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88619 Z-80/60 Service Manual

1. Section 6 Schematics July 2006 C LL _ Hydraulic Schematic 2 Wheel Drive with 4 Wheel Steer View 1 A B D E F G H K L M N 1 TURNTABLE PRIMARY LIFT PRIMARY BOOM SECONDARY BOOM LIFT SECONDARY BOOM ROTATE 7 1 5 1 26 8 19 3 L min EXTEND RETRACT 5 3 6 18 9 13 63 L min EXTEND RETRACT 1 COUNTERBALANCE VALVE 3 gpm 11 4 L min 3 9 7 4 4 gpm 36 7 16 7 L min RATIO PRESSURE 2 CI UAM A 1000 psi 69 bar A A A 1 5 1 2000 psi 138 bar 5 3 1 2000 psi 138 bar iQ Wi S Ww M is ULM 3 1 2500 psi 172 CHARGE FILTER ie eee E dS ase MI A 3 1 3000 psi 207 bar D A 3 1 3300 psi 227 5 bar Le SE 1 5 1 3500 psi 241 3 NNNM A 31 3500 psi 241 3 3 HIGH PRESSURE FILTERS
2. July 2006 Section 6 Schematics Engine Relay and Fuse Panel Legend REV oF us _ DEUTZ F4L 913 U 5 6 7 8 corer before serial number 339 d cm Dj CL LABEL DESCRIPTION GENIE P N FTT gu m CR1 START RELAY 61225 E 5 5 7 1 CR2 IGNITION FUEL RELAY 34052 1 d cu a af CR5 HORN RELAY 34052 1 CR17 HYDRAULIC OIL COOLER FAN RELAY 34052 F7 FUSE 20A HYDRAULIC OIL COOLER FAN 60536 OPTION F16 FUSE 70A ENGINE RPM AND COLD START 88151 J RELAY 11 CRS 11 GRI Pha 1 17 FUSE 20A STARTER AND ALTERNATOR 60536 F20 FUSE 20A ENGINE RPM 60536 d PR2 STARTING AID RELAY 61225 Mar l Or 7 1 O co H ol lo l CM LM mo Lo uu eye DEUTZ BFAL 2011 5 6 7 8 c 3F236 after serial number 338 1 LABEL DESCRIPTION GENIE P N 0828 CR1 START RELAY 61225 3 E F7 3 B2 CR28 ENGINE RUN ALTERNATOR FIELD RELAY 34052 ES E 205 CR5 HORN RELAY 3
3. H amp 8 QN9 HSNS H9 qN9 HSNS 9 Hg qN9 HSNS e CD LO N 3335 5909 gt aass 4 a 828 evr wR eS erp i 5 yedo S190 Sus 1 lt NE o lt E A 9 oviasi 2 OvldS1 a 5 i 0 c 5 5 E Qu HN 318SSeLd Qu HW 318SSzld tE golL n aul 88 167 8 QH HM 318SS2 LA QH HM 318SS LA ygh 4271 s dado aasivu 977 e Hado aasivd 09 0 85 2 5 2 xz ovzss 58 e sy 092557 8 H0 S 90 x8 HO S 192 HM LS 5 Mm TIE 18 09590 78 085 90 8 085 90 aul 828 osr aul 8218 DE ye do ST90 x8 HO S 19 ya 13 9309 P ovine O Hm 3 oviss HA Ta oO e T evt ig Hw G 8S92 d yB HN a1aSgzld 98812 aul 9 08 8 0188981 8 HM Q 18S92 LA ug russo 93
4. A B D E 1 2 3 FUNCTION M1 1 ENT 1 I i 1 5 Id 2 As H 2 PTEST2 L min n Re 03 Ex 1 0 9 V 17 4 645 19 i 3625 psi if 17 250 bar 6 4 2 i 1 5 4 7 FUNCTION a PUMP i AUXILIARY PUMP Me ipu ELE Iss eee ess ou BL1 T1 17e bar e poy fe et 3 1 L __ __ _ LL HYDRAULIC ROTARY COUPLER 3 1 7 8 Genie TEREX COMPANY 6 37 Z 80 60 Part No 88619 REV H J K M N PRIMARY BOOM SECONDARY BOOM LIFT SECONDARY BOOM 7 1 5 1 gpm 26 8 19 3 L min EXTEND RETRACT 5 3 6 18 9 13 63 L min EXTEND RETRACT COUNTERBALANCE VALVE hie cae
5. Section 6 Schematics July 2006 Electrical Symbols Legend REV FS1 ES 4 OPS1 BLK 15A NC Circuit breaker Foot switch Quick disconnect with amperage Oil pressure switch terminal Power relay normally closed P1 T circuits connect Emergency Stop Horn or alarm button normally closed Toggle switch Sending unit Connection no terminal 47878 Flashing beacon NO 5777775 8 59 z Hydraulic oil Control relay contact cooling fan Circuits crossing normally open no connection DS Gauge e Oil temperature Diode switch 2 Auxiliary pump normally open Coil Hour meter 1 i CTS1 0 L3 Coolant temperature Ep UE epe switch Battery normally open ee Tilt sensor LED fo 2 1 E vw cet BE WE 5 25A Q ax DU Fuse UCM Relay Service bypass with amperage Starting aid recovery glow plug or s key switch A flame ignitor d Steer sensor passtnbessssessasasesseny oF KS1 25 a Sy Power relay ALTERNATOR 771 U al Chassis ground 21 CUN I ME rs ws sp Ha m
6. Hydraulic Schematic REV 4 Wheel Drive with 2 Wheel Steer View 1 A B D E G K L M N 1 TURNTABLE PRIMARY LIFT PRIMARY BOOM SECONDARY BOOM LIFT SECONDARY BOOM ROTATE 5 1 26 8 19 3 L min EXTEND RETRACT 5 3 6 18 9 13 63 L min EXTEND RETRACT COUNTERBALANCE VALVE 3gpm ii 4L mn ga 9 7 4 4 36 7 16 7 L min 6 1 2 1 23 7 95 L min 2 RATIO PRESSURE A A 3 1 1000 psi 69 bar A 1 51 2000 psi 138 bar M 1 N 31 2000 psi 138 bar o 1 M LM A 3 1 2500 psi 172 bar Hx I A 81 3000 psi 207 bar La cdi a E 3 1 3300 psi 227 5 bar PN Ay 1 5 1 3500 psi 241 3 A 3 1 3500 psi 241 3 bar 3 R2 REXT RRET HIGH PRESSURE FILTERS 4 GRE FUNCTION gt TE MANIFOLD Bib 21 2500 psi 2600 psi JIB BOOM 4 Le 1 Ly 172 bar 179 bar PLATFORM ROTATE PLATFORM LEVEL 1 25 0 75 1 4 2500 psi rt 0 3 1 14 L min 0 65 2 46 L min 4 75 L min 2 84 L min is eee PTEST ad D 172 bar n Qp SSSsS RS Tae SRS pere ee et Qoo rep 1 1300psi 1300ps
7. a g 5 125 56 888 c z E gc g 2298 E 86222 508555 19 6a Ey E r 6zcb xmr Beas w peugeot 849 Sera 0886 nw 4 lt 1 2853 3523208 68822 39 2 8 Continued on View 5 gt _ 5 J15 BLACK 4 PIN 5 918 5 J13 WHITE 23 PIN 578 SENE POWER ENGINE 2 Q Q Tagg 5 C84TAY GN BK C84TAY GN BK deum E 5 6 C83TAX GN WH C83TAX GN WH 3 555 S30 2 P85TTSR GR P85TTSR GR Iz 25 lt OOGO a 4 r _ RET85TTSR BR RET85TTSR BR 5 ON 5 ul ug gt lt MESE 22 6 12560 455 DETAIL 50 5885 1 F OPT 120VAC W REGULATOR 5 TURNTABLE 3 CB iss TILT P32 GEN HAPN IBS SENSOR J32 ENG HAPN 30A 180 4 RD 12VDC RED 1 C45GEN GR WH 2 WT 286165 5 BR R4SGEN A BRN r YLIBAT lt 93 YEL 3 BR PASGEN B 55 1 PURPLE F45GEN lt F PURPLE 1 1 WHTNEUTRAL
8. 9 2 an EE gee 1 2385 5 g 4 58 2225 0 z t HaeoZz2229 ERE ok Eggs u 84 4 55 Xag 225909 ub 23 SoG geek 2225208 8 42203285 Les Sooo a amp J15 BLACK4PIN x fa s J13 WHITE 23 PIN zl fa rs le fel lel l oo fto fo A 20 o d fou foo 4 POWER HARNESS 12 211212 ENGINE HARNESS 2 2 22 2 ntin n View al EE amp E E E EE 2 2 E eR ETIE 14 At f 5 5 I C84TAY GN BK 84 f 2 2 E zm C83TAX GN WH C83TAX GN WH 5 lt Y T 2 5 B P85TTSR GR P85TTSR GR 7 amp E E RETB5TTSP BR lt lt ae ae 8 508 5 88554 2 amp 5 10 20 DEGREE 1 z 1 nom 866 5 66966 gt 8 SENSOR ALARM 6 SET AT 4 5 DEGREES 1 ee 98 26 tuat uere pcp ested 25 DETAIL B mE IS OPTIONAL 120VAC W REGULATOR J32 ENG HARNESS A 30A 1 30 4 RD 12VDC 2 RED C45GEN GR WH NS wr za as 5 BR R45GEN A 5 BRN 3 4 AS YUBATGND lt 23 YEL BR PA5GEN B BRN i PURPLE FA5GEN 4 PURPLE i r W
9. INYA 4 p 2 oe e 2 1 1 15 9 2 S 8 292 1 18188 1815 5 Id z 2333 a Id z 25 Zanw tr HOLVH3N39 OV 8 ol 8 o g nnm m AO 8 Q I NHOH 88 e id 1 8 EE 2 2 o 2 EO a T z e m 6a 9 a 8 gt y c EB O CK O 9 96 vH 8 2 v Yd LNOX c E 4 HO HMd 5 ze H8 OQN9 tH C D H amp NO H 9 5 H8 ON9 IH 91 lt Zo E HO HMd amp 5 NO LNOA _ 9S EK uouMd iH gt 8s SE 2 28 lt 5 8 HO HMd _ 5 2 UAND EH M8 L00A n ik N 5 com TA LNOA 2H Sor_ S 8er eH gt 6 1 yi avs 14 lt S1d 8d 1 lt HM LNOA tH 5 8 2 ozn QNO 3 20 14 ugl3HSld S udinox vu 2 4 USNS LIL 12 42 H9 S1dS8d 6 TA LNOA 2H 18 315 vH gt 9 8 LL 14 lt ye d9 Ayly80 QNO NIL 61 14 lt yg o HO HMd HO HMd 5 v S HSNS AUL N 5 2 8114 Ho mdyls 5 2 MS 1003 51 9
10. REV Hydraulic Schematic 2 Wheel Drive with 4 Wheel Steer View 2 N M L K H G F E D C B A 1 3 1 5 HYDRAULIC ROTARY COUPLER 00 5222 7 CYLINDERS u SS Nem 2 M7 FRONT LEFT FRONT RIGHT REAR LEFT REAR RIGHT REAR E RIGHT f STEERING STEERING STEERING STEERING dat bac er lt cp _ 1 11 FLB FLR FRB FRR RLB RLR RRR 193bar 1 1 2 B eo ey le 211 adi d I oo 3 50 e e is 1 1 ey Tear et T T4 e Ld T des Oot 0 0 X S e joie Op S AC S NEN 6C 1 eC eX 1 2 3 1 2gpm 2 3 gpm 1 2 gpm 2 3 gpm 1 2 2 3 12 Ww 8 7 L min 4 5 L min 87 L min 4 5 L min 18 7 L min 4 5 L min 18 7 L min 4 5 1 H 4 8 1 1 feces 4 NEN 20 s ysl ema w 0 030 inch 4 n 4 P SI EIL D H 202 BAS e OSCILLATEMANIFOLD FOUR WHEEL STEER MANIFOL
11. STR LS T5 FROM OC TO OC PMAN GR QO 68 EA 8 Ses deseen ot 18 010 2 6917 0 38 L min PLATFORM MANIFOLD e 1 500 5 34 5 5cuin 82 cc ACCUMULATOR J July 2006 Section 6 Schematics REV C Hydraulic Schematic 2 Wheel Drive with 2 Wheel Steer View 2 N M L K J H G F E D C B A 3 1 5 2 4 6 1 ee HYDRAULIC ROTARY COUPLER f 2B 3 1 Te 22244 T _ gest B 2 REAR M7 FRONT LEFT FRONT RIGHT RIGHT STEERING STEERING OQ 4 280psi 25 C NNI a E 1 2 Ms Haba CH g 5 AQ 9 11 lt o bo i e 69 Ger A 2 3 gpm 1 2 gpm 2 3 gpm 1 2 gpm A 187 L min 4 5 L min 8 7 L min 4 5 L min 1 202 H LH
12. HYDRAULIC ROTARY COUPLER FRONT RIGHT 8 M6 2gpm 7 6 L min LBRAKE B A 24 5 er 2 gpm 7 6 L min 2 26 APT EST e S wM T 0 762 f 0 4 E DRIVE MANIFOLD RBRAKE BRAKE M7 CDRI M5 2 gpm 7 6 L min LBRAKE R2SPEED a gt L2SPEED SPEED July 2006 Section 6 Schematics Hydraulic Schematic 4 Wheel Drive with 4 Wheel Steer View 2 California Proposition 65 WARNING The exhaust from this product contains chemicals known to the State of California to cause cancer birth defects or other reproductive harm Genie North America Phone 425 881 1800 Toll Free USA and Canada 800 536 1800 Fax 425 883 3475 Genie Australia Pty Ltd Phone 61 7 3375 1660 Fax 61 7 3375 1002 Genie Scandinavia Phone 46 31 575100 Fax 46 31 579020 Genie China Phone 86 21 53852570 Fax 86 21 53852569 Genie France Phone 33 0 2 37 26 09 99 Fax 33 0 2 37 26 09 98 Genie Malaysia P
13. cu J RN LEE E mes E e E il 68 TII SEENEN S 0 762 mm ci 433 VE WI 6B e 5 TE i VE wf e O s TWO WHEEL REAR E OSCILLATE MANIFOLD STEER MANIFOLD LEFT e MES ee e L L2SPEED HYDRAULIC WELDER OPTION RBRAKE 22 20 al Nla c ONES 7 Me 71 3 5 GPM hu D 8 210C G2 461 12 5 KW GENERATOR A TEREX COMPANY Part No 88619 Z 80 60 6 38 July 2006 Section 6 Schematics Hydraulic Schematic 2 Wheel Drive with 2 Wheel Steer View 2 July 2006 Section 6 Schematics Hydraulic Schematic 2 Wheel Drive with 4 Wheel Steer View 1
14. CAB Load sensing circuit square end right side steer cylinder extend Check valve pp CAC Load sensing circuit square end left side steer cylinder extend Check valve 65 psi 4 5 CAD Prevents steer cylinder from moving when not steering Check valve 65 psi 4 5 bar CAE Prevents steer cylinder from moving when not steering July 2006 REV C Torque 8 10 ft Ibs 11 14 Nm 26 30 ft lbs 35 41 Nm 26 30 ft lbs 35 41 Nm 20 25 ft lbs 27 34 Nm 20 25 ft lbs 27 34 Nm 20 25 ft lbs 27 34 Nm 20 25 ft lbs 27 34 Nm 20 25 ft lbs 27 34 Nm 26 30 ft lbs 35 41 Nm 20 25 ft lbs 27 34 Nm 8 10 ft lbs 11 14 Nm 20 25 ft lbs 27 34 Nm 20 25 ft lbs 27 34 Nm 8 10 ft lbs 11 14 Nm 8 10 ft lbs 11 14 Nm 20 25 ft lbs 27 34 Nm 20 25 ft lbs 27 34 Nm Z 80 60 Part No 88619 Section 4 Repair Procedures July 2006 MANIFOLDS REV C CJ 83 Part No 88619 Section 4 Repair Procedures July 2006 MANIFOLDS REV How to Adjust the Oscillate Relief Valve Perform this procedure with the boom in the stowed position This procedure will require two people 1 Remove the drive chassis cover from the square end of the machine 2 Connect a
15. 2 15 Hydraulic Hose and Fitting Torque Specifications 2 16 SAE and Metric Fasteners Torque Charts Nt 2 17 Scheduled Maintenance Procedures Introduction bete nbi mista mecs 3 1 B Pre Delivery Preparation 4 3 3 Maintenance Inspection 4444 4 4 0 000000 3 5 C Checklist A Procedures A 1 Inspect the Manuals and 3 7 2 Perform Pre operation Inspection pt 3 8 Perform Function Tests Re 3 8 Part No 88619 Z 80 60 vii September 2006 SSS eo TABLE OF CONTENTS Section3 Rev Scheduled Maintenance Procedures continued 4 Perform Engine Maintenance Nt 3 9 A 5 Check the Hydraulic Filter Condition Indicators 3 10 6 Perform 30 Day Service Ne 3 11 A 7 Perform Engine Maintenance ppp 3 12 8 Grease the Turntable Rotation Bearing and Rotate Gear 3 13 A 9 Inspect the Fuel Filter Water Separator Diesel Models 3 13 A 10 Perform Engine Maintenance Deutz 3 15 A 11 Replace the Drive Hub 3 15 A 12 Perform Engine Maintenance Gasoline LPG Models 3 17 B Checklist B Procedures B 1 Inspect the Batteries 3 18 B 2 Inspect the Electrical 0 3 19 B
16. CN Load sensing circuit circle end This list continues on the next page left side steer cylinder extend Torque 26 30 ft Ibs 35 41 Nm 26 30 ft lbs 35 41 Nm 8 10 ft lbs 11 14 Nm 20 25 ft lbs 27 34 Nm 26 30 ft lbs 35 41 Nm 26 30 ft lbs 35 41 Nm 20 25 ft lbs 27 34 Nm 20 25 ft lbs 27 34 Nm 20 25 ft lbs 27 34 Nm 20 25 ft lbs 27 34 Nm 20 25 ft lbs 27 34 Nm 20 25 ft lbs 27 34 Nm 8 10 ft lbs 11 14 Nm 8 10 ft lbs 11 14 Nm Z 80 60 Part No 88619 Section 4 Repair Procedures July 2006 MANIFOLDS REV C CJ 81 Part No 88619 Section 4 Repair Procedures 1 MANIFOLDS Four Wheel Steer and Oscillate Manifold continued Index No 15 16 17 18 19 20 21 22 23 24 25 26 27 28 29 30 31 Schematic Description Item Function Check valve CO Load sensing circuit circle end right side steer cylinder extend Solenoid valve 3 position 4 way CP Steer left right circle end left side steer cylinder Solenoid valve 3 position 4 way CQ Steer left right circle end right side steer cylinder Flow regulator valve 1 2 4 5 L min
17. CR us Square end left side steer cylinder retract circuit Check valve CS uos Load sensing circuit square end left side steer cylinder retract Check valve 65 psi 4 5 Prevents steer cylinder from moving when not steering Check valve 65 psi 4 5 CU Prevents steer cylinder from moving when not steering Flow regulator valve 2 3 8 7 L min CV Square end right side steer cylinder extend circuit Flow regulator valve 1 2 gpm 4 5 L min before software revision 1 04 1 5 gpm 5 7 L min after software revision 1 03 CW Square end right side steer cylinder retract circuit Flow regulator valve 2 3 8 7 L min Square end left side steer cylinder extend circuit Check valve ous Load sensing circuit square end right side steer cylinder retract Check valve 65 psi 4 5 CZ Prevents steer cylinder from moving when not steering Check valve 65 psi 4 5 bar CAA Prevents steer cylinder from moving when not steering Check valve
18. Current limiting Battery separator Limit switch ALTERNATOR Main key switch device 6 14 Z 80 60 Part No 88619 July 2006 Section 6 Schematics REV 25 9 1 7 bar Filter with bypass valve relief setting fixed displacement 70 t bi directional variable displacement bi directional amp 2 speed bi directional E Pump prime mover engine or motor Double acting cylinder Accumulator ny 035 0 89 mm Orifice with size X Shut off valve E Check valve 1 200 psi 13 8 bar e 1 i p Relief valve with pressure setting Directional valve mechanically activated AL Pilot operated 3 position 3 way shuttle valve All A 5096 50 Flow divider combiner valve with pressure balancing orifice and flow percentages Part No 88619 Hydraulic Symbols Legend H 7 Differential sensing valve Solenoid operated proportional valve E Priority flow regulator valve L Solenoid operated 2 position 3 way directional valve 3000 psi 206 8 bar S pue Counterbalance valve with pressur
19. 1 14 xx Qu si uma wuviv auis 2 IS 91 J waviv NOOV38 5 14 fe0 Ld 8 HM d I6rH amp 5 222 I13HOM Qu HN d IgrH a 21 Ho nad IS be HMad AHd9Sd 2 2 agg a c HIWHO 1V1d Z d 8 MW qd Add95S 2 X8 HM 110 70 40163 NOod HNd 8 H0 SL d uMd 100 H 1002 9 rier NYOH HNM NH9tyO 14 lt HM NOOd2sd 0 14 lt NOOL ON CIRCUIT BOARD DB9 CONNECTOR Continued on View 2 2 3 4 5 6 7 8 Part No 88619 enie Z 80 60 A TEREX COMPANY G 6 20 July 2006 Section 6 Schematics REV C Electrical Schematic View 4 N M L K J H G F E D C B A LOCKOUT VALVE 1 SIG PRI BOOM LENGTH 3 STATUS PRI BOOM LENGTH 100 STATUS PRI BOOM DOWN STATUS AUXILIARY HYD RECOVERY SIGNAL AUXILIARY HYD RECOVERY SIGNAL MULTI FUNCTION VLV RECOVERY SIGNAL MULTI FUNCTION VLV RECOVERY SIGNAL BOOM RET RECOVE
20. M OMS 3 es 5 Q F Ai BN i E Di m 11 1 H Pee 97 SHAXE t t t 4 e a si T 1 2 1 18 11 fum 4 4 i i ow HE wwe oe TE oM I HD oi 1 1 4 22281 1 Jd rzm2emse ec 1 4 1 i 1 rt T N M p 4 IT rm 11 AUX2 752 pp Sore ecg 4 3000 psi 8 10 279 1 3625 psi 17 Aux 207 bar i 250bar iT Wwe a p 6 69 L E mei FF 4 t Lo w v __ PRL PRR PLU PLD 10 5 11 15 o WD AUXILIARY amp 0 38 L min O to to ME e pet PUMP p i e GL Ls 801 1 5 CR 25 1 22 9 ino at P nl dem 6 X r X 4 0 i e 172 bar 6 1 4 3200 psi 220 6 bar p ee 6 TANK
21. Drive With the key switch Forward not stowed drive 120 default 50 min Functions OFF press and hold speed 120 default 50 min the button and turn Forward low drive speed 96 120 max and 50 min the key switch to the Forward high drive speed 96 100 default ON position Release 12096 max and 5096 min the button and Reverse not stowed drive 100 default press speed 120 max and 50 min 100 default Reverse low drive speed 120 max and 50 min 100 default Reverse high drive speed 120 max and 50 min 100 default Drive acceleration 120 max and 50 min 100 default Drive deceleration 100 max and 0 min 75 default Speed limit on steer angle 4 2 Z 80 60 Part No 88619 July 2006 Section 4 Repair Procedures REV DISPLAY MODULE Screen or Procedure Description Range Menu Boom With the key Primary boom up 120 max and 50 min Function switch OFF press speed stowed 100 default Speeds and hold the button and turn the key switch to the ON position Release the button and press Primary boom up speed raised Primary boom down speed stowed Primary boom down speed raised Primary boom extend speed Primary boom retract speed Secondary boom up speed stowed Secondary boom up speed raised Secondary boom down speed stowed Secondary boom down speed raised Secon
