair the leak the fuel filter immediately. hose from the fuel filter to the injection pump hose from the injection pump to the injectors Part No. 75861 Genie Z-60/34 3 - 49...
  • Page 72: Perform Engine Maintenance - Deutz Models

    3 Raise the machine 6 inches / 15 cm and place Deutz FL 1011F Workshop Manual blocks under the drive chassis for support. Genie part number 52229 4 Remove the lug nuts. Remove the tire and wheel assembly.
  • Page 73 13 Place the hub on a flat surface and gently pry the bearing seal out of the hub. Remove the rear bearing. 14 Pack both bearings with clean, fresh grease. Part No. 75861 Genie Z-60/34 3 - 51...
  • Page 74 Section 3 • Scheduled Maintenance Procedures November 2003 REV A This page intentionally left blank. 3 - 52 Genie Z-60/34 Part No. 75861...
  • Page 75: Repair Procedures

    Red—used to indicate the presence of an imminently Read, understand and obey the safety rules hazardous situation which, if not and operating instructions in the Genie Z-60/34 avoided, will result in death or Operator’s Manual. serious injury. Be sure that all necessary tools and parts are Orange—used to indicate the...
  • Page 76: Platform Controls

    Remove all rings, watches and other jewelry. ALC-500 circuit board drive/steer joystick controller secondary boom up/down joystick controller primary boom up/down and turntable rotate left/right joystick controller 4 - 2 Genie Z-60/34 Part No. 75861...
  • Page 77: Joysticks

    Result: The alarm should sound indicating successful joystick calibration. 6 Repeat this procedure for each joystick controlled machine function including the thumb rocker steer switch. No machine fuction should operate while performing the joystick calibration procedure. Part No. 75861 Genie Z-60/34 4 - 3...
  • Page 78 4 times. for function speeds. Result: There should be a pause and the alarm should sound 4 times indicating that the machine is in max-out calibration mode. 4 - 4 Genie Z-60/34 Part No. 75861...
  • Page 79 10 Compare the function ramp rate time with the 2WD models 1 second table below and determine whether the ramp decelerate, shift from high to low speed rate time needs to increase or decrease. 4WD models 3.5 seconds Part No. 75861 Genie Z-60/34 4 - 5...
  • Page 80 7 Momentarily activate the drive enable toggle waiting time. switch in the right direction 8 times. Result: There should be a pause and the alarm should sound 8 times indicating that the machine is in threshold calibration mode. 4 - 6 Genie Z-60/34 Part No. 75861...
  • Page 81: Platform Components

    9 Use a soft metal drift and drive the barrel-end pin out. Do not rest the entire weight of the boom on the blocks. 10 Carefully pull the cylinder out of the primary boom. Part No. 75861 Genie Z-60/34 4 - 7...
  • Page 82: Platform Rotator

    Secure the container to the boom. 3 Open the top bleed valve on the rotator, but do not remove it. top bleed valve bottom bleed valve container clear hose 4 - 8 Genie Z-60/34 Part No. 75861...
  • Page 83 7 Remove the hose from the bleed valve and clean up any hydraulic oil that may have spilled. 8 Rotate the platform fully in both directions and inspect the bleed valves for leaks. Part No. 75861 Genie Z-60/34 4 - 9...
  • Page 84: Jib Boom Components

    Crushing hazard. The platform Component damage hazard. pivot weldment may become Hoses can be damaged if they are unbalanced and fall when kinked or pinched. removed from the machine if not properly supported. 4 - 10 Genie Z-60/34 Part No. 75861...
  • Page 85: Jib Boom Lift Cylinder

    4 Remove both of the jib boom leveling links from unbalanced and fall when it is the machine. removed from the machine if it is not properly attached to the overhead crane. Part No. 75861 Genie Z-60/34 4 - 11...
  • Page 86 Remove the jib boom lift cylinder from the machine. Crushing hazard. The jib boom lift cylinder could become unbalanced and fall when removed from the machine if not properly attached to the overhead crane. 4 - 12 Genie Z-60/34 Part No. 75861...
  • Page 87: Jib Boom / Platform Rotate Manifold Components Before Serial Number 4461

