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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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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.
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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.
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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...
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...
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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...
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...
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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...
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...
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...
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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...
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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...
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.
· 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...
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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...
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...
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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...
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...
(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.
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).
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...
• 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.
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...
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...
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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...
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.
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.
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...
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...
(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:...
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...
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...
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...
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...
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...
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...
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...
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...
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...
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...
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...
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.
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.
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.
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...
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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...
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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...
(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.
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...
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...
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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...
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...
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.
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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...
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...
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...
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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...
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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...
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.
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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...
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Section 3 • Scheduled Maintenance Procedures November 2003 REV A This page intentionally left blank. 3 - 52 Genie Z-60/34 Part No. 75861...
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...
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...
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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...
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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...
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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...
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...
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...
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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...
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...
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...
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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...
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...
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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...
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.
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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...
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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...
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...
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...
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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...
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...
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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...
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...
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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...
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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...
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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...
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...
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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...
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...
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...
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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...
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.
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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...
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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...
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...
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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...
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...
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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.
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...
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...
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.
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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.
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...
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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...
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.
OR use a grounded wrist strap. 5 - 2 Genie Z-60/34 Part No. 75861...
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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...
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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...
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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...
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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...
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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...
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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...
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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...
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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...
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#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...
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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...
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#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...
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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...
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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...
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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...
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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...
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Section 5 • Fault Codes November 2003 This page intentionally left blank. 5 - 18 Genie Z-60/34 Part No. 75861...
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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.
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...
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...
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...
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November 2003 Section 6 • Schematics Hydraulic Schematic, 2WD Models (before serial number 4461)