22. dos Olio Wik EW TTE 1 v m 1 1 11 i e e ls P zi it LIN L bp 1 ec i MS y H 3 4 3000 psi mee 7 poem preme NES E lod Lo 21 3625 psi 2 8 if 17 aux 207 bar iT Ne i is eb 6 MEE 2 Qno qm 72 oic podes PRL PRR PLU __ PLD Ju 5 Ri n NH O6 Le 0 1gpm lt e tio 1 320 psi PUMP AUXILIARY e e Wiis B 0 38 L min 7 ober PUMP e LL L 4 4 i t AT 0 090 inch B L1 L2 5 i VN amp do ozszmm T 1 4 E40 1 15 sonne Se on je De o F 3200 psi pow aem i 6 TANK Ng ty Se ee E 1 ee Osc T2 STR LS T5 FROM OC Hq 5 amp o stot M 3 1 5 2 4 6 P ic eg De en e bee pe l i HYDRAULIC ROTARY COUPLER e 44
23. 3 60 E 2 Grease the Steer Axle Wheel Bearings 2WD Models 3 62 E 3 Perform Engine Maintenance Perkins and Ford Models 3 63 E 4 Perform Engine Maintenance Ford 3 64 E 5 Perform Engine Maintenance Diesel Models 3 65 E 6 Perform Engine Maintenance Deutz 3 66 E 7 Perform Engine Maintenance Deutz 3 67 E 8 Perform Engine Maintenance Deutz 3 67 A TEREX COMPANY Part No 88619 Z 80 60 ix September 2006 SSS TABLE OF CONTENTS Section4 Repair Procedures hee tcv 4 1 Display Mao 4 2 Platform Controls 1 1 ALC 1000 Circuit 4 9 1 2 Membrane Decal 4 10 1 9 JOWSUCKS nee er roba dec ete t 4 11 B Platform Components 251 Blatform ii ebbe tbe teda 4 18 2 2 Platform Leveling 4 18 2 3 Pl tform Botator z uem ere n eal t pe nme aes 4 20 2 4 Calibrate the Platform Overload System if equipped 4 22 Jib Boom Components 3 1 JID BOOM m 4 25 3 2 Jib Boom Lift Cylinder Ne 4 27
24. HAMVy8 H9d800 Ibo eor AWA 13H 399 00 399 00 Ty zor ATA 1X3 AW QN31X3 NW NMOG ud 80 74 lt 00 lt ATA NW dni Idd 0 4 lt qu nadroo 8 lib esr ATA dn Woos OAS 0 74 lt 210 LWN18 048SZ19 lt ET gt ver oa wa 04S 50 lt 2006 Electrical Schematic View 12 Section 6 Schematics 0 lt 69r MOO MO LOY LL aa JHad600 lt gt gt 9p Wa 02 lt 1 esr Na dn ia H8 P L3HATA SLVLOW 319VINHnL ro rd au Hw 3u1900 AW 138 1X3 NOog 0 4 lt Qu xg JH34d600 AIA WOOS pE 3A1VA 074 Hg9JL3HAIA J14 WHITE 35 PIN MANIFOLD HARN 3 8 01859214 035 1X3 Wa 93 319YN3 1X3 co 3195821 xg H anassz LA 2i OAS Wa 93 118 D gt 5 o 1 O IITI HE E 0 9 5 5 3 eo O 5 O e 1 Tol M oo Section 6 Schematics GM 3 0L Engine Electric
25. low idle adjustment screw b high idle adjustment screw 4 Adjust the low idle adjustment screw until low idle meets specification Tighten the locknut 5 Push and hold the function enable high speed button Note the engine rpm on the display Refer to Section 2 Specifications If the high idle is correct disregard adjustment step 6 6 Loosen the yoke lock nut Turn the high idle adjustment nut and solenoid boot counterclockwise to increase the rpm or clockwise to decrease the rpm Tighten the yoke lock nut and recheck the rpm Be sure the solenoid fully retracts when activating high idle Part No 88619 September 2006 Section 3 Scheduled Maintenance Procedures REV CHECKLIST B PROCEDURES Perkins models 4 Push and hold the function enable high speed button Note the engine rpm on the display 1 Start the engine from the ground controls Refer to Section 2 Specifications 2 PushoneoftheLCD If high idle rpm is correct disregard screen buttons shown until 4 el adjustment step 5 engine rpm is displayed Refer to Section 2 Specifications 5 Loosen the yoke lock nut then turn the high idle adjustment nut and solenoid boot counterclockwise to increase the rpm or 3 Loosen the low idle lock nut and turn the low clockwise to decrease the rpm Tighten the idle adjustment screw clockwise to increase the yoke lock nut and confirm the rpm rpm or counterclockwise to de
26. or 1a ig au Sxdo6u 60 14 3 Ss 1 8 LATA 80 14 lt ye do a1dS19 pi 13A31 1v 1d orn go ig 2 V dOHd 114919 Tihs dn 13A31 1V 1d Syg at E 8 i 1 N 8 ZNA 6 air 288 i 1 ZATA lt lt 84r dn air gt 5 8 9 8 1 8 v JJONO 049 Db MO LOY LW1d 85 5 5 i T 2 1 v 330 NO 60 44 0 gt 227 MOO LOY IW1d 5 1 242 5 ie 8845 ATA 10 48 NH8 13HATA 2 i 268 z amp 1 I N Bu 22 208 2 EL lt lt 261 8830 8 5 2 8 452 1 aa 1 e HLS 20 gt B NE 1 i O o 1 2 1 p EET NR ERIS AE 1 5 6 25 enie Z 80 60 A TEREX COMPANY G Part No 88619 July 2006 Section 6 Schematics Electrical Schematic View 8 July 2006 Section 6 Schematics Electrical Schematic View 9 Section 6 Schematics July 2006 1 Electrical Schematic View 9 z 8 8 E amp BEL g gt 2 95555 og
27. Components 4 1 Primary Boom Cable 4 29 4 2 Primary BOOM eee eet e nace oe a ce 4 32 4 3 Primary Boom Lift Cylinder 4 36 4 4 Primary Boom Extension 4 37 4 5 Primary Boom Angle 1 4 39 4 6 Secondary Boom 4 42 4 7 Secondary Boom Lift Cylinder 4 44 B Engines 5 1 lt ama 4 47 5 2 m 4 47 5 3 Engine Fault Codes Gasoline LPG 4 54 Ground Controls 6 T Circuit Boards oreet 4 55 6 2 Membrane Decal 4 56 Genie A TEREX COMPANY x Z 80 60 Part No 88619 September 2006 TABLE OF CONTENTS Section4 Rev Repair Procedures continued B Hydraulic Pumps 71 Function Pump een Ce eie qt lee ee eee 4 57 4 58 Manifolds 8 1 Function Manifold 1 4 60 8 2 Function Manifold 2 4 62 8 3 Valve Adjustments Function Manifold pp 4 64 0 4 70 8 5 Turntable Rotation Manifold pp 4 72 8 6 Platform Rotate 4 73 8 7 2 Wheel Steer and Oscillate 4 74 8 8 4 Wheel Steer and Oscillate Manifold 4 80 8 9 Oil Diverter
28. EEEE g 8435 TITT 846 00096 5 imc gt J32 ENG HARN S woo ES lt 8832 52 Y ui P ul x 2 ont o Continued on View 10 5 DETAIL T 9 1 OPT 120VAC W REGULATOR 2 2 1 96 a P32 GENHARN 8 178 5 gt 0 RD 12VDC E RED 5 3 WH R45GEN A lt WH GND lt g3 BR BR BK PA5GEN B 2 BK GR F45GEN lt F BK WH 1 1 5 i WH NEUTRAL 5 120VAC g C 9 RES PoS SEE DETAIL D FOR 220VAC i GENERATOR W REGULATOR 4 9 BK 120VAC e 10 15 E LUNAR OLE IIE eID SRE TEE en AER RERO a me 8 E EDO TEM C26TSR WT RD Es 5 8 8 F16 START C25PSR WT BK F17 ENGINE C34SA BK WH C ti d Vi 42 F22 GLOW PLUGS ontinued on lt lt In lt ics i RCR 5 a C21IGN WH e CR2 ENG FUEL 86 30 RELAY 85 P34SA BK WH To R21IGN WH 4 J13 WHITE 23 PIN P46HN WH ao P116HYD OR m ee P35RPN RD i z DETAIL 6 5 5 J82 ENG HARN P32 GEN HARN OPT 220VAC W REGULATOR STARTER 30 aa RELAY PN ee 5 5 2780 30A 1 RD 12VDC lt uc 87 187185 4 X E 9 i o 1 1 2 CR5
29. ete eee S ME _ 2 2 et ee Osc 2 STR LS T5 FROM OC TO OC LASS 5 i 4 sod i KI 1 5 2 4 16 Jie IT l TM HYDRAULIC ROTARY COUPLER 12 X 0 19pm 1 4 2 7 PLATFORM MANIFOLD ee rM 1 T 500 psi 34 5 5 N_A 82 cc ACCUMULATOR 69 8 Genie A TEREX COMPANY 6 41 Z 80 60 Part No 88619 July 2006 Section 6 Schematics REV C Hydraulic Schematic 4 Wheel Drive with 2 Wheel Steer View 2 N M L K J H G F E D C B A 3 1 5 2 4 6 iN en MM MUR ee 1 HYDRAULIC ROTARY COUPLER 2B 3 1 4 T6 DRIVE MANIFOLD west rI AE REAR ii 2 FRONT LEFT FRONT RIGHT
30. a retaining clamp b canister end cap c dust discharge valve Part No 88619 September 2006 Section Scheduled Maintenance Procedures REV Perkins 804C 33 2 Remove the engine tray retaining fastener located under the engine tray Swing the engine tray out and away from the machine 3 Install the fastener that was just removed through the engine tray and into the engine tray anchor hole in the turntable AWARNING Crushing hazard Failure to install the fastener into the engine tray anchor hole to secure the engine tray from moving could result in death or serious injury All Models 4 Release the clamps from the end cap of the air filter canister Remove the end cap 5 Remove the filter element 6 Clean the inside of the canister and the gasket with a damp cloth 7 Install the new filter element 8 Install the air filler canister end cap and connect the end cap retaining clamp A TEREX COMI Part No 88619 CHECKLIST C PROCEDURES C 5 Replace the Fuel Water Separator Diesel Models Genie specifications require that this procedure be performed every 500 hours or annually whichever comes first Regular replacement of the fuel filter water separator is essential for good engine performance Failure to perform this procedure can lead to poor engine performance and or hard starting and continued use may result in component damage Extremely dirty conditions may require this
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32. turntable dial indicator drive chassis turntable rotation bearing 5 Atthe dial indicator adjust it to zero the indicator 6 Fully extend the boom and lower to a horizontal position TEREX COMPANY 3 54 Z 80 60 Part No 88619 September 2006 Section Scheduled Maintenance Procedures REV D 5 Replace the Drive Hub Oil Replacing the drive hub oil is essential for good machine performance and service life Failure to replace the drive hub oil at yearly intervals may cause the machine to perform poorly and continued use may cause component damage Drive Hubs 1 Select the drive hub to be serviced Drive the machine until one of the two plugs is at the lowest point 2 Remove both plugs and drain the oil into a suitable container 3 Drive the machine until one plug is at the top and the other is at 90 degrees a models with pipe plugs b models with o ring plugs Part No 88619 CHECKLIST D PROCEDURES 4 Fill the hub with oil from the top hole until the oil level is even with the bottom of the side hole Apply pipe thread sealant to the plugs Install the plugs 5 Models with pipe plugs Apply pipe thread sealant to the plugs and install the plugs Models with O ring plugs Install the plugs into the drive hub 6 Repeat steps 1 through 5 for the other drive hub Turntable Rotate Drive Hub 1 Secure the turntable from rotating with the turntable
33. FM Equalizes pressure on both sides of divider combiner valve FQ 30 35 ft Ibs 41 47 Nm 14 Bi directional flow control valve 2 gpm 7 6 FN Equalizes pressure on both sides of divider combiner valve 30 35 ft Ibs 41 47 Nm 15 Check valve FO Drive motor anti cavitation 20 25 ft lbs 27 34 Nm 16 Flow divider combiner valve Controls flow to circle end drive motors in forward and reverse 90 100 ft Ibs 122 136 Nm 17 Flow divider combiner valve FQ uus Controls flow to divider combiner valves FJ and FP 90 100 ft Ibs 122 136 Nm 18 Check valve Drive motor anti cavitation 20 25 ft lbs 27 34 Nm Genie A TEREX COMPANY 4 90 Z 80 60 Part No 88619 July 2006 Section 4 Repair Procedures REV MANIFOLDS 0 FA FB FC FD FE A TEREX COMPANY Part No 88619 Z 80 60 4 91 Section 4 Repair Procedures July 2006 MANIFOLDS REV B 13 10 Press and hold the function enable high rpm Valve Adjustments AWD select button rabbit symbol Traction Manifold 5 11 Adjust the internal hex socket until the pressure reading on the gauge is 40 psi 2 8 bar less than the pressur
34. _ PP 2 PRET _ _ REXT PRET MC Ve FUNCTION 9 C 2 ms MANIFOLD le eli mni ae 2500 psi 2600 psi JIB BOOM a PMP i71 mt O Pal PLATFORM ROTATE PLATFORM LEVEL 1 25 0 75 gpm 1 59 eH 2500 psi Fa rey 0 3 1 14 L min 0 65 2 46 L min 4 75 L min 2 84 L min i PTEST 1 1 1 172 bar cur 1 4 if 1300 psi 1300 psi 771 n ALLY 8966 AAF EP Of gt ALA A 1 1 d H 1 I ST 4 PTEST2 ie E ug 22 QUE olo NOE oM HD o 2 09 t N 3000 psi por pee 1 pcm ji 1 3625 psi 8 1 17 aux 207 bar SC eee ue ae 1 250bar he fe bi 6 4 Ib e In iba e iba a 941 TE ir MAG LE ME LSTEST 0 TI ii 1 o 1 1 __ PRL _ PRR PLU _ PLD D 5 Ege 4 x F4 il FUNCTION M e XH 9 v r 0 1 gpm e lt e ak oe fone obi et eil oti l Je et 1 1 22bar 1 1 la i 3 42 11
35. Part No 88619 A TEREX COMPANY Z 80 60 Section 5 Fault Codes m Q FORD ECM FAULT CODE CHART July 2006 REVA Code Problem Cause Solution 144 Adaptive Learn Low LPG Engine wire harness may have an intermittent short to 5V DC or 12V DC OR fuel system components may be faulty Repair short in engine wire harness OR test and repair the fuel system components 161 System Voltage Low Battery is faulty OR alternator is not charging OR battery supply wiring to ECM is open or shorted Replace battery OR repair alternator OR repair battery supply wiring to ECM 162 System Voltage High Alternator is overcharging the battery when engine RPM is greater than 1500 rpm Repair or replace the alternator 211 IAT High Voltage IAT sensor wiring and or connections are open or shorted OR sensor is faulty OR engine intake air temperature is too cold Repair wiring and or connections OR replace sensor OR direct warmer air into air intake 212 IAT Low Voltage IAT sensor wiring and or connections are open or shorted OR sensor is faulty OR engine intake air temperature is too hot Repair wiring and or connections OR replace sensor OR direct cooler air into air intake 213 IAT Higher Than Expected 1 Air intake temperature is greater than 200 F with the engine g
36. and Fastener Torq ue Result The oil level should be even with the bottom of the side plug hole If necessary remove the top plug and add oil until the oil level is even with the bottom of the Failure to maintain proper drive hub oil levels may side plug hole cause the machine to perform poorly and 4 Models with pipe plugs Apply pipe thread continued use may cause component damage sealant to the plugs and install the plugs Drive hubs Models with O ring plugs Install the plugs into the drive hub Torque to Specification 1 Drive the machine to rotate the hub until one of Refer to Section 2 Specifications the plugs is located on top and the other one is at 90 degrees 5 Repeat steps 1 through 4 for the other drive a hub 6 Checkthe torque of the drive hub mounting fasteners Refer to Section 2 Specifications a models with pipe plugs b models with o ring plugs A TEREX COMPANY Part No 88619 Z 80 60 3 25 Section 3 Scheduled Maintenance Procedures September 2006 CHECKLIST B PROCEDURES REV C Turntable rotate drive hub B 10 1 Remove the plug located on the side ofthe hub Test the Ground Control Override and check the oil level properly functioning ground control override is Result The oil level should be even with the essential to safe machine operation The ground bottom of the plug hole opening control override function is intended to allow ground p
37. 14 Check valve 65 psi 4 5 bar BN This list continues on the next page Z 80 60 Function Torque Steer left right right side steer cylinder Steer left right left side steer cylinder 26 30 ft Ibs 35 41 Nm 26 30 ft lbs 35 41 Nm 26 30 ft lbs 35 41 Nm 26 30 ft lbs 35 41 Nm Oscillate cylinder left side Oscillate cylinder right side Oscillate circuit 20 25 ft lbs 27 34 Nm Left side steer cylinder extend circuit 20 25 ft lbs 27 34 Nm Left side steer cylinder retract circuit 20 25 ft lbs 27 34 Nm Load sensing circuit left side steer cylinder retract 8 10 ft lbs 11 14 Nm Prevents steer cylinder from moving when not steering 20 25 ft lbs 27 34 Nm Prevents steer cylinder from moving when not steering 20 25 ft lbs 27 34 Nm Right side steer cylinder extend circuit 20 25 ft lbs 27 34 Nm Right side steer cylinder retract circuit 20 25 ft lbs 27 34 Nm Prevents steer cylinder from moving when not steering 20 25 ft lbs 27 34 Nm Prevents steer cylinder from moving when not steering 20 25 ft lbs 27 34 Nm Part No 88619 July 2006 Section 4 Repair Procedures REV MANIFOLDS 3 BL E BK BG 7 BJ BI 0 Genie A TEREX COMPANY Part No 88619 Z 80 60 4 75 Section 4 Repair Procedures July 2006 1 MANIFOLDS REV
38. How to Disassemble the Primary Boom Complete disassembly of the primary boom is only necessary if the outer or inner primary boom tube must be replaced The extension cylinder can be removed without completely disassembling the boom See 4 4 How to Remove the Primary Boom Extension Cylinder 1 Remove the primary boom See 4 2 How to Remove the Primary Boom 2 Place blocks under the barrel end of the primary boom extension cylinder for support 3 Remove the pin retaining fastener from the extension cylinder barrel end pivot pin at the pivot end of the primary boom 4 Use soft metal drift to remove the pin Crushing hazard The primary AWARNING boom could become unbalanced and fall if not properly supported when the pivot pin is removed 5 Remove and label the location of the wear pads from the platform end of the primary boom Pay careful attention to the location and number of shims used with each wear pad 6 Attach a lifting strap from an overhead crane to the extension boom assembly A TEREX COMI Part No 88619 BOOM COMPONENTS 7 Support and slide the extension boom assembly out of the primary boom tube and place it on a structure capable of supporting it AWARNING Crushing hazard The extension boom tube could become unbalanced and fall if not properly supported when removed from the primary boom tube During removal the overhead crane strap will need to be adjusted for proper balanci
39. Turntable rotate left 35 40 ft lbs 47 54 Nm Op Ou A TEREX COMPANY Part No 88619 Z 80 60 4 73 Section 4 Repair Procedures July 2006 MANIFOLDS 8 7 REV Two Wheel Steer and Oscillate Manifold The Two Wheel Steer and Oscillate manifold is mounted inside the drive chassis at the square end of the machine Index Schematic No Description Item 1 Solenoid valve 3 position 4 way BA 2 Solenoid valve 3 position 4 way Solenoid valve 2 position way BC Solenoid valve 2 position 3 way BD 5 Relief valve 750 to 860 psi 51 71 to 59 3 bar ssa 6 Flow regulator valve 2 3 gpm 8 7 L min BF 7 Flow regulator valve 1 2 4 5 L min before software revision 1 04 1 5 5 7 L min after software revision 1 03 BG 8 Check valve BH 9 Check valve Bl 10 Check valve BJ 11 Flow regulator valve 2 3 8 7 L min BK 12 Flow regulator valve 1 2 gpm 4 5 L min before software revision 1 04 1 5 gpm 5 7 L min after software revision 1 03 BL 18 Check valve 65 psi 4 5 bar BM