    Solenoid valve, 2 position 2 way ..BB ..Jib boom up/down ......20-25 ft-lbs / 27-34 Nm Orifice, 0.031 inch / 0.787 mm ..BC ..Platform rotate circuit Orifice, 0.031 inch / 0.787 mm ..BD ..Platform rotate circuit Part No. 75861 Genie Z-60/34 4 - 13...
  • Page 88: Jib Boom / Platform Rotate Manifold Components (After Serial Number 4460)

    Jib boom up/down ......20-25 ft-lbs / 27-34 Nm Orifice, 0.030 inch / 0.762 mm ..BF ..Platform rotate circuit Orifice, 0.030 inch / 0.762 mm ..BG ..Platform rotate circuit 4 - 14 Genie Z-60/34 Part No. 75861...
  • Page 89: Primary Boom Components

    Bodily injury hazard. Spraying hydraulic oil can penetrate and burn skin. Loosen hydraulic connections very slowly to allow the oil pressure to dissipate gradually. Do not allow oil to squirt or spray. Part No. 75861 Genie Z-60/34 4 - 15...
  • Page 90 16 Remove the cable track guide fasteners from the platform end of the primary boom. 17 Remove the cable track mounting fasteners that attach the lower cable track to the primary boom. 4 - 16 Genie Z-60/34 Part No. 75861...
  • Page 91: Primary Boom

    A 7 link repair section of cable procedure requires specific repair track is available through the skills, lifting equipment and a Genie Industries Service Parts suitable workshop. Attempting this Department. procedure without these skills and tools could result in death or serious injury and significant component damage.
  • Page 92 12 Attach a similar lifting device to the primary boom lift cylinder. 13 Place a 24 inch/61 cm long block of wood across the lower secondary boom leveling links to support the primary boom lift cylinder. 4 - 18 Genie Z-60/34 Part No. 75861...
  • Page 93 Pay careful attention to the platform end of the primary boom. location and amount of shims Pay careful attention to the used with each wear pad. location and amount of shims used with each wear pad. Part No. 75861 Genie Z-60/34 4 - 19...
  • Page 94: Primary Boom Lift Cylinder

    3 Place a 24 inch/61 cm long block of wood cylinder with an appropriate lifting device. across the lower secondary boom leveling links to support the primary boom lift cylinder when the rod-end pivot pin is removed. 4 - 20 Genie Z-60/34 Part No. 75861...
  • Page 95: Primary Boom Extension Cylinder

    When removing a hose assembly or fitting, the O-ring on the fitting and/or hose end must be replaced and then torqued to specification during installation. Refer to Section Two, Hydraulic Hose and Fitting Torque Specifications. Part No. 75861 Genie Z-60/34 4 - 21...
  • Page 96 Bodily injury hazard. Spraying hydraulic oil can penetrate and burn skin. Loosen hydraulic connections very slowly to allow the oil pressure to dissipate gradually. Do not allow oil to squirt or spray. 4 - 22 Genie Z-60/34 Part No. 75861...
  • Page 97: Platform Leveling Master Cylinder

    1 Remove the pin retaining fasteners from the the oil pressure to dissipate master cylinder rod-end pivot pin. Use a soft gradually. Do not allow oil to metal drift to remove the pin. squirt or spray. Part No. 75861 Genie Z-60/34 4 - 23...
  • Page 98 7 Lower the master cylinder down and out of the upper pivot and remove it from the machine. Crushing hazard. The master cylinder could become unbalanced and fall when removed from the machine if not properly attached to the overhead crane. 4 - 24 Genie Z-60/34 Part No. 75861...
  • Page 99: Secondary Boom Components