40. Z 80 60 REV C 4 Connect a 0 to 5000 psi 0 to 350 bar pressure gauge to the LS port on the function manifold 5 Startthe engine from the ground controls 6 Simultaneously push and hold the function enable high speed button and the secondary boom up extend button and fully raise the secondary boom 7 Continue holding the function enable high speed button and the secondary boom up extend button while observing the reading on the pressure gauge Refer to Section 2 Specifications 8 Turn the engine off Use a wrench to hold the relief valve and remove the cap item B 9 Adjust the internal hex socket Turn it clockwise to increase the pressure or counterclockwise to decrease the pressure Install the relief valve cap AWARNING Tip over hazard Do not adjust the relief valve higher than specified 10 Repeat steps 5 through 7 to confirm relief valve pressure 11 Remove the pressure gauge 12 Remove the jumper wire from LSS2AO limit switch connector Connect the limit switch to the wire harness 13 Install the secondary boom end cover and tighten the retaining fasteners Part No 88619 July 2006 Section 4 Repair Procedures REV How to Adjust the Secondary Boom Down Relief Valve 1 Connect 0 to 5000 psi 0 to 350 bar pressure gauge to the Ls port on the function manifold 2 Start the engine from the ground controls 3 Press and release the rpm select button until the engine changes to
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42. no unable to complete R repaired Comments Pre Delivery Preparation Y N R Pre operation inspection completed Maintenance items completed Function tests completed Model Serial number Date Machine owner Inspected by print Inspector signature Inspector title Inspector company Section Scheduled Maintenance Procedures September 2006 This page intentionally left blank A TEREX COMPANY 3 4 Z 80 60 Part No 88619 September 2006 Section 3 Scheduled Maintenance Procedures Maintenance Inspection Report Model Serial number Date Hour meter Machine owner Inspected by print Inspector signature Inspector title Inspector company Instructions Make copies of this report to use for each inspection Select the appropriate checklist s for the type of inspection to be performed Daily or 8 hour Inspection A Quarterly or 250 hour Inspection A B Six Month or 500 hour Inspection A B C Annual or 1000 hours Inspection A B C D 2 Year or 2000 hour Inspection A B C D E Place a check in the appropriate box after each inspection procedure is completed Use the step by step procedures in this section to learn how to perform these inspections If any inspection receives tag and remove the machine from service repair and re inspect it After repair place a check in the R box Legend Y yes acceptable no remove fr
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44. C 6 Engine maintenance Checklist D Rev Y NR D 1 Boom wear pads D 2 Free wheel configuration D 3 Turntable rotation bolts D 4 Turntable bearing wear D 5 Drive hub oil D 6 Engine maintenance Perform every 1000 hours D 7 Replace hydraulic filters Comments E 3 Engine maintenance Perform every 2400 hours E 4 Engine maintenance Perform every 3000 hours E 5 Engine maintenance Perform every 5000 hours E 6 Engine maintenance Perform every 6000 hours E 7 Engine maintenance Perform every 12000 hours IT E 8 Engine maintenance A TEREX COMPANY Part No 88619 September 2006 Section 3 Scheduled Maintenance Procedures REV A 1 Inspect the Manuals and Decals Maintaining the operator s and safety manuals in good condition is essential to safe machine operation Manuals are included with each machine and should be stored in the container provided in the platform An illegible or missing manual will not provide safety and operational information necessary for a safe operating condition In addition maintaining all of the safety and instructional decals in good condition is mandatory for safe machine operation Decals alert operators and personnel to the many possible hazards associated with using this machine They also provide users with operation and maintenance infor
45. ead NdVWV 93 d9 zHqN9 enie G A TEREX COMPANY 6 19 Z 80 60 Part No 88619 July 2006 Section 6 Schematics Ex Electrical Schematic View 2 Platform Controls PCON July 2006 Section 6 Schematics Electrical Schematic View 3 Ground Controls TCON REV Continued on View 4 July 2006 Electrical Schematic View 3 Ground Controls TCON Section 6 Schematics 4 5 5 zz 4 0 zz lt 96 5 1 4 00 gt lt 2 2 ogouu Frnt OD GZS 266 Shoes gt 0 0 Sg a P3 gt T 9 Pe u gt a 32245 2u0HG o lt cs amp 5 2 JJydozrec ze 5 Im 8 z gt gt gt z 5 9 5 9 9 220984 D X amp ca 2 2 8 338883 805 P5 8 0526 a 8 o 8 SE 5 O gt 5 gt o E 5 5 5 Ez 8 m a 5 0 Zu 2 588 a
46. 29 26 0 o 9 1420 10 09 19 2 27 Bolt torque sequence from above turntable 6 Lower the boom to the stowed position 7 Confirm that each bearing mounting bolt under the drive chassis is torqued in sequence to specification Refer to Section 2 Specifications 0 1 15 18 Q 8 14 6 Bolt torque sequence from below chassis Part No 88619 September 2006 Section Scheduled Maintenance Procedures REV 8 Lower the secondary boom to the stowed position 9 Remove the engine tray retaining fastener from the engine tray anchor hole at the pivot end of the engine tray 10 Swing the engine tray in towards the machine 11 Install the bolt that was just removed into the original hole to secure the engine tray AWARNING Crushing hazard Failure to install the bolt into the engine tray to secure it from moving could result in death or serious injury A TEREX Part No 88619 CHECKLIST D PROCEDURES D 4 Inspect for Turntable Bearing Wear Periodic inspection of turntable bearing wear is essential to safe machine operation good machine performance and service life Continued use of a worn turntable bearing could create an unsafe operating condition resulting in death or serious injury and component damage Perform this procedure with the machine on a firm level surface and the boom in the stowed position
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48. 6 12 IN 5 1 5 6 Holo m Ed IN aj gt LIE 23 A NI oo De o M N w o 1c1N 2163 eleole o o 1 4 40 SIAN 019 g B oo o 9 oo E T m A EN zal o N to iji a N A 1 40010 ofA o 1 4100109 End AOI Lon k 1 4 400 OS 101 41 15151 1 1 1 41 0151 co NI NJ oo RIN NI cola Aa o 20 A 74 77 535 157 214 210 285 420 570 562 583 791 78 1055 682 925 909 1233 N e Ao 10 eJ co Nie gt 25 gt 3 o De lt gt on AIO eic o N N A Part No 88619 Z 80 60 2 17 Section 2 Specifications July 2006 E This page intentionally left blank A TEREX COMPANY 2 18 Z 80 60 Part No 88619 September 2006 Section 3 Scheduled Maintenance Procedures Scheduled Maintenance Procedures Observe and Obey Maintenance inspections shall be completed by a person trained
49. EG Charge pressure 20 25 ft lbs 27 34 Nm 8 Shuttle valve 3 position 3 way EH s Charge pressure circuit that directs hot oil out of low pressure side of drive pump 30 35 ft lbs 41 47 Nm 9 Bi directional flow control valve 4 5 17 L MIN El is Equalizes pressure on both sides of divider combiner valve EJ 30 35 ft lbs 41 47 Nm 10 Flow divider combiner valve EJ us Controls flow to drive motors in forward and reverse 90 100 ft Ibs 122 136 Nm Genie A TEREX COMPANY 4 86 Z 80 60 Part No 88619 July 2006 Section 4 Repair Procedures REV MANIFOLDS EG A TEREX COMPANY Part No 88619 Z 80 60 4 87 Section 4 Repair Procedures July 2006 MANIFOLDS REV 8 11 10 Press and hold the function enable high rpm Valve Adjustments 2WD select button rabbit symbol position Traction Manifold i 11 Adjust the internal hex socket until the pressure reading on the gauge is 40 psi 2 8 bar less than the pressure reading taken in step 5 Turn How to Adjust the Charge it clockwise to increase the pressure or Pressure Relief Valve counterclockwise to decrease the pressure Install the valve cap i ith th 2 4 12 Turn the engine off and remove the pressure 100 F to 150 38 C to 65 5 C gauge 1 Connect a
50. REV B 2 4 Platform Overload System How to Calibrate the Platform Overload System if equipped Calibration of the platform overload system is essential to safe machine operation Continued use of an improperly calibrated platform overload system could result in the system failing to sense an overloaded platform The stability of the machine is compromised and it could tip over Perform this procedure with the machine on a firm level surface 1 Turn the key switch to platform control Start the engine and level the platform 2 Determine the maximum platform capacity Refer to the machine serial plate 3 Remove all weight tools and accessories from the platform Failure to remove all weight tools and accessories from the platform will result in an incorrect calibration 4 Using a suitable lifting device place a test weight equal to the maximum platform capacity at the center of the platform floor Part No 88619 July 2006 Section 4 Repair Procedures REV PLATFORM COMPONENTS 5 Move the platform up and down by hand so it 6 Move the platform up and down by hand so it bounces approximately 2 5 to 5 cm 1 to 2 inches Allow the platform to settle bounces approximately 2 5 to 5 cm 1 to 2 inches Allow the platform to settle O Result The alarm should be off The platform O Result The alarm should be off The platform overload indicator light should be off at the platform controls and the
51. Section Scheduled Maintenance Procedures m M E M H MAINTENANCE INSPECTION REPORT Model Serial number Date Hour meter Machine owner Inspected by print Inspector signature Inspector title Inspector company Instructions Make copies of this report to use for each inspection Select the appropriate checklist s for the type of inspection to be performed Daily or 8 hour Inspection A Quarterly or 250 hour Inspection A B Six Month or 500 hour Inspection A B C Annual or 1000 hours Inspection A B C D 2 Year or 2000 hour Inspection A B C D E Place a check in the appropriate box after each inspection procedure is completed Use the step by step procedures in this section to learn how to perform these inspections If any inspection receives tag and remove the machine from service repair and re inspect it After repair place a check in the R box Legend Y yes acceptable no remove from service R repaired Checklist C Rev B Y NR July 2006 Checklist E Rev B Y NR C 1 Engine maintenance E 1 Replace hydraulic oil C 2 Grease platform overload if equipped E 2 Wheel bearings 2WD models C 3 Test the platform overload if equipped C 4 Engine Air Filter C 5 Replace filter separator Perform every 800 hours
52. UNUSED 6 V52AFV BL RD 7 P56PRV RD 7 V52REV BL RD 8 UNUSED 8 V36RRS BL 9 UNUSED 9 V37RRS BL BK 10 D80SHIELD 11 UNUSED 12 UNUSED 13 UNUSED 14 UNUSED 15 CA7OUT WH BK 16 C46HRN WH 17 D81CAN GR 18 D82CAN YL 19 UNUSED 20 UNUSED 21 UNUSED 22 UNUSED 23 P23PCON BK Lo Ac PIN NUMBERING FOR 23 PIN CONNECTORS Genie CONNECTOR REV B 10 C111RRS OR 11 C111LRS OR 12 C111RFS OR 13 1111 5 OR 14 VLVRET2 BR 15 V32BRK WH RD 16 V36LRS BL 17 V37LRS BL BK 18 V36RFS BL 19 P110RT BK 20 P109ANG GR WH 21 V37RFS BL BK 22 V36LFS BL 23 V37LFS BL BK DCON DRIVE CHASSIS CONTROLLER 431 1 GND DCON BR 2 P21DCON WH 3 P53LS RD 4 UNUSED 5 S56PRV RD 6 C61AXRT GR 7 UNUSED 8 AXLE RET GND 9 C61LS GR 10 D80SHLD 11 RS232 RXD 12 RS232 TXD 13 BOOT 14 UNUSED 15 C61LS A GR 16 UNUSED 17 D81CAN GR 18 D82CAN YL 19 RS232 GND 20 UNUSED 21 UNUSED 22 UNUSED 23 C61LS A GR 6 10 A TEREX COMPANY Z 80 60 Part No 88619
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54. mode 13 Push one of the LCD screen buttons shown 4 until secondary boom status is displayed 14 Raise the secondary boom until the display shows gt 35 DEGREES 15 Locate the secondary boom 2 angle operational limit switch LSS2AO on the inside of the turntable riser 16 Carefully disconnect the wire harness from LSS2A0 and install a wire jumper between pins 1 and 2 of the deutsch connector on the wire harness Install a second wire jumper between pins 3 and 4 of the deutsch connector Result The display should show at 65 DEGREES A TEREX COMI Part No 88619 CHECKLIST B PROCEDURES 17 Press and hold the low speed function enable button and extend the secondary boom Result The secondary boom should extend 12 inches 30 5 cm and stop The engine should stop and the display will show P9B SAFETY FAULT and P11 SAFETY FAULT W Result If the engine does not stop and the secondary boom continues to extend the secondary boom 1 retracted safety limit switch LSS1RS is out of adjustment or the wiring circuit is faulty and will need to be replaced or repaired AWARNING Bodily injury hazard If the secondary boom continues to extend without stopping the engine stop immediately and retract the secondary boom Failure to retract the secondary boom could result in death or serious injury 18 Remove the wire jumpers installed in step 16 and connect the wire harness to 1
55. 1 Grease the turntable bearing See A 7 Grease the Turntable Bearing and Rotate Gear 2 Torque the turntable bearing bolts to specification See D 3 Check the Turntable Rotation Bearing Bolts 3 Start the machine from the ground controls and raise the boom to full height Do not extend the boom Section 3 Scheduled Maintenance Procedures September 2006 CHECKLIST D PROCEDURES REV 4 Place a dial indicator between the drive chassis 7 Note the reading on the dial indicator and the turntable at a point that is directly under or inline with the boom and no more than 1 inch 2 5 cm from the bearing O Result The measurement is less than 0 063 inch 1 6 mm The bearing is good Result The measurement is more than 0 063 inch 1 6 mm The bearing is worn and needs to be replaced To obtain an accurate x measurement place the dial indicator no more than 1 inch 2 5 cm from the turntable 8 Fully retract the boom and raise the boom to full rotation bearing height Visually inspect the dial indicator to be sure the needle returns to the zero position X 9 Remove the dial indicator and rotate the turntable 90 10 Repeat steps 4 through 9 until the rotation N bearing has been checked in at least four equally spaced areas 90 apart 11 Lower the boom to the stowed position and turn the machine off 12 Remove the dial indicator from the machine
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58. 4 19313 5 dnndAdvYmIXny T N e N Part 88619 6 32 REVA July 2006 Section 6 Schematics n Electrical Schematic View 14 Perkins 804C 33 Engine after serial number 328 D C B A F4 oog Nu a E22 agg A ze 288 ES 28 88 Cont d on View 5 588 ES 88 ontinue n View LL c X X J15 BLACK4PIN 99 9 J13 WHITE 23 PIN 2 F F 8 S Bi 2 ENGINE 3 NALA 1 1 amp c C84TAY GN WH Emm 2 cog 2 2 558 BES 8 22 5 228 2 P85TTSR GR 5 21220 aoc c 4
59. 5 3 6 18 9 13 63 L min EXTEND RETRACT COUNTERBALANCE VALVE 2 3 11 4 L min 9 7 4 4 36 7 16 7 1 6 1 2 1 23 7 95 L min A dii ame AN RATIO PRESSURE 1000 69 bar HN 1 RS To Ai A 1 51 2000 psi 138 bar 1 1 1 i 3 1 2000 psi 138 bar d 5 Me TAT PET H M ol A 31 2500 psi 172 bar CHARGE FILTER 51 A 3 1 3000 psi 207 bar E A 3 1 3300 psi 227 5 bar arr 9 Ay 1 5 1 3500 psi 241 3 bar 3 asb pow fof A 3 1 3500 psi 241 3 bar RA TRL TRR 1 2 REXT RRET Me ee eee Ic ch oq ees rper o EE 1 FUNCTION om gne MANIFOLD olim E eeu rums 4 2600 psi JIB BOOM 3 DANE Lt e 179 bar PLATFORM ROTATE PLATFORM LEVEL 1 25 gpm 0 75 gpm PUMP MET 69 B 1 Qi 0 3gpm 1 14 L min 0 65 gpm 2 46 L min 4 75 L min 2 84 L min 1 d 1 172 Pr i WERT 2 1300psi 1300 psi 1 Ttt 7 4 puro 5 Kl s9 6bar 89 6 bar E A e AUA e A 11 i ira 2 y 2 i i 11 T T 14 1 x l fis 103 T m ves Me tari tart Fa
60. Geni Service Manual iE September 2006 2 80 60 from serial number 101 September 2006 Introduction Important Read understand and obey the safety rules and operating instructions in the Genie Z 80 60 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 Contact Us http Awww genieindustries com e mail techsup genieind com A TEREX COMPANY Copyright 2003 by Genie Industries 88619 Rev B July 2006
61. Secondary boom function disabled SEC LT AC generator NO BELT HI_LO HYDRL Alarm Motion AL Travel TR AL Descent DE AL Travel and Decent TD AL Lift drive cut outs No NO Drive cutout while not stowed DCONS Lifting or Driving LORDR Auxiliary drive OPT YES NO Proximity kill switch OR Platform overload sensing OVERLOAD NONE PROX PLTFS Work light YES NO Flashing beacon YES NO Drive lights YES NO Disable steer mode change while driving YES NO Rocker joystick steering YES NO Chassis Tilt Cutout YES NO Foot Switch Lockout 0 to 30 minutes Generator Off Delay 0 to 10 seconds 0 to 30 minutes holding or Z button will cause display to scroll through options or increment number settings Part No 88619 A TEREX COMPANY 4 7 Section 4 Repair Procedures July 2006 Platform Controls The platform controls contains two printed circuit boards The LED circuit board is mounted to the underside of the control box lid which contains the LED s The LED circuit board sends the input from the operator to the platform controls ECM circuit board PCON The ECM circuit board PCON sends the data to the turntable control box TCON for processing The platform controls ECM circuit board ALC 1000 communicates with the turntable controls The joystick controllers at the platform controls utilize Hall Effect technology and require no
62. TOL Part 88619 G enie 2 80 60 July 2006 Section 6 Schematics Electrical Schematic View 14 Perkins 804C 33 Engine after serial number 328 July 2006 Section 6 Schematics 255 Electrical Schematic View 15 Ford LRG 425 Engine Section 6 Schematics July 2006 Electrical Schematic View 15 REV A Ford LRG 425 Engine A B C D E F G H J K L M N oot d 1 gt 1 508 5 Lae 22 88 Eo ze e SS _ eg J13 WHITE 23 PIN 85845 ENGINEHARN BERE RR RR ik Continued on View 5 BEBO B ea a C8ATAY GN BK J15 BLACK 4 PIN 2 Irx riir 22 C35RPM BK RD 235 5185555 409 83TAX GN WH POWER HARN Zee Soa a P85TTSR GR lm o a 7 4 zgguulb RETesTTSR BR 4 85 95858558 a lt 49 2 era OO 6 of Quom Fo oO gt x
63. 11 BK 2 RD WH 12 BR GND GR Inside Enclosure 12 5 KW HYDRAULIC GENERATOR TCON paa ES NEUTRAL BUSS BAR CON Su 3 NEMA 4 CONTROL BOX PCON c 8 9 8 is L1 L2 L3 50 AMP 3 POLE CIRCUIT BREAKER WITH INTEGRAL ikohms 3 BNC ci 124 ohm A1 BATTERY 11 0 1 12 4 2 2 SENSOR POWER 5 VDC C12 COM a 3 6 pW BATTERY O RED RED 124 oh 208 51HG GR Bt VALVE 0 FWD COIL 3 GND n 1 4 os ORANGE ig WATE OUTLET 18 2 2 8 Er GR BK Renesas Bs OUTPUT BYPASS OMRON eal de 9 CH E H B RS232RxD 02 D TIME DELAY E 11 i BLACK te 7 c D1 ANALOG 0 JOYSTICK MODULE 4S D2 ANALOG 1 DIO 5 2 D3 DIG IN 3 NC aS BLACK BLACK 12GA GREEN E1 NOT USED poe Eg ne NOT USED TO 9 GROUN AX5 F1 DIGINOP GREEN ees STUD ON F2 DIG IN 1 GENERATOR ON BAT2 m 5 NEL gt DIGIN2 D SX Controller 110 VAC GFI 0 A BLACK 12GA 2 2 SILVERY 8 GA 4 CONDUCTOR fA ON 8 GA
64. 45 50 Nm 8 10 ft lbs 11 14 Nm 50 55 ft lbs 68 75 Nm 30 35 ft lbs 41 47 Nm 30 35 ft lbs 41 47 Nm 30 35 ft lbs 41 47 Nm 30 35 ft lbs 41 47 Nm 33 37 ft lbs 45 50 Nm A TEREX COMPANY Z 80 60 Part No 88619 July 2006 Section 4 Repair Procedures REV MANIFOLDS A TEREX COMPANY Part No 88619 Z 80 60 4 61 Section 4 Repair Procedures July 2006 MANIFOLDS 8 2 Function Manifold View 2 Index Schematic No Description Item 1 Solenoid valve 2 position 2 way Pa 2 Relief valve 2600 psi 179 bar 3 Proportional solenoid valve 4 Solenoid valve 3 position 4 way Ss 5 Check valve 6 Relief valve 1300 psi 89 6 bar Us 7 Solenoid valve 2 position 3 way 8 Proportional solenoid valve W 9 Solenoid valve 2 position 3 way X 10 Check valve Ys 11 Solenoid valve 2 position 3 way Zu 12 Solenoid valve 2 position 3 way AA 13 Proportional solenoid valve AB 14 Check valve AC 15 Check valve 5 psi 0 34 bar AD 16 Check valve 5 psi 0 34 bar AE 17 Check valve 5 psi 0 34 bar AF 18 Relief valve 3000 psi 207 bar AG 19 Check valve 5 psi
65. AWARNING Electrocution hazard Contact with electrically charged circuits could result in death or serious injury Remove all rings watches and other jewelry Component damage hazard Electrostatic discharge ESD can damage printed circuit board components Maintain firm contact with a metal part of the machine that is grounded at all times when handling printed circuit boards OR use a grounded wrist strap CAUTION 3 Carefully disconnect the ribbon cable from the LCD display circuit board 4 Remove the LCD display circuit board retaining fasteners 5 Carefully remove the LCD display circuit board from the ground control box lid Section 4 Repair Procedures July 2006 GROUND CONTROLS 6 2 5 Membrane Decal The membrane decal is a special decal that 6 consists of a decal with an electronic membrane on the backside The membrane contains touch sensitive areas that when pushed activates the machine functions The membrane buttons activate machine functions similar to toggle switches but do not have any moving parts How to Replace the Membrane 7 Decal 1 Turn the key switch at to the off position 8 2 Pushin the red Emergency Stop button to the off position at both the ground and platform 9 controls 3 Remove the ground control box lid fasteners Open the control box lid 4 Tagand disconnect the two ribbon cables from the membrane decal at the ECM circuit board AWARNING Electrocution hazard Contac
66. Contact with electrically charged circuits could result in death or serious injury Remove all rings watches and other jewelry 1 Tag and disconnect the wiring from the coil to be tested 2 Test the coil resistance Result The resistance should be within specification plus or minus 30 Result If the resistance is not within specification plus or minus 30 replace the coil A TEREX Part No 88619 MANIFOLDS How to Test a Coil Diode Properly functioning coil diodes protect the electrical circuit by suppressing voltage spikes Voltage spikes naturally occur within a function circuit following the interruption of electrical current to a coil Faulty diodes can fail to protect the electrical system resulting in a tripped circuit breaker or component damage AWARNING Electrocution hazard Contact with electrically charged circuits could result in death or serious injury Remove all rings watches and other jewelry 1 Test the coil for resistance See 8 14 How to Test a Coil Valve coil resistance specifications Proportional solenoid valve 12V DC 4 to 60 schematic items G R and BB 3 position 4 way solenoid valve 12V DC 4 5 to 6 50 schematic items GB GP and GQ 3 position 4 way solenoid valve 10V DC 5 to 70 schematic items O S BA BB CA CB CP and CQ 2 position 2 way solenoid valve 10V DC 5 5 to 7 50 schematic items C and P 2 position 3 way solen
67. Lockout Low RPM Low fuel Motor Shift Speed Multi Function Valve Platform Control Primary Ext Ret Lockout Platform Level Down Platform Level Flow Control Platform Level Up Platform Rotate Flow Control Platform Rotate Control Platform Rotate Left CCW Platform Rotate Right CW Power Power to Length Sensor Platform Tilt Alarm Platform Tilt Sensor Part No 88619 Section 6 Schematics WIRE CIRCUIT LEGEND Suffix Definition Suffix FE Pressure Comp Enable PCE TCN Pressure Sender PSR GND Pressure Switches PS HRN Primary Boom Angle Sensor PBS HS Primary Boom Down PBD HG Primary Boom Ext Ret Lockout Valve PBL IGN Primary Boom Extend PBE JBD Primary Boom Extend Retract Flow Control PER JBU Primary Boom Retract PBR JBS Primary Boom Angle Sensor PBS JUD Primary Boom Down PBD JD Primary Boom Ext Ret Lockout Valve PBL JFC Primary Boom Extend PBE JSV Primary Boom Extend Retract Flow Control PER JU Primary Boom Retract PBR JER Primary Boom Up PBU JBE Primary Boom Up Dwn Flow Control PUD JBR Primary Boom Extend Retract Signal PLS JRL Primary Boom Up Down Signal PES JRR Primary Lockout PL JPW Primary Length Sensor PSL LPS Propel Signal JPL LF Program Setup Enable PSE LFS Propel Lockout PLL Proportional Valve PRV LRS Proximity Sensor PXS LS Receptacle REC LSR Recovery RCV LDS Retract Lockout RL LO Return RET LS Reverse REV LOF Right Front RF 5 Right Front Steer Sensor RFS MFV Right Re
68. Repair Procedures July 2006 ENGINES GM models 5 Remove the fasteners securing the muffler to the exhaust manifold Burn hazard Hot engine parts can ACAUTION cause severe burns 6 Remove muffler mounting bracket fasteners Remove the muffler and bracket assembly from the engine 7 Remove the hose clamp securing the air filter assembly to the air inlet tube 8 Remove the air cleaner bracket fasteners Remove the air cleaner and bracket assembly from the engine 9 Support the drive pump with an appropriate lifting device Do not apply any lifting pressure 10 Remove all of the remaining bell housing to engine fasteners Carefully pull the pump away from the engine and secure it from moving Component damage hazard CAUTION Hoses can be damaged if they are kinked or pinched 11 Remove the flex plate mounting fasteners and remove the flex plate from the engine flywheel Ford models 5 Tag and disconnect the wire harness from the oxygen sensor 6 Remove the exhaust pipe heat shield fasteners from the top of the muffler Burn Hazard Hot engine parts can ACAUTION cause severe burns A TEREX COMI REV B 7 Remove the muffler retainer bracket fasteners 8 Remove the muffler fasteners securing the muffler to the exhaust manifold Remove the muffler from the bracket 9 Remove the muffler bracket retaining fasteners Remove the muffler bracket from the engine 10 Close the shutoff valve on the Liqu
69. Two Wheel Steer and Oscillate Manifold continued Index Schematic No Description Item Function Torque 15 Check Valve Load sensing circuit right side steer cylinder retract 8 10 ft Ibs 11 14 Nm 16 Check Valve ee Load sensing circuit right side steer cylinder extend 8 10 ft lbs 11 14 Nm 17 Check Valve nettes Load sensing circuit left side steer cylinder extend 8 10 ft lbs 11 14 Nm Genie 4 76 Z 80 60 Part No 88619 July 2006 Section 4 Repair Procedures REV MANIFOLDS 9 BC BD O gt 18 BO 4 s Ce N 7 9 13 f 2 ES 20 9 12 BF 6 BG 7 BJ BI 09 Part No 88619 Z 80 60 Section 4 Repair Procedures July 2006 MANIFOLDS REV How to Adjust the Oscillate 6 Adjust the internal hex socket Turn it clockwise Relief Valve Perform this procedure with the to increase the pressure or counterclockwise to decrease the pressure Install the relief valve cap boom in the stowed position ip j p AWARNING Tip over hazard Do not adjust Perform this procedure with the engine running at high RPM This procedure will require two 7 people the relief valve higher than specified Repeat steps 3 through 4 to confirm relief valve pressure 1 Remove the drive chassis cover from the 8 Remove the pressure gauge
70. boom on the blocks 4 Tag disconnect and plug the hydraulic hoses from the platform leveling cylinder at the bulkhead fittings located inside the boom tube at the platform end Cap the bulkhead fittings on the boom tube AWARNING 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 5 Remove the pin retaining fasteners from the platform leveling cylinder rod end pivot pin Do not remove the pin 6 Remove the external snap rings from the barrel end pivot pin Do not remove the pin 7 Support and secure the jib boom cylinder to the jib boom with a strap or other suitable device Protect the cylinder rod from damage Crushing hazard The jib boom ACAUTION cylinder will fall if not properly supported when the platform level cylinder rod end pivot pin is removed A TEREX COMI Part No 88619 PLATFORM COMPONENTS 8 Use a soft metal drift to remove the barrel end pivot pin Crushing hazard The platform AWARNING and jib boom will fall when the platform leveling cylinder barrel end pivot pin is removed if not properly supported 9 Support the rod end of the platform level cylinder 10 Use a soft metal drift to tap the platform level cylinder rod end pivot pin half way out and lower one of the leveling arms to the ground Tap the pin the other direction and lower
71. m c D M NU IL EE zi Co ECC DOE er Lin 0 080 inch EH 9 Ti t min lt e lt E fem m Ie PAN une WE SS de amp amp 2 Q O 1 3200 psi uu wd i d M 220 6 d 1 i 6 Tank M lh fae fami e Jie 4 Osc T2 STR LS 5 FROM TO OC PMAN ES mE WY 1 4 4 PN LS HYDRAULIC ROTARY COUPLER 0 1gpm I X 01 2 5 LE 6 10 88 L min MM 7 PLATFORM MANIFOLD TT TTT E 34 5 bar 5cuin _ 82 cc pium 8 Genie 6 39 Z 80 60 Part No 88619 July 2006 Section 6 Schematics
72. min Settings Release the button ramp deceleration 100 default 150 max and 50 min 100 default 150 max and 50 min 100 default 150 max and 50 min 100 default 150 max and 50 min 100 default 150 max and 50 min 100 default 150 max and 50 min 100 default 150 max and 50 min 100 default A TEREX COMPANY Part No 88619 July 2006 Section 4 Repair Procedures REV DISPLAY MODULE Screen or Procedure Description Range Menu Valve With the key switch OFF Reset drive valve defaults 4 Calibration Press and hold the Reset primary boom up down button and turn the key switch to the ON position Release the button and press 1 valve defaults Reset primary boom extend retract valve defaults Reset secondary boom valve defaults Reset turntable rotate valve defaults Allow primary boom up down speed calibration Allow primary boom extend retract speed calibration Allow secondary boom up down speed calibration Allow turntable rotate speed calibration Reset drive joystick defaults Reset primary boom up down joystick defaults Reset primary boom extend retract joystick defaults Reset secondary boom joystick defaults Reset turntable rotate joystick defaults Reset steer joystick defaults Part No 88619 A TEREX COMPANY Section 4 Repair Procedures Eee
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74. square end of the machine 9 2 Connect a 0 to 5000 psi 0 to 350 bar pressure gauge to the test port on the two wheel steer and oscillate manifold 3 Start the engine from the platform controls 4 Press down the foot switch and manually activate one of the oscillate limit switches Hold the switch in the activated position and observe the reading on the pressure gauge Refer to Section 2 Specifications 5 Turn the engine off Use a wrench to hold the relief valve and remove the cap item BE TEREX COMPANY Install the drive chassis cover Part No 88619 July 2006 Section 4 Repair Procedures REV MANIFOLDS This page intentionally left blank A TEREX COMPANY Part No 88619 Z 80 60 4 79 Section 4 Repair Procedures July 2006 MANIFOLDS 8 8 Four Wheel Steer and Oscillate Manifold REV The Four Wheel Steer and Oscillate manifold is mounted inside the drive chassis at the square end of the machine Index Schematic No Description Item Function 1 Solenoid valve 3 position 4 way Steer left right square end right side steer cylinder 2 Solenoid valve 3 position 4 way CB Steer left right square end left side steer cylinder 3 Check Valve Load sensing circuit circle end right side steer cylinder retract 4 Check valve 65 psi 4 5 Prevents steer cylinder
75. 0 34 bar AH 20 Differential sensing valve 150 psi 10 3 Al 21 Relief valve 3200 psi 220 6 bar AJ 4 62 Function Secondary boom extend circuit Secondary boom as Turntable rotate left right i Turntable rotate left right Differential sensing circuit turntable rotate iut Primary boom extend 32 23 Primary boom Primary boom extend retract DS Primary boom down Jeden Differential sensing circuit primary boom up down ads Secondary boom sesh Secondary boom down Secondary boom extend retract Differential sensing circuit secondary boom extend retract ee Blocks flow from auxiliary pump 1 to function pump 1 vd Blocks flow from function pump 1 to auxiliary pump 1 Blocks flow from auxiliary pump 2 to function pump 2 m Oscillate and platform manifold system 525 Blocks flow from function pump 2 to auxiliary pump 2 Genie REV Torque 20 25 ft lbs 27 34 Nm 20 25 ft lbs
76. 0 to 600 psi 0 to 50 bar pressure gauge to the test port on the drive pump 2 Use a wrench to hold the charge pressure relief valve and remove the cap item EG 3 Turn the internal hex socket fully a clockwise direction until it stops Install the cap 4 Start the engine from the ground controls 5 Press and hold the function enable high rpm select button rabbit symbol position Note the reading on the pressure gauge 6 Turn the engine off 7 Remove the pressure gauge from the drive pump Connect the gauge to the test port located on the drive manifold 8 Use wrench to hold the charge pressure relief valve and remove the cap from the valve item EG 9 Start the engine from the ground controls TEREX COMPANY 4 88 Z 80 60 Part No 88619 July 2006 Section 4 Repair Procedures REV MANIFOLDS This page intentionally left blank A TEREX COMPANY Part No 88619 Z 80 60 4 89 Section 4 Repair Procedures July 2006 2 MANIFOLDS REV 8 12 Traction Manifold 4WD The 4WD traction manifold is mounted inside the drive chassis at the circle end of the machine Index Schematic No Description Item Function Torque 1 Check valve 5 psi 0 34 bar EA uu Drive motor anti cavitation 30 35 ft Ibs 41 47 Nm 2 Solenoid valve 2 position 3 way 2 speed drive motor shift 26 30 ft lbs 35 41 Nm 3 Solenoid valve 2