    Dealer service is required. Follow the disassembly steps to the point required to complete the repair. Then re-assemble the secondary boom by following the disassembly steps in reverse order. Part No. 75861 Genie Z-60/34 4 - 25...
  • Page 100 Crushing hazard. Failure to secure secure the upper pivot from moving. the engine pivot plate from moving 8 Attach a 5 ton/5,000 kg overhead crane to the could result in death or serious injury. 4 - 26 Genie Z-60/34 Part No. 75861...
  • Page 101 Cap the fittings on the Crushing hazard. The secondary cylinder. boom lift cylinder could become unbalanced and fall when removed from the machine if not properly supported by the overhead crane. Part No. 75861 Genie Z-60/34 4 - 27...
  • Page 102 Do not allow oil to squirt or spray. 33 Attach a lifting strap from an overhead crane to the lug on the rod end of the master cylinder. 4 - 28 Genie Z-60/34 Part No. 75861...
  • Page 103 Part No. 75861 Genie Z-60/34 4 - 29...
  • Page 104: Secondary Boom Lift Cylinders

    Hose and Fitting Torque properly supported by the Specifications. overhead crane. 1 Attach a lifting strap from an overhead crane to the lug on the rod end of the secondary boom lift cylinder. 4 - 30 Genie Z-60/34 Part No. 75861...
  • Page 105 Crushing hazard. The secondary boom lift cylinder could become unbalanced and fall when removed from the machine if not properly supported by the overhead crane. Part No. 75861 Genie Z-60/34 4 - 31...
  • Page 106: Rpm Adjustment

    Deutz models inch flex plate with raised spline 9.5 mm engine flywheel inch / 9.5 mm gap - Deutz Models Ford models inch inch / 1.6 mm gap - Ford Models 1.6 mm 4 - 32 Genie Z-60/34 Part No. 75861...
  • Page 107: Engine Fault Codes - Ford Models

    123 1 Open the ground controls side turntable cover. three times again indicating the 2 Locate the run/test toggle switch inside of the end of the stored codes. ground control box. Part No. 75861 Genie Z-60/34 4 - 33...
  • Page 108 5 minutes. Electrocution hazard. Contact with electrically charged circuits could result in death or serious injury. Remove all rings, watches and other jewelry. 3 Connect the negative battery cable to the battery. 4 - 34 Genie Z-60/34 Part No. 75861...
  • Page 109: Hydraulic Pumps

    Rexroth and then torqued to specification service center. Call Genie Industries Service during installation. Department to locate your local authorized service Refer to Section 2, Hydraulic Hose center.
  • Page 110 320 psi / 22 bar. 5 Ford models: Connect the LPG hose to the LPG tank and open the valve on the tank. 6 Start the engine from the ground controls and check for hydraulic leaks. 4 - 36 Genie Z-60/34 Part No. 75861...
  • Page 111: Function Manifold Components - View 1

    Check valve, 50 psi / 3.45 bar ... U ... Pressure in from drive pump ..... 30-35 ft-lbs / 41-47 Nm Differential sensing valve ....V ... Secondary boom up/down ....30-35 ft-lbs / 41-47 Nm Differential sensing valve ....W ..Primary boom up/down ..... 30-35 ft-lbs / 41-47 Nm Part No. 75861 Genie Z-60/34 4 - 37...
  • Page 112 Section 4 • Repair Procedures November 2003 MANIFOLDS REV A 4 - 38 Genie Z-60/34 Part No. 75861...
  • Page 113: Function Manifold Components - View 2

    ........20-25 ft-lbs / 27-34 Nm Check valve ........AL ..Jib select ........... 20-25 ft-lbs / 27-34 Nm Check valve ........AM ..Jib select ........... 20-25 ft-lbs / 27-34 Nm Part No. 75861 Genie Z-60/34 4 - 39...
  • Page 114 Section 4 • Repair Procedures November 2003 MANIFOLDS REV A 4 - 40 Genie Z-60/34 Part No. 75861...
  • Page 115: Function Manifold Components (After Serial Number 4460)

    0.1 gpm / 0.37 L/min ......HS ..Flow control ........20-25 ft-lbs / 27-34 Nm Differential sensing valve ....HT ..Function pressure control ....30-35 ft-lbs / 41-47 Nm This parts list continues. Please turn the page. Part No. 75861 Genie Z-60/34 4 - 41...
  • Page 116 Section 4 • Repair Procedures November 2003 MANIFOLDS REV A 31 30 Valves hidden Valves hidden from above from above view view Top View Front View 25 24 4 - 42 Genie Z-60/34 Part No. 75861...
  • Page 117 Solenoid valve, 2 position 3 way ..IK ..Boom retract ........30-35 ft-lbs / 41-47 Nm Diagnostic nipple ....... IL ..Testing Check valve ........IM ..Jib boom select ......... 20-25 ft-lbs / 27-34 Nm Part No. 75861 Genie Z-60/34 4 - 43...
  • Page 118 Section 4 • Repair Procedures November 2003 MANIFOLDS REV A 31 30 Valves hidden Valves hidden from above from above view view Top View Top View Front View 25 24 4 - 44 Genie Z-60/34 Part No. 75861...
  • Page 119: Valve Adjustments - Function Manifold

    Tip-over hazard. Do not adjust valve pressure. the relief valve higher than 8 Remove the pressure gauge. specified. 7 Repeat steps 2 through 5 and recheck relief valve pressure. 8 Remove the pressure gauge. Part No. 75861 Genie Z-60/34 4 - 45...
  • Page 120 Install the relief valve cap. Tip-over hazard. Do not adjust the relief valve higher than specified. 7 Repeat steps 2 through 5 and recheck relief valve pressure. 8 Remove the pressure gauge. 4 - 46 Genie Z-60/34 Part No. 75861...
  • Page 121: Turntable Rotation Manifold Components

    1 2 3 4 5 6 1 2 3 4 5 6 1 2 3 4 5 6 1 2 3 4 5 6 1 2 3 4 5 6 1 2 3 4 5 6 Part No. 75861 Genie Z-60/34 4 - 47...
  • Page 122: Brake/Two-Speed Manifold Components (Before Serial Number 4461)

    Solenoid valve, 2 position 3 way ..DB ... 2 speed ..........20-25 ft-lbs / 37-34 Nm Orifice, 0.042 inch / 1.066 mm ..DC ... To tank Check valve ........DD ... Pressure ..........10-12 ft-lbs / 14-16 Nm 4 - 48 Genie Z-60/34 Part No. 75861...
  • Page 123: Brake/Two-Speed Manifold Components (After Serial Number 4460)

    Solenoid valve, 2 position 3 way ..EB ... 2 speed ..........20-25 ft-lbs / 37-34 Nm Check valve ........EC ... Pressure ..........10-12 ft-lbs / 14-16 Nm Orifice, 0.042 inch / 1.066 mm ..ED ... To tank Part No. 75861 Genie Z-60/34 4 - 49...
  • Page 124: Directional Valve Manifold Components

    The directional valve manifold is mounted inside the drive chassis at the non-steer end. Index Description Function Torque Cap ..............Breather ..........20-25 ft-lbs / 27-33 Nm Spool valve ............Directional control 4 - 50 Genie Z-60/34 Part No. 75861...
  • Page 125 6 the machine tipping over. through 10 OR consult Genie Industries Service Department. 3 Check the tire pressure in all four tires and add air if needed to meet specification.
  • Page 126: 2Wd Drive Manifold Components