77. 30 35 degrees Used to switch platform primary boom leveling parameters LSP1EO Limit Switch Primary Boom 1 Extend Operational Switch closes as the primary boom extends the last 6 to 12 inches signaling the computer LSS2AS Limit switch Secondary Boom 2 Angle Safety Switch Secondary boom angle full extension angle up all the way secondary boom extend allowed Backup switch for 682 LSP1RO Limit Switch Primary Boom 1 Retract Operational Switch closes when the primary boom is fully retracted TEREX COMPANY Part No 88619 Z 80 60 6 9 Section 6 Schematics July 2006 Drive Chassis and Platform Controller Pin Legend CONNECTOR J22 PCON PLATFORM CONTROLLER J22 1 VLVRET7 BR 2 UNUSED 3 C17PRL GR 4 C18PRR GR BK 5 C43JU GR 6 C44JD GR BK 7 C14PLU OR 8 C15PLD OR BK 9 UNUSED 10 R90PXS RD BK 11 C90PXS RD BK 12 UNUSED 13 UNUSED 14 UNUSED 15 C88PTS RD BK 16 56 5 RD 17 C56PTS RD 18 S14PLU RD 19 PLATRET BR 20 C84TAY GR BK 21 P85PTS GR 22 23 P87PTS RD WHITE 224 CONNECTOR J31 BLACK 23 PIN J32 WHITE 23 PIN CONNECTOR PCON DCON PLATFORM DRIVE CHASSIS CONTROLLER CONTROLLER J21 J32 1 UNUSED 1 VLVRET BR 2 P52PCON BL RD 2 V61AXRT GR 3 UNUSED 3 V60AXEX GR WH 4 S56PRV RD 4 V29MS RD WH 5 UNUSED 5 UNUSED 6
78. 4 6 1 2 1 23 7 95 L min qa RATIO PRESSURE 1000 psi 69 A CH de A NE 2000 psi 138 bar A 2000 psi 138 bar M M o MGE UD o A 2500 psi 172 bar A 3000 psi 207 bar 76 A 3300 psi 227 5 bar ee A 3500 psi 241 3 bar A 3500 psi 241 3 bar PRET T3 TAL R1 R2 REXT mn oles uin eam olim t 2500 psi 2600 psi JIB BOOM 1 o 172 179 PLATFORM ROTATE PLATFORM LEVEL 1 25 0 75 e 25004 ro O5 0 3 gpm 1 14 L min 0 65 gpm 2 46 L min 4 75 L min 2 84 L min 1300 psi 1800 psi ie 4 2 t Toes if 89 6 89 6 5 OF gt A A 1 18 1 15601 Q9 M IE DM oi LZ dS E T E asl 10 TA RI RON 1 1 X m uc PLU PLD JU JD O6 WH 79 i 2 E jets RTT RR RR EXE i e e o y bosd 1 69 4 3200 psi imr or 220 6 bar aen ee a ee cc um pe ee ae
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80. 54 3 kW 2500 rpm Net intermittent Firing order 1 3 4 2 Low idle 1500 rpm Frequency 372 Hz High idle 2350 rpm Frequency 582 8 Hz Compression ratio 17 5 1 Compression pressure Pressure psi or bar of the lowest cylinder must be at least 75 of the highest cylinder Governor centrifugal mechanical Valve clearance cold SPECIFICATIONS Lubrication system Oil pressure hot 40 to 60 psi at 2000 rpm 2 8 to 4 1 bar Oil capacity 11 quarts including filter 10 4 liters Oil viscosity requirements Units ship with 15W 40 Extreme operating temperatures my require the use of alternative engine oils For oil requirements refer to the Engine Operator Handbook on your machine Oil temperature switch Torque 8 18 ft lbs 11 24 Nm Oil temperature switch point 275 F 135 C Oil pressure switch Torque 8 18 ft lbs 11 24 Nm Oil pressure switch point 7 psi 0 48 bar Continuous improvement of our products is a Genie policy Product specifications are subject to change without notice Intake 0 012 in 0 3 mm Exhaust 0 020 in 0 5 mm Genie Part No 88619 Z 80 60 2 11 Section 2 Specifications September 2006 lt SPECIFICATIONS REV C Fuel injection system Injection pump make Bosch Injection pump pressure maximum 15 000 psi 1034 bar Injector opening pressure 3046 psi 210 bar Fuel Requirement For fuel requirements refer to the engine Operator s Manual on you
81. 75 Primary 2 Lockout BL 76 Pri boom 3 extended WH 77 Lower angle 1 operational WH BK 78 Upper angle 2 operational BK 79 power from TCON ESTOP N A 80 Can 2 0 J1939 Shield GR 81 Can 2 0 J1939 Low YL 82 Can 2 0 J1939 High GR WH 83 Tilt signal x axis GR BK 84 Tilt signal y axis GR 85 Tilt sensor power OR 86 Hydraulic filter restricted RD 87 Platform level safety power RD BK 88 Platform level safety output BR 89 Platform level safety ground RD BK 90 Proximity kill RD WH 91 Gate Interlock WH BK 92 Motor speed LO HI WH RD 93 Motor bypass WH 94 Load sensor OR 95 Tether ESTOP return RD 96 Tether power BK 97 Tether ESTOP power WH 98 J1708 high 6 6 July 2006 REV B Color Circuit and Primary function BK WH RD WH BK OR OR RD BK WH BK RD WH RD WH BK GR OR RD 99 100 101 102 103 104 105 106 107 108 109 110 111 112 113 114 115 116 117 118 119 120 121 122 123 124 125 126 127 128 J1708 low Outrigger lowered Outrigger raised Pothole protector up Pothole protector down Proprietary data buss i e ITT or AP Proprietary data buss i e ITT or AP Spare Alternator field Engine status Sensor pwr Sensor return Steer signal Steer signal to solenoid valve Multi function valve Load moment overweight Load moment underweight Hydraulic oil cooler Flashing beacon Lift speed reduction Hydraulic pressure sensor output
82. 8 8 amp CA5GEN GRAWH 2 WH 26 WH R45GEN A lt 86 HORN 5 88 30 as si CR17 BATGND BR BR BR GND lt 5 1 5 pew 86 5 30 530 COOLER 50 5 ox Sta 87 8 85187 87 15 85187 87a GR BK WH F45GEN lt 1 8 Che 4 GLOW PLUG 1 i 59 a RELAY i 2 2 x o WH NEUTRAL PE 8 5 5 5 i 7 187185 of 9 A 5 5 5 1 22019 D i 7 ALTERNATOR 8 6 ae 8 508 T i d 1 RESET CBS SEE DETAIL C FOR tt 2 82 5 X 5 p 1 N 120VAC GENERATOR W REGULATOR 4 Bien 208 157 t 8 5 E lt 5 i i BK 220VAC e lt a 5 1 i PERCER orsi EU g 5 ors 1 T 3 8 56 c z STA a N J120 Ry 2 5 iz amp 1 5 IND 9 E a amp REGULATOR 8 8 2 e 95 8 8 amp k E es 2 2 1 5 2 e lt lt lt lt lt lt e o tu Em lt T T a T xor 2 g E a e zx 8 Ea z2o a S zc 2 Sug E gt tao o5 5 Sz uo lt a 3d T E 20a 4 rr go 5 862 aou 8 21 3 ENGINEBLOCK lt 2 rc Sou aS 5 22 50 A 2 55 ou lt ro a 5 xa o 0 852 o 55 0 Be Es E gt La 2 5 xo cro
83. AWARNING Crushing hazard Keep hands clear of the block when lowering the primary boom 6 Simultaneously push and hold the function enable high speed button and the primary boom down button Observe the pressure reading on the pressure gauge Refer to Section 2 Specifications 7 Turn the engine off Use a wrench to hold the relief valve and remove the cap item E 8 Adjust the internal hex socket Turn it clockwise to increase the pressure or counterclockwise to decrease the pressure Install the relief valve Extend Relief Valve 1 Connect a 0 to 5000 psi 0 to 350 bar pressure gauge to the LS port on the function manifold 2 Startthe engine from the ground controls 3 Raise the boom to a horizontal position Turn the engine off 4 Locate the boom extended limit switch LSP1EO on the outside of the primary boom 5 Remove the limit switch mounting bracket retaining fasteners 6 Pullthe limit switch and bracket assembly out of the boom tube and let it hang down 7 Startthe engine from the ground controls and press and release the rpm select button until AWARNING Tip over hazard Do not adjust the engine changes to high idle ihe jin 8 Simultaneously push hold the function enable high speed button and the primary boom 9 Start the engine and repeat steps 6 through 8 to extend button with the primary boom fully confirm the relief valve pressure extended Observe the reading on the pressu
84. DISPLAY MODULE July 2006 REV Screen or Procedure Description Range Menu Sensor With the key switch OFF Set unit levels to gravity Calibration press and hold the Unit level Y axis millivolts button and turn the key per degree switch to the ON position Unit level X axis millivolts Release the button per degree and press 4 Set platform level to gravity Platform level sensor millivolts per degree Reset blue end blue side steer sensor YES NO Reset yellow end blue side steer sensor YES NO Reset blue end yellow side steer sensor YES NO Reset yellow end yellow side steer sensor YES NO Reset all steer sensors YES NO Reset primary boom angle sensor YES NO Primary boom angle 35 deg YES NO Primary boom angle 65 deg YES NO Default With the key switch OFF Reset drive functions Reset press and hold the Reset boom functions button and turn the key Reset lift function ramps switch to the ON position Reset all Release the button and press A TEREX COMPANY Part No 88619 July 2006 Section 4 Repair Procedures REV B DISPLAY MODULE Screen or Procedure Description Range Menu Options With the key switch Boom length limit OFF press and hold the button and turn the key switch to the ON position Release the button and press No limit NO LT Secondary boom extend disabled EXT LT
85. Do How to Bleed the Platform not apply any lifting pressure Rotator 10 Remove the eight mounting bolts from the platform mounting weldment Before serial number 229 11 Remove the center bolt and slide the platform Do not start the engine Use mounting weldment off of the platform rotator auxiliary power for all machine Cusine 4 The iat functions in this procedure rushing hazard The platform AWARNING mounting weldment may become 1 Connect a clear hose to the top bleed valve unbalanced and fall if it is not Place the other end of the hose in a container properly supported to collect any drainage Secure the container to the boom 12 Support the platform rotator Do not apply any lifting pressure 13 Remove the pin retaining fasteners from the jib boom and jib boom leveling arms to platform rotator pivot pins Do not remove the pins 14 Support the jib boom leveling arms with a suitable lifting device 15 Use a soft metal drift to remove both pins and remove the platform rotator from the machine AWARNING 2 hazard jib boom eveling arms may fall if they are not properly supported when the jib boom leveling arm pivot pin is removed top bleed valve bottom bleed valve clear hose container CAUTION Component damage hazard The platform angle sensor is a very sensitive instrument It can be damaged internally if the platform 2 rotator is dropped or sustains any physical shock even if the damage is not v
86. Electrical Schematic View 2 Platform Controls PCON 6 19 B Electrical Schematic View 3 Ground Controls 6 20 B Electrical Schematic View 4 ssssssssssssseeeeeneenneneen nennen 6 21 B Electrical Schematic View 5 6 22 B Electrical Schematic View 6 4 6 23 Electrical Schematic View 7 1 nnne 6 24 Electrical Schematic View 8 0 1 6 25 Electrical Schematic View 9 Nt 6 26 B Electrical Schematic View 10 Limit Switches sssenssseeeeessnrnnrrrrrrrreeeeserrnrrne 6 27 B Electrical Schematic View 11 Deutz FAL 913 Engine before serial number 339 pp 6 28 A Electrical Schematic View 11 Deutz BFAL 201 1 after serial number 338 Ne 6 29 Electrical Schematic View 12 02 4 00 6 30 Electrical Schematic View 13 GM 3 0L 6 31 Electrical Schematic View 14 Perkins 704 30 Engine before serial number 329 pp 6 32 Electrical Schematic View 14 Perkins 804C 33 Engine after serial number 328 ee 6 33 A Electrical Schematic View 15 Ford LRG 425 Engine pp 6 34 A Electrical Schematic View 16 Hydraulic Generator Option 6 35
87. First Edition Second Printing Genie and Z are registered trademarks of Genie Industries in the USA and many other countries 6 Printed on recycled paper Printed in U S A Part No 88619 September 2006 INTRODUCTION Serial Number Legend Genie A TEREX COMPANY Model Z 80 60 Serial number 28006 12345 Model year 2006 Manufacture date 01 05 06 Electrical schematic number 50188 Machine unladen weight Rated work load including occupants 500 Ib 227 kg Maximum number of platfrm occupants 2 Maximum allowable side force 150 Ib 670 N Maximum allowable inclination of the chassis 0 deg 280 06 12345 Maximum wind speed 28 mph 12 5 m s Maximum platform height 86 ft 26 38 Model Sequence number Maximum platform reach 60 ft 18 28 Gradeability N A Country of manufacture USA This machine complies with ANSI A92 5 CAN B 354 4 Model year Genie Industries 18340 NE 76th Street Serial label located under cover Redmond WA 98052 Serial number USA stamped on chassis C PN 77055 Part No 88619 Z 80 60 lii September 2006 SSS eS This page intentionally left blank iv Z 80 60 Part No 88619 September 2006 Section 1 Safety Rules Safety Rules Danger Failure to obey the instructions and safety rules in this manual and the Operator s Manual
88. LENGTH allow only secondary boom retract unknown length Display message on LCD Stop all secondary boom functions Fault check allow only secondary boom retract SEC BOOM ANGLE Once the boom is retracted allow unknown angle secondary boom down Display message on LCD Dayenn RE Normal function except threshold for Not calibrated one or the other direction is zero Calibrate thresholds Display message on LCD UP DOWN EXT RET warning device FLOW VALVE Value at 5 0 V Value Too High Limited speed and direction frozen Power up controller with the Value Too Low at zero and neutral alarm sounds problem corrected Value at 0 V SEC BOOM EXT VALVE SEC BOOM RET VALVE SEC POEM EE Limited speed and direction frozen Power up controller with the Fault check SEC BOOM DOWN VALVE at zero and neutral alarm sounds problem corrected Power up controller with the problem corrected SEC EXT SEQ VALVE SEC DWN SEQ VALVE A TEREX COMPANY 5 2 Z 80 60 Part No 88619 July 2006 Section 5 Fault Codes REV A CONTROL SYSTEM FAULT CODES Error Source Error Type Effects Recovery Actions ENGINE SPEED underspeed Range check low oil Power up controller with the problem OIL PRESSURE Display message on LCD corrected WATER OIL TEMP Range check high temperature OIL PRESSURE SENSOR Fault check Display message on LCD Power up controller with the problem WATER OIL TEMP SENSOR corrected AXL
89. Limited speed and direction frozen at Power up controller with problem Value too low zero and neutral alarm sounds corrected Value at 0 V LF STR ANG SNSR RF STR ANG SNSR LR STR ANG SNSR RR STR ANG SNSR Fault check Limited speed and direction frozen at Power up controller with the problem zero and neutral alarm sounds corrected FOOTSWITCHTIMEOUT Displaymessage on LOD display Recycle power A TEREX COMPANY 5 8 Z 80 60 Part No 88619 July 2006 Section 5 Fault Codes REVA Ford Engine ECM Fault Code Chart Code Problem Cause Solution Closed Loop Multiplier High 111 Heated Oxygen Sensor wiring and or connections open or shorted OR sensor is faulty OR there are Repair wiring and or connections OR replace sensor OR repair vacuum and exhaust LPG vacuum leaks or exhaust leaks leaks 1 1 2 25 Open Inactive Heated Oxygen Sensor wiring and or connections Repair wiring and or connections OR replace Bank 1 open or shorted OR sensor is faulty sensor 1 1 3 25 Open Inactive Heated Oxygen Sensor wiring and or connections Repair wiring and or connections OR replace S Bank 2 open or shorted OR sensor is faulty sensor Post cat oxygen sensor open 114 The post cat Heated Oxygen Sensor wiring and or connections are open or shorted OR sensor is cold non responsive or inactive for 60 seconds or longer Repair wiring and or connections OR replace t
90. Operator Handbook GM part number 36100007 GM 3 0L Operator Handbook REV 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 84792 To access the engine 1 Remove the engine tray retaining fastener located under the engine tray Swing the engine tray out and away from the machine 2 Install the fastener that was just removed through the engine tray and into the engine tray anchor hole in the turntable AWARNING Crushing hazard Failure to install the fastener into the engine tray anchor hole to secure the engine tray from moving could result in death or serious injury Genie part number 77738 Genie 3 42 Z 80 60 Part No 88619 September 2006 Section 3 Scheduled Maintenance Procedures Checklist C Procedures REV C 1 Perform Engine Maintenance Diesel Models Engine specifications require that this procedure be performed every 500 hours Deutz Models Required maintenance procedures and additional engine information are available in the Deutz 913 Operation Manual Deutz part number 0297 7341 OR the Deutz BF4L2011 Operation Manual Deutz part number 0297 9929 Deutz 913 Operation Manual Perkins Models Required maintenance procedures and additional engine information are available in
91. REV 10 Check the ambient air temperature and adjust the specific gravity reading for each cell as follows Add 0 004 to the reading of each cell for every 10 5 5 C above 80 F 26 7 C e Subtract 0 004 from the reading of each cell for every 10 5 5 below 80 F 26 7 C Result All battery cells display a specific gravity of 1 277 or greater The battery is fully charged Proceed to step 13 Result The difference in specific gravity readings between cells is greater than 0 1 OR the specific gravity of one or more cells is less than 1 177 Replace the battery Check the battery acid level If needed replenish with distilled water to 1 8 inch mm below the bottom of the battery fill tube Do not overfill 12 Install the vent caps and neutralize any electrolyte that may have spilled A TEREX COMI Part No 88619 CHECKLIST B PROCEDURES B 2 Inspect the Electrical Wiring Maintaining electrical wiring in good condition is essential to safe operation and good machine performance Failure to find and replace burnt chafed corroded or pinched wires could result in unsafe operating conditions and may cause component damage AWARNING Electrocution hazard Contact with hot or live circuits could result in death or serious injury Remove all rings watches and other jewelry 1 Open the engine side turntable cover 2 Remove the engine tray retaining fastener Swing the en