    Diagnostic nipple ....... FG ..Testing Shuttle valve, 3 position 3 way ..FH ..Change pressure, hot oil shuttle ..30-35 ft-lbs / 41-47 Nm Diagnostic nipple ....... FI ..Testing 4 - 52 Genie Z-60/34 Part No. 75861...
  • Page 127 November 2003 Section 4 • Repair Procedures REV A MANIFOLDS Part No. 75861 Genie Z-60/34 4 - 53...
  • Page 128: Valve Adjustments, 2Wd Drive Manifold

    3 Turn the engine off and connect a 0 to 600 psi / 0 to 41 bar pressure gauge to the diagnostic nipple located on the drive manifold. 4 - 54 Genie Z-60/34 Part No. 75861...
  • Page 129: 4Wd Drive Manifold Components

    Check valve, 5 psi / 0.34 bar ..... GN ..Drive motor anti-cavitation ....20-25 ft-lbs / 27-34 Nm Flow divider/combiner valve ....GO ..Controls flow to steer end drive motors in forward and reverse ......... 90-100 ft-lbs / 120-133 Nm Part No. 75861 Genie Z-60/34 4 - 55...
  • Page 130 Section 4 • Repair Procedures November 2003 MANIFOLDS REV A STEER END NON-STEER END 4 - 56 Genie Z-60/34 Part No. 75861...
  • Page 131: Valve Adjustments, 4Wd Drive Manifold

    3 Turn the engine off and connect a 0 to 600 psi / 0 to 41 bar pressure gauge to the diagnostic nipple located on the drive manifold. Part No. 75861 Genie Z-60/34 4 - 57...
  • Page 132: Valve Coils, How To Test A Coil

    REV A 8-13 How to Test a Coil Diode Valve Coils Genie incorporates spike-suppressing diodes in all of its directional valve coils except proportional How to Test a Coil valves and coils with a metal case. Properly functioning coil diodes protect the electrical circuit A properly functioning coil provides an by suppressing voltage spikes.
  • Page 133 Resistor, 10Ω Ω Ω Ω Ω of the coil. Genie part number 27287 5 Momentarily connect the positive lead from the multimeter to the positive terminal on the 9V DC The battery should read 9V DC or battery.
  • Page 134: Turntable Rotation Components

    4 - 60 Genie Z-60/34 Part No. 75861...
  • Page 135: Axle Components

    Always use a new cotter pin when installing a castle nut. 10 Install the dust cap, then the tire and wheel assembly. Torque the wheel lug nuts to specification. Refer to Section 2, Specifications. Part No. 75861 Genie Z-60/34 4 - 61...
  • Page 136 Crushing hazard. The oscillate at the steer end. Remove the cover. cylinder could become unbalanced and fall when it is removed from the machine if it is not properly attached to the overhead crane. 4 - 62 Genie Z-60/34 Part No. 75861...
  • Page 137: Fault Codes

    Fault Codes Before Troubleshooting: Read, understand and obey the safety rules and operating instructions printed in the Genie Z-60/34 Operator’s Manual. Be sure that all necessary tools and test equipment are available and ready for use. Observe and Obey: Read each appropiate fault code thoroughly.
  • Page 138: Fault Codes - Control System

    OR use a grounded wrist strap. 5 - 2 Genie Z-60/34 Part No. 75861...
  • Page 139 Just calibrated of alarm. (transient) Boom 2 directional Limited speed and valves direction frozen at Power up Fault zero and neutral. controller with Alarm sounds problem corrected. indicating fault. Continued on next page Part No. 75861 Genie Z-60/34 5 - 3...
  • Page 140 Self-clearing. Just calibrated is zero. (transient) Drive enable Enable override Power up override switches Fault direction is frozen at controller with neutral. problem corrected. 5 - 4 Genie Z-60/34 Part No. 75861...
  • Page 141 Initiate 1-second beep Self-clearing. Just calibrated of alarm. (transient) Steer directional Limited speed and valves direction frozen at Power up Fault zero and neutral. controller with Alarm sounds problem corrected. indicating fault. Part No. 75861 Genie Z-60/34 5 - 5...
  • Page 142 Check Engine Light. Refer to Repair Procedure 6-4, How to Retrieve Engine Fault Codes. Use the Fault Code Chart on the following pages to aid in identifying the fault. 5 - 6 Genie Z-60/34 Part No. 75861...
  • Page 143 OR sensor is faulty sensor OR replace fuel OR Low (LPG) OR fuel quality is poor OR test and repair the fuel fuel system components may system components. be faulty. Continued on next page Part No. 75861 Genie Z-60/34 5 - 7...
  • Page 144 ECM is open supply wiring to ECM. or shorted. Alternator is overcharging the Repair or replace the System Voltage High battery when engine RPM is alternator. greater than 1500 rpm. 5 - 8 Genie Z-60/34 Part No. 75861...
  • Page 145 Voltage sensor OR replace sensor connections open or shorted OR fill engine coolant level to OR sensor is faulty OR specification. coolant level is low. Continued on next page Part No. 75861 Genie Z-60/34 5 - 9...
  • Page 146 Never Crank Synced open or shorted OR there is a secure OR repair wiring At Start poor system ground and/or connections to sensor connection OR sensor is OR replace sensor. faulty. 5 - 10 Genie Z-60/34 Part No. 75861...
  • Page 147 #2 Injector Driver #2 Open OR fuel injector #2 is faulty OR OR replace fuel injector #2 ECM is faulty. OR replace the ECM. Continued on next page Part No. 75861 Genie Z-60/34 5 - 11...
  • Page 148 OR replace ignition coil #1. Wiring and/or connections to Repair wiring and/or Coil Driver #1 Shorted ignition coil #1 shorted OR connections to ignition coil #1 ignition coil #1 is faulty. OR replace ignition coil #1. 5 - 12 Genie Z-60/34 Part No. 75861...
  • Page 149 #2 shorted OR connections to ignition coil #2 ignition coil #2 is faulty. OR replace ignition coil #2. If this fault appears on your machine, contact Genie FPP1 High Voltage Not used. Industries Service Department. If this fault appears on your...
  • Page 150 OR there is a poor TPS2 and/or connections to one or system ground connection OR both TPS sensors OR replace one or both throttle position one or both TPS sensors. sensors are faulty. 5 - 14 Genie Z-60/34 Part No. 75861...
  • Page 151 Spark Rev Limit sticking open OR there are air repair any air leaks between leaks between the throttle body the throttle body and cylinder and cylinder head. head. Continued on next page Part No. 75861 Genie Z-60/34 5 - 15...
  • Page 152 External 5V DC Ref shorts OR locate and ground OR there is a faulty Lower than Expected troubleshoot or repair faulty engine sensor OR ECM is engine sensor OR replace faulty. ECM. 5 - 16 Genie Z-60/34 Part No. 75861...
  • Page 153 Locate and repair any engine Loose wire connections to harness wiring damage or RTI 3 Loss ECM OR ECM is faulty. shorts to ECM to be sure they are secure OR replace ECM. Part No. 75861 Genie Z-60/34 5 - 17...
  • Page 154 Section 5 • Fault Codes November 2003 This page intentionally left blank. 5 - 18 Genie Z-60/34 Part No. 75861...
  • Page 155 Do not allow oil to squirt Read, understand and obey the safety rules or spray. and operating instructions printed in the Genie Z-60/34 Operator's Manual. General Repair Process Be sure that all necessary tools and test equipment are available and ready for use.
  • Page 156: Electrical Symbols Legend

    Gauge sending unit Battery Toggle switch DPDT Fuse with amperage N.O. Fuel or RPM Battery separator Control relay contact solenoid normally open Starting aid: glow plug or Circuit breaker flame ignitor with amperage Coil 6 - 2 Genie Z-60/34 Part No. 75861...
  • Page 158: Electrical Schematic-Deutz F4L 1011F Models