92. Test Switch Seen GR BK Green Black GR WH Green White RD Red RD BK Red Black RD WH Red White OR Orange OR BL Orange Blue OR BK Orange Black OR RD Orange Red WH White WH BK White Black WH RD White Red YL Yellow 6 4 Z 80 60 Part No 88619 July 2006 REV Color Circuit and Primary function RD RD BK RD WH WH WH BK WH RD BK BK WH BK RD BL BL BK BL WH BL RD 10 11 12 13 14 15 16 17 18 19 20 21 22 23 24 25 26 27 28 30 Primary boom up drive Primary boom down drive Primary boom up dwn FC proportional valve drive Turntable rotate left valve drive Turntable rotate right valve drive Turntable rotate FC proportional valve drive Primary boom extend Primary boom retract Primary boom Extend Retract proportional valve drive Secondary boom up valve drive Secondary boom down valve drive Secondary boom up dwn FC proportional valve drive Drive enable Platform level up valve Platform level down valve Platform up dwn FC proportional valve drive Platform rotate left valve driver Platform rotate right valve driver Jib select valve driver circuit 12 battery supply 12 ignition supply Keyswitch power to platform ESTOP Power to platform Power to warning senders Power to oil pressure sender Power to temp sender Auxiliary power Platform level alarm Drive motor shift speed Forward EDC A Part No 88619 A TEREX Se
93. Type Effects Recovery Actions Sound audible warning and flash primary boom down LED at the medium rate and display message on Value at 5 0 V LCD screen PRI BOOM ANG SENSOR Correct problem SHORTED HIGH Primary boom up inhibited Primary boom velocity limited to 50 of default value Sound audible warning and flash primary boom down LED at the medium rate and display message on OR ANGLE Value at 0 V LCD screen PRI BOOM ANG SENSOR Correct problem SHORTED LOW Primary boom up inhibited Primary boom velocity limited to 50 of default value Sound audible warning at the medium rate and display message on LCD Not calibrated screen PRI BOOM ANG SENSOR NOT CALIBRATED inhibit primary Calibrate primary boom angle sensor boom up from platform control Just calibrated Initiate one Second Dee Sr audible Self clearing transient warning device Value at5 0V at 5 0 V Value too Limited speed and direction frozen at Power up controller with problem Value too low zero and neutral alarm sounds corrected PROPEL JOYSTICK ValueatOV at ValueatOV V zero and neutral warning device Normal function except threshold for Not calibrated one or the other direction is zero Display message on LCD PROPEL VALVES FWD J Initiate one second beep of audible PROPEL VALVES REV ust calibrated Warrilticrdevice Self clearing transient PROPEL EDC FWD Value at 5 0 V PROPEL EDC REV Q E Value Too High Limited s
94. When removing a hose assembly or fitting the O ring on the fitting and or hose end must be replaced 8 and then torqued to specification during installation Refer to Section 2 Hydraulic Hose and 9 Fitting Torque Specifications 1 Raise the primary boom to a horizontal position 2 Extend the primary boom until the primary boom extension cylinder rod end pivot pin is accessible Genie A TEREX 3 5 REV Remove the access cover from the pivot end of the primary boom Place blocks under the barrel end of the primary boom extension cylinder for support Tag disconnect and plug the primary boom extension cylinder hydraulic hoses Cap the fittings on the cylinder AWARNING Bodily injury hazard Spraying 7 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 Working at the platform end of the boom remove the external snap rings from the extension cylinder rod end pivot pin Use a soft metal drift to remove the pin AWARNING Crushing hazard The primary boom could fall when removed from the extension boom if not properly supported Remove the barrel end pivot pin retaining fasteners Place a rod through the barrel end pivot pin and twist to remove the pin Part No 88619 September 2006 Section 4 Repair Procedures REV 10 Working at the pivot end of the boom
95. a minimum of 20 the coil and or its internal diode are faulty and the coil should be replaced 4 94 Z 80 60 Part No 88619 July 2006 Section 4 Repair Procedures REV B 9 1 Turntable Rotation Assembly How to Remove a Turntable Rotation Assembly 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 2 Hydraulic Hose and Fitting Torque Specifications Perform this procedure with the platform between the circle end tires and with the machine ona firm level surface 1 Secure the turntable from rotating with the turntable rotation lock pin unlocked locked 2 Remove the ground controls side fixed turntable cover TEREX COMPAR Part No 88619 Z 80 60 Turntable Rotation Components Tag disconnect the hydraulic hoses from the turntable rotation motor Cap the fittings on the motor Attach a lifting strap from an overhead crane or other suitable lifting device to the lifting eye on the turntable rotation assembly Remove the turntable rotator mounting bolts and remove the turntable rotation assembly from the machine Repeat steps 3 through 5 for the other turntable rotation assembly Tip over hazard If the turntable rotation lock pin is not properly installed machine stability is compromised and the machine could tip over when the drive hub is removed from th
96. adjustment The operating parameters of the joysticks are stored in memory at the turntable controls If a joystick controller error occurs or if a joystick is replaced it will need to be calibrated before that particular machine function will operate See 1 8 How to Calibrate a Joystick Each joystick controller should operate smoothly and provide proportional speed control over its entire range of motion A TEREX COMPANY REV B gt o platform controls ALC 1000 circuit board primary boom extend retract joystick secondary boom up extend and down retract joystick drive steer joystick controller LED circuit board primary boom up down and turntable rotate left right joystick Part No 88619 July 2006 Section 4 Repair Procedures REV 1 1 ALC 1000 Circuit Board When the ALC 1000 circuit board is replaced the joystick controllers will need to be calibrated See 1 3 How to Calibrate a Joystick How to Remove the ALC 1000 Circuit Board 1 Push in the red Emergency Stop button to the off position at both the ground and platform controls 2 Locate the cables that connect to the bottom of the control box Tag each cable and its location at the control box 3 Disconnect the cables from the bottom of the platform control box 4 Remove the control cable plug retaining fasteners from the bottom of the platform control box 5 Remove the platform cont
97. and overheating the engine OR sensor wires and or connections open or shorted OR sensor is faulty OR coolant level is low Repair engine cooling system problems OR repair open or shorted wiring to sensor OR replace sensor OR fill engine coolant level to specification 224 CHT Higher Than Expected 2 Coolant temperature at the cylinder head is 250 F Engine cooling system is malfunctioning and overheating the engine OR sensor wires and or connections open or shorted OR sensor is faulty OR coolant level is low Repair engine cooling system problems OR repair open or shorted wiring to sensor OR replace sensor OR fill engine coolant level to specification 231 MAP High Pressure Open or shorted wiring and or connections to MAP sensor OR sensor is faulty Repair wiring and or connections to sensor OR replace MAP sensor 232 MAP Low Voltage Open or shorted wiring and or connections to MAP sensor OR sensor is faulty Repair wiring and or connections to sensor OR replace MAP sensor 234 BP High Pressure MAP sensor is faulty OR ECM is faulty Replace MAP sensor OR replace the ECM 235 BP Low Pressure MAP sensor is faulty OR ECM is faulty Replace MAP sensor OR replace the ECM 242 Crank Sync Noise Crankshaft position sensor wiring and or connections open or shorted OR there is a poor system ground connection OR sensor is faulty Be sure system ground connections are in
98. and a suitable workshop Attempting this procedure without these skills and tools could result in death or serious injury and significant component damage Dealer service is strongly recommended 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 2 Hydraulic Hose and Fitting Torque Specifications 1 Raise the primary boom to a horizontal position 2 Raise the secondary boom until the primary boom lift cylinder rod end pivot pin is above the counterweight 3 Attach a 5 ton 5000 kg overhead crane to the platform end of the primary boom Support the boom Do not apply any lifting pressure 4 36 Z 80 60 Part No 88619 September 2006 Section 4 Repair Procedures REV BOOM COMPONENTS 4 Support both ends of the primary boom lift 10 Use a soft metal drift to remove the barrel end cylinder with a second overhead crane or similar lifting device 5 Place blocks under the primary boom lift cylinder linkage arms for support 6 Tag disconnect and plug the primary boom lift cylinder hydraulic hoses Cap the fittings on the cylinder AWARNING 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 7 Remove the pin retaining fastener f
99. and or connections OR replace sensor OR repair any vacuum and exhaust leaks OR replace fuel OR test and repair the fuel system components Closed Loop Multiplier High 111 Heated Oxygen Sensor wiring and or connections open or shorted OR sensor is faulty OR there are Repair wiring and or connections OR replace sensor OR repair vacuum and exhaust LPG vacuum leaks or exhaust leaks leaks 1 1 2 25 Open Inactive Heated Oxygen Sensor wiring and or connections Repair wiring and or connections OR replace Bank 1 open or shorted OR sensor is faulty sensor 1 1 3 25 Open Inactive Heated Oxygen Sensor wiring and or connections Repair wiring and or connections OR replace S Bank 2 open or shorted OR sensor is faulty sensor Post cat oxygen sensor open 114 The post cat Heated Oxygen Sensor wiring and or connections are open or shorted OR sensor is cold non responsive or inactive for 60 seconds or longer Repair wiring and or connections OR replace the post cat oxygen sensor Closed Loop Multiplier High Gasoline 121 Heated Oxygen Sensor wiring and or connections open or shorted OR sensor is faulty OR there are vacuum leaks or exhaust leaks OR fuel pressure is low OR the fuel injectors need cleaning or replacing Repair wiring and or connections OR replace sensor OR repair any vacuum and exhaust leaks OR test the fuel pressure OR clean or replace the fuel injectors Genie
100. and qualified on the maintenance of this machine Scheduled maintenance inspections shall be completed daily quarterly six months annually and every two years as specified on the Maintenance Inspection Report AWARNING Failure to perform each procedure as presented and scheduled could result in death serious injury or substantial machine damage M Immediately tag and remove from service damaged or malfunctioning machine Repair any machine damage or malfunction before operating machine Keep records on all inspections for three years Unless otherwise specified perform each procedure with the machine in the following configuration Machine parked on a firm level surface Boomin the stowed position Turntable rotated with the boom between the circle end yellow arrow wheels Turntable secured with the turntable rotation lock pin Key switch in the off position with the key removed Wheels chocked All external AC power supply disconnected from the machine A TEREX COMI About This Section This section contains detailed procedures for each scheduled maintenance inspection Each procedure includes a description safety warnings and step by step instructions Symbols Legend A AWARNING ACAUTION CAUTION Safety alert symbol used to alert personnel to potential personal injury hazards Obey all safety messages that follow this symbol to avoid possible injury o
101. beginning with step 1 Tip over hazard If the boom does not stop at 65 immediately release the function enable button and lower the primary boom Failure to lower the boom could cause the machine to tip over resulting in death or serious injury A TEREX COMI REV C 4 6 Secondary Boom How to Remove the Secondary Boom AWARNING Bodily injury hazard The procedures in this section require specific repair skills lifting equipment and a suitable workshop Attempting this procedure without these skills and tools could result in death or serious injury and significant component damage Dealer service is required 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 2 Hydraulic Hose and Fitting Torque Specifications 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 1 Remove the primary boom See 4 2 How to Remove the Primary Boom Part No 88619 September 2006 Section 4 Repair Procedures REV C BOOM COMPONENTS 2 Tag disconnect and plug the hydraulic hoses at 5 Install the bolt that was just removed into the the primary boom lift cylinder Cap the fittings anchor hole to secure the engine tray from on the cylinder moving AWARNING Bodily injury hazard Spraying A
102. boom lift cylinder lever arm primary boom hose cover primary boom link arm pivot pin primary lift cylinder pivot pin rod end primary lift cylinder pivot pin barrel end primary extend cylinder pivot pin rod end platform level cylinder pivot pin barrel end secondary boom pivot pin secondary lift cylinder pivot pin barrel end secondary lift cylinder pivot pin rod end secondary extend cylinder pivot pin rod end secondary boom lever arm pivot pin primary boom pivot pin primary extend cylinder pivot pins barrel end ATT m n 4 r S t u V w x y 4 28 Z 80 60 Part No 88619 September 2006 Section 4 Repair Procedures REV 4 1 3 Primary Boom Cable Track The primary boom cable track guides the cables and hoses running up the boom It can be repaired 5 link by link without removing the cables and hoses that run through it Removing the entire primary boom cable track is only necessary when performing major repairs that involve removing the primary boom 6 How to Remove the Cable Track 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 2 Hydraulic Hose and Fitting Torque Specifications 1 Tag and disconnec
103. button e twice 4 Use the scroll button to scroll through the menu until RESET STEER JOYSTICK DEFAULTS 18 displayed Press the button to select yes then press the button 5 Do not start the engine 6 Locate the drive steer joystick REV B 7 Move the drive steer joystick or thumb rocker switch if equipped full stroke in the left direction and hold for 5 seconds then return to the center or neutral position 8 Move the drive steer joystick or thumb rocker switch if equipped full stroke in the right direction and hold for 5 seconds then return to the center or neutral position Result The alarm at the ground controls should sound for a successful calibration W Result If the alarm does not sound repeat calibration procedure Primary boom extend retract functions Id 1 Turn the key switch to the off position 2 Press and hold the enter button on the ground control panel while turning the key switch to platform controls 3 Press the minus button twice then press the enter button 4 twice 4 Use the scroll button to scroll through the menu until RESET PRIMARY BOOM EXTEND RETRACT JOYSTICK DEFAULTS is displayed Press the button to select ves then press the button Do not start the engine Locate the primary boom extend retract joystick TEREX COMPANY Z 80 60 Part No 88619 July 2006 Section 4 Repair P
104. contact with a metal part of the machine that is grounded at all times when handling printed circuit boards OR use a grounded wrist strap CAUTION MPANY Part No 88619 July 2006 Section 4 Repair Procedures REV B PLATFORM CONTROLS Close the control box lid Remove the platform controls decal from the platform control box Carefully remove the membrane decal from the platform control box while guiding the ribbon cables out of the control box lid Remove any decal adhesive from the control box lid with a mild solvent Do not allow any solvent to come 1 3 Joysticks How to Calibrate a Joystick The joystick controllers on this machine utilize digital Hall Effect technology for proportional control If a joystick controller is disconnected or replaced it must be calibrated before that particular machine function will operate in contact with the membrane The joystick must be calibrated circuit board before the threshold max out or 8 Install the new membrane decal while guiding ramping can be set the ribbon cables through the control box lid After each joystick is calibrated check the display at the ground control box There should be no calibration faults shown on the display If calibration faults exist repeat steps 1 through 8 for that joystick controlled function Be sure that all LED locations on the membrane decal align with the LEDs on the membrane circuit board 9 Install a n