    OPS S2 STARTER PUMP REGULATOR IND. NOTE: 1) ALL SWITCHES AND CONTACTS ARE SHOWN WITH THE BOOM IN THE STOWED POSITION AND KEYSWITCH "OFF". 2) THIS WIRE FOR UNITS WITHOUT GENERATOR OPTION. 6 - 3 Genie Z-60/34 Part No. 75861...
  • Page 159: Deutz F4L 1011F Models

    TB36 TB37 TB12 TB32 TB31 TB30 TB17 TB18 TB40 TB46 TB46 TB44 TB43 NOHC NOHC NCHO NCHO NOTE: 1) ALL LIMIT SWITCHES SHOWN WITH THE BOOM IN STOWED POSITION EXCEPT AS NOTED. Part No. 75861 Genie Z-60/34 6 - 4...
  • Page 160: Deutz F4L 1011F Models

    November 2003 Section 6 • Schematics Electrical Schematic- Deutz F4L 1011F Models...
  • Page 161: Ground Control Box Wiring Diagram

    TO PLATFORM C-BOX, TERMINAL 22-23 RED-20B BK/WH-34A (CABLE#3) TO PLATFORM C-BOX, TERMINAL 1-19 RED-24A ENGINE BK/RD-E.H. (CABLE#4) TO FUNCTION MANIFOLD HARNESS AUXILARY POWER RELAY GROUND STUD GLOW PLUG POWER RELAY BK-H.C. + BR-H.C. BR-2 Part No. 75861 Genie Z-60/34 6 - 5...
  • Page 162 November 2003 Section 6 • Schematics Ground Control Box Wiring Diagram- Deutz F4L 1011F Models...
  • Page 163 CP2-2 OR R40LS1 (SPLICE TO R40LS1) HIGH/LOW START TS14 GLOW PLUG HORN DRIVE PLATFORM PLATFORM AUXILIARY PUMP SPEED EMERGENCY STOP ROTATE BOOM LEVEL GR/BK HIGH/LOW REMOVE FOR GENERATOR OPTION CE SEE DETAIL A Part No. 75861 Genie Z-60/34 6 - 6...
  • Page 164 November 2003 Section 6 • Schematics Platform Control Box Wiring Diagram- Deutz F4L 1011F Models...
  • Page 166: Electrical Schematic-Ford Lrg-425 Efi Models

    ENGINE HARNESS FORD 42 PIN PLUG NOTE: 1) ALL SWITCHES AND CONTACTS ARE SHOWN WITH THE BOOM IN THE STOWED POSITION AND KEYSWITCH "OFF". 2) THIS WIRE FOR UNITS WITHOUT GENERATOR OPTION. 6 - 7 Genie Z-60/34 Part No. 75861...
  • Page 167: Ford Lrg-425 Efi Models

    TS59 TS63 TS60 TS58 TB44 TB19 TB40 TB13 TB15 TB10 TB11 TB17 TB14 TB12 TB36 TB37 TB32 TB31 TB30 TB18 TB46 TB46 TB44 TB43 Y19 Y20 Y52 Y53 NOHC NOHC NCHO NCHO Part No. 75861 Genie Z-60/34 6 - 8...
  • Page 168: Ford Lrg-425 Efi Models

    November 2003 Section 6 • Schematics Electrical Schematic- Ford LRG-425 EFI Models...
  • Page 169: Ground Control Box Wiring Diagram