105. controls side turntable cover 9 Support the hydraulic tank with an appropriate lifting device 10 Remove the hydraulic tank mounting fasteners 11 Remove the hydraulic tank from the machine AWARNING Crushing hazard The hydraulic tank could become unbalanced and fall if not properly supported when removed from the machine 12 Remove the hydraulic return filter housing mounting fasteners Remove the hydraulic return filter housing from the hydraulic tank 13 Remove the suction strainers from the tank and clean them using a mild solvent Part No 88619 September 2006 Section 3 Scheduled Maintenance Procedures REV 14 Rinse out the inside of the tank using a mild solvent 15 Install the suction strainers using a thread sealant on the threads 16 Install the drain plug using a thread sealant on CHECKLIST E PROCEDURES 24 Prime the pump Refer to Repair Procedure 7 2 How to Prime the Pump Always use pipe thread sealant when installing the suction hose fittings and the drain plug the threads Component damage hazard The CAUTION engine must not be started with 17 Install the hydraulic return filter housing onto the the hydraulic tank shut off valves tank in the closed position or 18 Install the hydraulic tank onto the machine component damage will occur If the tank valves are closed 19 Install the two suction hoses to the suction remove the key from the key strainer
106. elsewhere in this manual THREAD Grades lt Grade 8 LUBED LUBED LUBED Nm inibs Nm Nm Nm intbs indbs 44 20 100 113 80 9 140 158 10 124 f 19 147 28 901 101 120 135 120 135 160 18 10 158 Lise LUBED LUBED ftibs Nm ftibs Nm ftibs Nm ftibs Nm 9 Nm 546 18 13 17 6 17 23 18 24 25 939 21 284 24 14 19 1 19 257 20 271 27 366 24 325 1 8 26 76 37 41 745 60 813 80 1084 68 921 5 9 16 7 1016 80 1084 110 149 959 126 4 115 90 122 120 162 145 142 149 162 110 203 130 230 366 320 583 350 637 480 867 530 962 990 1342 590 1071 670 1206 840 1518 930 1681 1460 2643 1640 2969 7 8 METRIC FASTENER TORQUE CHART This chart is to be used as a guide only unless noted elsewhere in this manual Size Class 4 6 Class 8 8 Class 10 9 Class 12 9 mm LUBED LUBED LUBED LUBED Nm 14551 Nm in bs in bs Nm_ linbs Nm in bs Nm in tbs Nm 1 24 41 4 63 54 618 58 663 78 884 68 775 91 103 407 69 7 87 93 1051 100 1131 132 15 16 132 155 17 6 RY ftibs Nm ftibs ftibs Nm ftibs Nm ftibs 23 6 46 7 535 16 24 14 20 20 12 18 1 18 L 9 200 16 220 406 9 8 12 12 12
107. fuel supply hose from the fuel tank to the fuel filter water separator Tighten the clamp 10 Clean up any diesel fuel that may have spilled during the installation procedure 11 Use a permanent ink marker to write the date and number of hours from the hour meter on the filter element Bleed the fuel system Before bleeding the system fill the fuel tank 12 Loosen the vent plug located on the fuel filter water separator head 13 Operate the priming lever of the fuel lift pump until fuel free from air comes from the vent plug Tighten the vent plug 14 Loosen the air vent screw located on top of the fuel injection pump 15 Tighten the air vent screw when air stops coming through the air vent 16 Clean up any diesel fuel that may have spilled during the bleeding procedure and dispose of properly 17 Start the engine from ground controls and check for leaks Part No 88619 September 2006 Section Scheduled Maintenance Procedures REV C 6 Perform Engine Maintenance Gasoline LPG Models Engine specifications require that this procedure be performed every 800 hours Proper engine maintenance following the engine manufacturer s maintenance schedule is essential to good engine performance and service life Failure to perform the maintenance procedures can lead to poor engine performance and component damage GM Models Required maintenance procedures and additional engine informatio
108. hard starting and continued use may result in component damage Extremely dirty conditions may require this procedure be performed more often Explosion and fire hazard Engine fuels are combustible Perform this procedure in an open well ventilated area away from heaters sparks flames and lighted tobacco Always have an approved fire extinguisher within easy reach Perform this procedure with the engine off 1 Open the turntable cover at the engine side of the machine Locate the fuel filter water separator Section 3 Scheduled Maintenance Procedures September 2006 CHECKLIST A PROCEDURES REV 2 Inspect the filter bowl for water 5 Clean up any fuel that may have spilled Result Water is not visible in the filter bowl If the fuel filter water separator is completely drained you must Wi Result There is water present Proceed to step prime the fuel filter water 3 separator before starting the 3 Loosen the vent plug located on the head of the engine fuel filter water separator See C 5 Replace The Fuel Filter Water Separator Element for instructions on how to prime the fuel filter water separator 6 Start the engine from the ground controls and check the fuel filter water separator and vent plug for leaks 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 a hea
109. hose cover could become unbalanced and fall if not properly supported when removed from the machine 18 Tag disconnect and plug each hydraulic hose from the bulkhead fittings that lead to the cable track Cap the fittings AWARNING 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 88619 September 2006 Section 4 Repair Procedures REV BOOM COMPONENTS 19 Tag and disconnect each electrical connectorto How to Repair the Cable Track wiring that leads to the cable track 20 Pull all hoses and electrical cables through the opening in the primary boom at the pivot end 21 Secure the upper and lower cable tracks together Component damage hazard CAUTION The boom cable track can be damaged if it is twisted A cable track repair kit is available through the Genie Industries 22 Attach a lifting strap from an overhead crane to Service Parts Department the cable track 23 Remove all cable track mounting fasteners 24 Carefully remove the cable track from the machine and lay it on a structure capable of supporting it Component damage hazard CAUTION The boom cable track can be damaged if it is twisted CAUTION Component damage hazard Cables and hoses can be damaged if they are kinked or pinched Part No 88619 1 Visuall
110. idle meets specification Tighten the locknut 7 Install the primary idle adjustment screw cap and tighten Do not over tighten 8 Loosen the secondary idle adjustment screw locknut Section 3 Scheduled Maintenance Procedures September 2006 CHECKLIST B PROCEDURES 9 Adjust the secondary adjustment screw until the low idle meets specification Tighten the locknut 10 Install the secondary idle adjustment screw cap and tighten Do not over tighten 11 Push and hold the function enable high speed button Note the engine rpm on the display Refer to Section 2 Specifications If the high idle is correct disregard adjustment step 12 12 Loosen the yoke lock nut Turn the high idle adjustment nut and solenoid boot counterclockwise to increase the rpm or clockwise to decrease the rpm Tighten the yoke lock nut and recheck the rpm Be sure the solenoid fully retracts when activating high idle Deutz BF4L2011 models 1 Start the engine from the ground controls 2 Push one of the LCD screen buttons shown until 4 engine rpm is displayed Refer to Section 2 Specifications A TEREX COMI REV C Skip to step 5 if the low idle rpm is correct 3 Loosen the locknut on the low idle adjustment screw
111. one of the two plugs is at the lowest point 2 Remove both plugs and drain the oil into a suitable container 3 Drive the machine until one plug is at the top i t 244 cone pas nae and the other is at 90 degrees models with pipe plugs models with o ring plugs Genie Part No 88619 Z 80 60 3 15 Section Scheduled Maintenance Procedures September 2006 CHECKLIST A PROCEDURES 4 Fill the hub with oil from the top hole until the oil level is even with the bottom of the side hole Apply pipe thread sealant to the plugs Install the plugs 5 Models with pipe plugs Apply pipe thread sealant to the plugs and install the plugs Models with O ring plugs Install the plugs into the drive hub 6 Repeat steps 1 through 5 for the other drive hub Turntable Rotate Drive Hub 1 Secure the turntable from rotating with the turntable rotation lock pin 3 unlocked locked 4 2 Remove the motor brake mounting bolts and then remove the motor and brake from the drive hub and set them to the side Component damage hazard CAUTION Hoses can be damaged if they are kinked or pinched 6 7 8 3 16 Z 80 60 REV motor b motor brake mounting bolts brake d drive hub e drive hub mounting bolts Remove the drive hub mounting bolts and use a lifting device to remove the drive hub from the machine Remove the plug from the side of the drive hub Drain the oil from t
112. psi 172 bar D Secondary boom down 5 Relief valve 1300 psi 89 6 bar E Primary boom down 6 Flow regulator valve 0 1 gpm 0 38 Bleeds off check valves differential sensing circuits to tank 7 Proportional solenoid valve Primary boom up down Solenoid valve 2 position 3 way Primary boom retract Check valye 2 Differential sensing circuit primary boom extend retract 10 Solenoid valve 2 position 3 way J Primary boom extend 11 Differential sensing valve K Turntable rotate left right 12 Differential sensing valve D Primary boom extend retract 13 Differential sensing valve M Primary boom up down 14 Priority flow regulator valve gpm 11 4 L MIN pp Controls flow to the oscillate and platform manifolds 15 Solenoid valve 3 position 4 way O Secondary boom extend retract Genie REV Torque 30 35 ft lbs 41 47 Nm 20 25 ft lbs 27 34 Nm 20 25 ft lbs 27 34 Nm 20 25 ft lbs 27 34 Nm 20 25 ft lbs 27 34 Nm 20 25 ft lbs 27 34 Nm 30 35 ft lbs 41 47 Nm 33 37 ft lbs
113. pump onto the bell housing mounting plate and torque the pump retaining fasteners to specification Refer to Section 2 Specifications for torque specifications CAUTION Component damage hazard Do not force the drive pump during installation or the flex plate teeth may become damaged Section 4 Repair Procedures July 2006 ENGINES REV B C 3 2 GM models 6 Install the pump coupler onto the pump shaft Ford Perkins and with the set screw toward the pump Leave the Deutz BF4L 2011 models appropriate gap between coupler and pump end plate for your engine 7 Install the pump and bellhousing assembly onto the engine Torque the bellhousing mounting bolts in sequence to 28 ft lbs 38 Nm Refer to the illustrations on the next page Component damage hazard Cy CAUTION When installing the pump do not force the pump coupler into the 55 flexplate or damage to the pump shaft seal may occur Component damage hazard Do CAUTION not force the drive pump during installation or the flex plate teeth may become damaged Deutz F4L 913 models TEREX COMPANY 4 52 Z 80 60 Part No 88619 July 2006 Section 4 Repair Procedures REV B ENGINES 8 Torque the bellhousing mounting bolts in sequence to 40 ft lbs 54 Nm Deutz BF4L 2011 models Deutz F4L 913 and Perkins 704 30 models Perkins 804C 33 and GM models Ford models A TEREX COMPANY Part No 88619 Z 80 6
114. shorted OR there is a poor system ground connection OR one or both throttle position sensors are faulty Be sure engine harness wiring and connections are in place and secure OR repair wiring and or connections to one or both TPS sensors OR replace one or both TPS sensors 536 TPS1 Lower than TPS2 The throttle position sensor wiring and or connections for either TPS1 or TPS2 open or shorted OR there is a poor system ground connection OR one or both throttle position sensors are faulty Be sure engine harness wiring and connections are in place and secure OR repair wiring and or connections to one or both TPS sensors OR replace one or both TPS sensors 537 Throttle Unable to Open Governor actuator is stuck closed OR wiring and or connections open or shorted OR governor actuator is faulty Repair wiring and or connections to governor actuator OR replace the governor actuator 538 Throttle Unable to Close Governor actuator is stuck open OR wiring and or connections open or shorted OR governor actuator is faulty Repair wiring and or connections to governor actuator OR replace the governor actuator 545 Governor Interlock Failure Engine harness wiring and or connections open or shorted OR there is a poor system ground connection OR ECM is faulty Repair wiring and or connections in engine harness OR replace the ECM 551 Max Governor Speed Override ECM needs to be re programmed OR t
115. should not operate 4 Turn the key switch to ground control 5 Check all machine function from the platform controls Result All machine functions should not operate 6 Turn the key switch to the off position O Result The engine should stop and no functions should operate A TEREX COM Part No 88619 CHECKLIST B PROCEDURES B 4 Check the Exhaust System Maintaining the exhaust system is essential to good engine performance and service life Operating the engine with a damaged or leaking exhaust system can cause component damage and unsafe operating conditions AWARNING Bodily injury hazard Do not inspect while the engine is running Remove the key to secure from operation A CAUTION Bodily injury hazard Beware of hot engine components Contact with hot engine components may cause severe burns 1 Remove the engine tray retaining fastener Swing the engine tray out away from the machine ici 14 yyy a engine tray anchor hole b engine tray retaining fastener Section Scheduled Maintenance Procedures September 2006 CHECKLIST B PROCEDURES 2 Locate the engine tray anchor hole at the pivot end of the engine tray 3 Install the bolt that was just removed into the anchor hole to secure the engine tray from moving AWARNING Crushing hazard Failure to install the bolt into the engine tray to secure it from moving could resul
116. the slave cylinder hydraulic hoses from the bulkhead fittings at the platform end of the primary boom Cap the bulkhead fittings AWARNING 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 11 Tag disconnect and plug the jib boom cylinder hydraulic hoses Cap the fittings AWARNING s injury hazard Spraying ydraulic 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 12 Remove the cotter pin from the platform end of the cable track tube Always replace the cotter pin with a new one when installing the cable track 13 Remove the fasteners from the cable track guide at the platform end of the primary boom Remove the cable track guide from the machine A TEREX REV C 14 Tag and disconnect the electrical connector from the limit switch at the pivot end of the primary boom 15 Remove all hose clamps for the primary boom lift cylinder hydraulic hoses The primary boom lift cylinder hydraulic hose clamps are located behind the cable track 16 Support the end cover from the secondary boom at the pivot end of the primary boom 17 Remove the cover retaining fasteners and remove the cover from the machine AWARNING Crushing hazard The secondary boom
117. to ACAUTION indicate the presence of a potentially hazardous situation which if not avoided may result in minor or moderate injury Be sure to wear protective eye wear and other protective clothing if the situation warrants it Be aware of potential crushing hazards Bl such as moving parts free swinging or unsecured components when lifting or placing loads Always wear approved steel toed shoes Workplace Safety 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 SN are properly maintained and ready for use Keep work surfaces clean and free of debris that could get into machine components and cause damage 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 any forklift overhead crane or Be sure Bes fasteners intended for one time use i e cotter pins and self locking nuts are not reused These components Without safety alert symbol used CAUTION to indicate the presence ofa may fail if they are used a second time porantialy hazardo Aiuraiton Be sure to properly dispose of old oil or which if not avoided may result in ay O PTOpEry roperty damage 2 other flu