    CHECK ENGINE TOGGLE SWITCH TS55 TS22 FUNCTION WH-ISM#7 ENABLE BR-CR1 WH-23B BLK-33A BR-GROUND BK-33B BLK/RED-35A WH/PUR-FEH WH CR2#87 RD/LGRN-FEH RD C23-7 RED-20A GROUND STUD RED-20B ENGINE ENGINE RED-24A HARNESS HARNESS BK-H.C. + BR-H.C. BR-2 Part No. 75861 Genie Z-60/34 6 - 9...
  • Page 170 November 2003 Section 6 • Schematics Ground Control Box Wiring Diagram- Ford LRG-425 EFI Models...
  • Page 171 CP2-2 OR R40LS1 (SPLICE TO R40LS1) TS14 HIGH/LOW DRIVE FUEL SPEED SELECT HIGH/LOW AUXILIARY PLATFORM EMERGENCY START PUMP PLATFORM ROTATE STOP HORN REMOVE FOR GENERATOR OPTION LEVEL GR/BK CE SEE DETAIL A Part No. 75861 Genie Z-60/34 6 - 10...
  • Page 172 November 2003 Section 6 • Schematics Platform Control Box Wiring Diagram- Ford LRG-425 EFI Models...
  • Page 173 November 2003 Section 6 • Schematics Part No. 75861 Genie Z-60/34 6 - 11...
  • Page 174: Hydraulic Symbols Legend

    2-speed, bi-directional 2 position, 2 way solenoid valve Pump prime mover (engine or motor) Differential sensing valve Directional valve pilot operated 2 position, 2 way Double acting cylinder Solenoid operated proportional valve 6 - 12 Genie Z-60/34 Part No. 75861...
  • Page 175: Hydraulic Schematic, 2Wd Models (Before Sn 4461)

    30 psi 2.1 bar REAR MASTER RIGHT SLAVE TEST 3 TEST 1 PLATFORM ROTATE STEERING 250 psi PLATFORM 17.2 bar LEVEL 700 psi 51.7 bar REAR TEST 2 LEFT 2WD TRACTION MANIFOLD OSCILLATE Part No. 75861 Genie Z-60/34 6 - 13...
  • Page 176 November 2003 Section 6 • Schematics Hydraulic Schematic, 2WD Models (before serial number 4461)
  • Page 177: Hydraulic Schematic, 4Wd Models (Before Sn 4461)

    2.0 gpm PLATFORM 7.5 L/min ROTATE 2.0 gpm 7.5 L/min 250 psi 17.2 bar STEERING PLATFORM LEVEL 700 psi 48.2 bar 2.0 gpm 7.5 L/min FRONT REAR LEFT LEFT 4WD TRACTION MANIFOLD OSCILLATE Part No. 75861 Genie Z-60/34 6 - 14...
  • Page 178: Hydraulic Schematic, 4Wd Models (After Sn 4460)

    November 2003 Section 6 • Schematics Hydraulic Schematic, 4WD Models (before serial number 4461)
  • Page 179 SLAVE TEST 3 TEST 1 SET @ .6 gpm 2.3 L/min PLATFORM ROTATE STEERING 250 psi PLATFORM 17.2 bar LEVEL 700 psi 51.7 bar REAR TEST 2 LEFT 2WD TRACTION MANIFOLD OSCILLATE Part No. 75861 Genie Z-60/34 6 - 15...
  • Page 180 November 2003 Section 6 • Schematics Hydraulic Schematic, 2WD Models (after serial number 4460)
  • Page 181 ROTATE 2.0 gpm 2.0 gpm 7.6 L/min 250 psi 7.6 L/min 17.2 bar STEERING PLATFORM LEVEL 700 PSI 51.7 bar 2.0 psi 7.6 L/min FRONT REAR LEFT LEFT 4WD TRACTION MANIFOLD OSCILLATE Part No. 75861 Genie Z-60/34 6 - 16...
  • Page 182 November 2003 Section 6 • Schematics Hydraulic Schematic, 4WD Models (after serial number 4460)
  • Page 183 Genie North America Phone 425.881.1800 Toll Free USA and Canada 800.536.1800 425.883.3475 Genie Holland Genie Australia Pty Ltd. Phone + Phone + 31 70 51 78836 61 7 3375 1660 Fax + Fax + 31 70 51 13993 61 7 3375 1002...

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