118. 0 4 53 Section 4 Repair Procedures July 2006 ENGINES 5 3 Engine Fault Codes Gasoline LPG Models How to Retrieve Engine Fault Codes When an engine malfunction is detected by the Electronic Control Module ECM a fault code is recorded and the check engine light will turn on at the platform controls Use the following procedure to retrieve the engine fault code to determine the engine malfunction Perform this procedure with the key switch in the off position 1 Open the engine side turntable cover 2 Locate the run test toggle switch located on the relay box cover 3 Pull out the red Emergency Stop button to the on position at the ground controls 4 Hold the run test toggle switch to the test position and turn the key switch to the ground controls position Result The check engine light should turn on The check engine light should begin to blink The check engine light will blink a 123 code three times before blinking a fault code if one is present A TEREX REV B 5 Continue to hold the run test toggle switch in the test position and count the blinks If any fault codes are present the ECM will blink a three digit code It will blink the first digit of a three digit code pause blink the second digit pause and then blink the third digit For example the check engine light blinks 5 consecutive times blinks 3 times and then 1 time That would indicate code 531 Before the fau
119. 00 rpm Frequency 538 2 Hz Compression ratio 9 25 1 Compression pressure minimum 100 psi Pressure psi or bar of lowest cylinder 6 9 bar must be at least 75 of highest cylinder Valve clearances Zero lash 1 full turn Lubrication system Oil pressure minimum 18 psi operating temp 2000 rpm 1 24 bar Oil capacity 5 quarts including filter 4 7 liters Oil viscosity requirements Extreme operating temperatures my require the use of alternative engine oils For oil requirements refer to the Engine Operator Handbook on your machine Continuous improvement of our products is a Genie policy Product specifications are subject to change without notice TEREX COMI Part No 88619 SPECIFICATIONS Starter motor Normal engine cranking speed 350 rpm Current draw normal load 400A Current draw maximum load 600A Current draw minimum 100A Batteries Type 12V DC Group 31 Quantity 2 Cold cranking ampere 1000A Reserve capacity 25A rate 200 minutes Electronic fuel pump Fuel pressure static 9 to 11 psi 0 6 to 0 76 bar Fuel flow rate 0 3 gom 1 14 L min Fuel Requirement For fuel requirements refer to the engine Operator s Manual on your machine Ignition system Spark plug type AC ACMR 43 LTS Spark plug gap 0 040 inch 1 01 mm Engine coolant Capacity 12 quarts 11 4 liters Alternator Output 66A 12V DC Fan belt deflection 0 5 in
120. 010 5000 psi 0 to 350 bar pressure gauge to the test port on the steer oscillate manifold 3 Start the engine from the platform controls Press down the foot switch and manually activate one of the oscillate limit switches Hold the switch in the activated position and observe the reading on the pressure gauge Refer to Section 2 Specifications 5 Turn the engine off Use a wrench to hold the relief valve and loosen the jam nut item CH 6 Adjust the stud with a hex wrench Turn it clockwise to increase the pressure or counterclockwise to decrease the pressure Install the relief valve cap AWARNING Tip over hazard Do not adjust the relief valve higher than specified 7 Repeat steps 3 through 4 to confirm relief valve pressure 8 Remove the pressure gauge Install the drive chassis cover TEREX COMPANY 4 84 Z 80 60 Part No 88619 July 2006 Section 4 Repair Procedures MANIFOLDS 8 9 Oil Diverter Manifold Components welder option The oil diverter manifold is mounted to the hydraulic generator located in the engine compartment Index Schematic No Description Item Function Torque 1 Pilot Operated Directional valve 2 position CBA Activates generator 80 90 ft lbs 108 122 Nm 2 Solenoid valve 2 position 3 CBB Pilot valve to diverter 35 40 ft lbs 47 54 Nm Orific
121. 10 2B 57255277777 3 T 2 5 E 6 6 2 10 38 L min 7 d PLATFORM MANIFOLD 34 5 5 82 Ed 8 Genie A TEREX COMPANY 6 43 Z 80 60 Part No 88619 Section 6 Schematics July 2006 Hydraulic Schematic 4 Wheel Drive with 4 Wheel Steer View 2 REV 6 44 gt 1 2 gpm 4 5 L min Y31dNOO AHVLOH REAR RIGHT STEERING DRIVE PUMP o4 69 2 8 gpm 8 7 L min 69 tO 69 1 2 4 5 L min PMP A 4 G1 12 5 KW GENERATOR G Lar CBI X 21 REAR LEFT STEERING 21CC G2 B 44 EN 87 Cin emp E r MANIFOLD CBE e Le O 1 2 4 5 L min FOUR WHEEL STEER MANIFOLD HYDRAULIC WELDER OPTION OIL COOLER DIVERTER Part No 88619 FRONT RIGHT STEERING 2 3 8 7 L min E e O e 69 1 2 4 5 L min FRONT LEFT STEERING OSCILLATE CYLINDERS
122. 10 LIMIT SWITCH 8 8 amp 88 18 ege 8 Q x rz z m 4 x x ers BEER 6 m o8 25 955r 550gzr 5cu2ogrcommos 225 622632 6 09 68 a a 2 ozn gt aa a 2188608 83 lt SSB88R8SSE5R 5 Goa o o enie A TEREX COMPANY Part No 88619 Z 80 60 6 21 July 2006 Section 6 Schematics Electrical Schematic View 4 July 2006 Section 6 Schematics Electrical Schematic View 5 Section 6 Schematics July 2006 1 Electrical Schematic View 5 REVC A B C D E F G H J K L M N 1 AUXILIARY HYD RECOVERY SIGNAL MULTI FUNCTION VLV RECOVERY SIGNAL BOOM RET RECOVERY SIGNAL BOOM DWN RECOVERY SIGNAL BOOM EXT RET FC RECOVERY SIGNAL BOOM UP DWN FC RECOVERY SIGNAL 15 POWER P15 ECU POWER EEO Ee EOE EE ee P_30 TO HORN BUTTON AUXILIARY HYD RECOVERY SIGNAL 095 MU
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124. 2 Locate the primary boom angle sensor inside the primary boom at the boom pivot pin 3 Tag and disconnect the electrical connector from the sensor 4 Remove the angle sensor mounting bracket retaining fasteners 5 Remove the wing nut from the threaded rod Do not disconnect the threaded rod from clevis yoke Section 4 Repair Procedures September 2006 BOOM COMPONENTS 6 Remove the angle sensor and bracket assembly 7 Remove the sensor retaining fasteners from the sensor bracket Remove the angle sensor 8 Install the new angle sensor onto the mounting bracket 9 Install the angle sensor and bracket assembly The sensor should be installed rotated in a fully counter clock wise position 10 Insert the threaded rod through the threaded rod adjustment bracket 11 Move threaded rod to the top of the slotted hole Tighten the wing nut and hex nut towards each other 12 Connect the electrical connector to the angle sensor 13 Calibrate the primary boom angle sensor See How to Calibrate the Primary Boom Angle Sensor Tip over hazard Failure to calibrate the primary boom sensor could cause the machine to tip over resulting in death or serious injury A TEREX REV C How to Calibrate the Primary Boom Angle Sensor Perform this procedure on a firm level surface with the boom in the stowed position A digital level will be required to perform this procedure 1 Turn the key switch to g
125. 20A HYDRAULIC OIL COOLER FAN 60536 RELAY uU F16 FUSE 20 ENGINE RPM AND COLD START 60536 17 FUSE 20A STARTER AND ALTERNATOR 60536 J HO cA 5d on HO cd CH PERKINS 804C 33 gt 77165 B1 after serial number 328 CR28 CR17 LABEL DESCRIPTION GENIE P N CR1 START RELAY 61225 b B F22 2 4 2 F7 4 B2 CR2 IGNITION POWER RELAY 34052 i 1 a ce nin DTD bb CR5 HORN RELAY 34052 n p CR15 GLOW PLUG RELAY 61225 O Ret CR17 HYDRAULIC OIL COOLER FAN RELAY 34052 L CR4 RPM RELAY 34052 cm oe E eni CR 5 F17 FUSE 20A ENGINE 60536 GND 7 FUSE 30A OIL COOLER RPM 94327 1 F16 FUSE 20A STARTER 60536 co OH 7 11 oH Ld oto 7 l F22 FUSE 70A GLOW PLUG 88151 2 D O de Qu cis c 8 EP FORD LRG
126. 27 34 Nm 20 25 ft lbs 27 34 Nm 26 30 ft lbs 35 41 Nm 8 10 ft lbs 11 14 Nm 30 35 ft lbs 41 47 Nm 33 37 ft lbs 45 50 Nm 30 35 ft lbs 41 47 Nm 33 37 ft lbs 45 50 Nm 8 10 ft Ibs 11 14 Nm 33 37 ft lbs 45 50 Nm 33 37 ft lbs 45 50 Nm 30 35 ft lbs 41 47 Nm 8 10 ft lbs 11 14 Nm 30 35 ft lbs 41 47 Nm 20 25 ft lbs 27 34 Nm 20 25 ft lbs 27 34 Nm 20 25 ft lbs 27 34 Nm 20 25 ft lbs 27 34 Nm 30 35 ft Ibs 41 47 Nm 30 35 ft Ibs 41 47 Nm A TEREX COMPANY Z 80 60 Part No 88619 July 2006 Section 4 Repair Procedures REV MANIFOLDS Part No 88619 Z 80 60 4 63 Section 4 Repair Procedures July 2006 MANIFOLDS 8 3 Valve Adjustments Function Manifold How to Adjust the System Relief Valve Perform this procedure with the boom in the stowed position 1 Locate the boom retracted limit switch LSP1RO limit switch on the outside of the primary boom at the pivot end of the primary boom 2 Tag and disconnect the wire harness from the limit switch and install a wire jumper between pins 1 and 2 of the limit switch connector Place another wire jumper between pins 3 and 4 of the limit switch connector 3 Connect a 0 to 5000 psi 0 to 350 bar pressure gauge to the PTEST port on the function manifold 4 Start the engine from the ground controls Press and release the rpm select button until the engin
127. 3 7 4 5 ft lbs 5 6 Nm Hand Tighten Only 17 Check valve GR Platform rotate circuit 4 70 Z 80 60 Part No 88619 July 2006 Section 4 Repair Procedures REV MANIFOLDS 8 Part No 88619 Z 80 60 4 71 Section 4 Repair Procedures July 2006 MANIFOLDS REVC 8 5 Turntable Rotation Manifold The turntable rotation manifold is mounted to the turntable rotation motor located in the boom storage compartment Index Schematic No Description Item Function Torque 1 Shuttle valve 2 position 3 way KK Turntable rotation brake release 10 13 ft Ibs 14 18 Nm 2 Counterbalance valve LL ius Turntable rotate right 35 40 ft lbs 47 54 Nm 3 Counterbalance valve MM Turntable rotate left 35 40 ft lbs 47 54 Nm KK TEREX COMPANY 4 72 Z 80 60 Part No 88619 July 2006 Section 4 Repair Procedures REV C MANIFOLDS 8 6 Platform Rotate Manifold The turntable rotation manifold is mounted to the turntable rotation motor located in the boom storage compartment Index Schematic No Description Item Function Torque 1 Counterbalance valve H nus Turntable rotation brake release 35 40 ft lbs 47 54 Nm 2 Counterbalance valve HB
128. 3 Test the Key Switch sssssssssssseseeeeeeeeeeneeeen nennen nennen 3 21 B 4 Check the Exhaust System pp 3 21 5 Inspect the Engine Air Filter be 3 22 B 6 Engine Maintenance Deutz Models pp 3 23 B 7 Check the Tires Wheels and Lug Nut Torque 2 3 24 B 8 Confirm the Proper Brake Configuration pp 3 24 B 9 Check the Drive Hub Oil Level and Fastener Torque 3 25 B 10 Test the Ground Control Override pp 3 26 11 Test the Platform Self leveling pe 3 27 B 12 Test the Engine Idle Select Operation 3 28 B 13 Test the Fuel Select Operation Gasoline LPG Models 3 29 B 14 Test the Drive Brakes Ne 3 30 B 15 Test the Drive Speed Stowed Position 3 30 B 16 Test the Drive Speed Raised or Extended Position 3 31 B 17 Test the Alarm and Optional Flashing Beacon 3 32 B 18 Perform Hydraulic Oil Analysis Ne 3 32 B 19 Check and Adjust the Engine 3 33 B 20 Test the Safety Envelope and Safety Circuits 3 36 Genie A TEREX COMPANY viii Z 80 60 Part No 88619 September 2006 OMM TABLE OF CONTENTS Section3 Rev Scheduled Maintenance Procedures continued B 21 Test the Primary Boom Self leveling 3 3
129. 3223 J31 TILT SNSR 8353 5 a ee a DETAIL 1 OPT 120VAC W REGULATOR 1 P32 GEN HARN XE 87 3 T 30 1155 4 RD 12VDC z RED O 2 5 z WH R4A5GEN A lt 3 BR GND lt 93 BR 1 BR BK PASGEN B lt Z BK GR F45GEN lt BKWH 1 1 a 1 WH NEUTRAL j 1 1 1 1 ps 28 Reser SEE DETAIL D FOR 220VAC 1 5 1 GENERATOR W REGULATOR 1 BK 120VAC e 1 15 1 GUTER IR 8 4 n a lt Conti d on View 12 Continued on View 10 ontinued on View C26TSR WT RD C25PSR WT BK 5 C33STR BK C39LP BL RD 34 C35RPM BK RD C21IGN WH e 4 BIBAT RD B1BAT RD TO J13 WHITE 23 PIN ENG HARNESS P1 22 P116HYD OR P116HYD OR 1 a rc 1 6 59 DETAIL gt 1 2 J32 ENG HARN P32 GEN HARN 875 3 OPT 220 W REGULATOR 1 6 7 5 PIBATRD 180 4 RD 12VDC 1 i 2 CRS 2 n C45GEN GRWH 3 WH 26555 og lt 6 HORN e 0 BATGND BR gt BR 5 BR 5 ches OIL COOLER 1 s RELAY 4 BR BK 5 85 85187 87 RELAY 1 SE BK WHI 5 m 5 4 a 1 d 1 oi 1 5 5 F
130. 4052 Ho ct n 1 5 0 0 CR15 GLOW PLUG RELAY 61225 R21 CR17 HYDRAULIC OIL COOLER FAN RELAY 34052 7 FUSE 20A HYDRAULIC OIL COOLER 60536 al s CRS 1 1 15 CRi5 F20 FUSE 20A ENGINE RPM 60536 F22 FUSE 60 GLOW PLUG 101340 1 d O GND d F23 FUSE 30A ENGINE 94327 c H H r Q H Lol Lo 1 LS GM 3 0L ca De a Lo Dg 6 7 8 Bg nn hg C LABEL DESCRIPTION GENIE P N CRI7 n CR2 IGNITION FUEL RELAY 34052 CR5 HORN RELAY 34052 2 3 4 4 CR17 HYDRAULIC OIL COOLER FAN RELAY 34052 CH ara ct H F7 FUSE 20A HYDRAULIC OIL COOLER FAN 60536 F17 FUSE 20A STARTER AND ALTERNATOR 60536 cre OPTION 1 1 h RELAY h 1 1 l HO tH Lod Genie Part No 88619 Z 80 60 6 11 Section 6 Schematics July 2006 Engine Relay and Fuse Panel Legend REV EC wo ne ele PERKINS 704 30 5 6 7 8 c_ Fiec 52 before serial number 329 2 chm 0 LABEL DESCRIPTION GENIE P N d 17 4 7 CR1 START RELAY 34052 1 2 3 4 CR2 IGNITION FUEL RELAY 34052 d Ln p n p H CR4 RPM RELAY 34052 t CR5 HORN RELAY 34052 CR17 HYDRAULIC OIL COOLER FAN RELAY 34052 OPTION CR5 ch 1 CR4 F7 FUSE
131. 425 gF165 gF205 7 O B1 cR cmz 1 LABEL DESCRIPTION GENIE P N 17 70 7 CR1 START RELAY 61255 1 2 3 4 B2 CR5 HORN RELAY 34052 Ln 1 0 22 09 CR17 HYDRAULIC OIL COOLER FAN RELAY 34052 L1 CR4 RPM RELAY 34052 ET fg R21 esie F7 FUSE 20A HYDRAULIC OIL COOLER 60536 L CR5 NT CR1 15 17 FUSE 20A STARTER AND ALTERNATOR 60536 E Ho oto l H r to ni 1 A Genie A TEREX COMPANY 6 12 Z 80 60 Part No 88619 July 2006 REV B 00000 00000000 1 COOOOOO Section 6 Schematics Turntable Controller Pin Legend J14 WHITE WHITE CCC CONNECTOR PIN NUMBERING FOR 23 PIN CONNECTORS Glos QG OOOCO 1 I 35 PIN PIN NUMBERING FOR 4 PIN CONNECTOR CONNECTORS PIN NUMBERING FOR J13 111 RBS D CONNECTOR 125 415 4 CONNECTOR J12 BLACK BLACK CCN CONNECTOR CONNECTOR 122221 lt lt LOWER PRI
132. 5 VLVRET1 BR TCON TURNTABLE CONTROLLER J13 1 VLVRET1 BR 2 C35RPM BK RD 3 C21IGN WH 4 C848A BK WH 5 V30FWD WH 6 V31REV WH BK 7 C46HN WH 8 C39LP BL RD 9 C33STR BK 10 C30EDC WH 11 C31EDC WH BK 12 C25PSR WH BK 13 C26TSR WH RD 14 RET85TTSR GR 15 P85TTSR GR 16 VLVRET2 BR 17 UNUSED 18 CA1RPM OR BK 19 UNUSED 20 GR WH 21 GR BK 22 C45GEN GR WH 23 VLVRETS BR TCON TURNTABLE CONTROLLER J15 1 BATVLV RD 2 BATGND BR 3 BATGND BR 4 BATECU RD enie Part No 88619 TCON TURNTABLE CONTROLLER J14 1 VLVRET4 BR 2 RD WH 3 CO9PERF BK RD 4 WH RD 5 C12FBFC 6 C72SBE 7 CO1PBU RD 8 CO2PBD RD BK 9 CO7PBE BK 10 CO8PBR BK WH 11 UNUSED 12 C115SD BL BK 13 R49LP WH BK 14 VLVRETS BR 15 UNUSED 16 UNUSED 17 C115LS RD BK 18 C114LS BK RD 19 C10SBU BL 20 C73SBR BL RD 21 C728BE BL WH 22 UNUSED 23 C113MFV OR RD 24 UNUSED 25 COATRL WH 26 COSTRR WH BK 27 VLVRTN7 BR 28 UNUSED 29 UNUSED 30 VL VRET6 BR 31 UNUSED 32 C27AUX RD 33 P125SBLE WH RD 34 P126SBLD WH BK 35 UNUSED A TEREX COMPANY Z 80 60 6 13
133. 5 RIGHT 1 p a STEERING STEERING TA FO d ep hor he min qne nac cquo moo M5 FF BE 3 eo 3 BA 06 207 5 50 9 0 8 0 0 60 He 1 19 3 bar L XI 99 7 6 L minl 2 17 6 L min it T7 gt X 50 50 EJ T T pe 50 j j 4 5 Limin 8 7 L min 4 2gpm 7 6Limin Ie 1028 89 msl Imei o IE NEN 11 T L a aan soe leu n did 8 111171 800 psi U Mf Un D 15311 T bet ba 23 45 LSU vi FRONT Ls 7 TWO WHEEL REAR j OSCILLATE MANIFOLD STEER MANIFOLD Iii LEFT Me RUE NES ee E IC NET BRAKE 8 12222222224 o rest BENT JI L2SPEED o 11 222 HYDRAULIC WELDER OPTION R2SPEED L OF 6 tere se Doe cele T ee eee at A INIT VE R ed ee ee lage ll gE 4 CBD 0 031 2 7 of oe je TMRA g 8 KW
134. 5 CONDUCTOR Hos WHITE SILVER BRASS ou BRASS 120 VAC I e inm m 0 e GFI GREEN Xa 8 g gt GREEN 12GA 2 GREEN wg 2 uA e BLACK 6 12 GA 3 CONDUCTOR 12 GA CONDUCTOR Theory of Operation ENCLOSURE 1 Arequest from PCON to turn the Generator on commands TCON to enable the High RPM output and the generator output DCON enables the motor stroke valve switching the motors to high speed low torque mode 2 The SX controller is turned ON supplying power to bypass valve and the change over relay The EDC valve is switched over to the output of the SX controller 3 When the AC generator is turned OFF the SX module will ramp the output to the EDC to threshold preventing cavitation to the hydraulic motor powering the generator When threshold is reached the bypass valve is turned OFF 7 4 The generator output is turned off when an operator engages the footswitch The propel function has a time delay to ensure the SX controller ramps the drive pump off and disengages the dump valve Adjustments 1 Connect a digital multimeter DMM with a frequency counter to the 110 vac outlet Adjust the potentiometer until a frequency of 66 5 HZ is obtained with no load on the generator Genie A TEREX COMPANY Part No 88619 Z 80 60 6 35 July 2006 Section 6 Schematics Electrical Schematic View 16 Hydraulic Generator Option July 2006 Section 6 Schematics Electrical Schematic View 17
135. 50 gt iQ HS QNO gt gt MS 1003 291 14 lt 514954 ur 1 lt e aavs 8 144 ye ad S1d88o z 9x HSNS QAYOT 28251 s ye InoATIH NIdSNS i Td M S dz gt dSNS 5 o e lt HO HMd Ti 5 060 5 5 2 H8 QN9 01 14 lt 5 gt 8 019 Ter E E 8 LATA 80 42 ye do d1dslo 8 IATA 1 0 14 lt Ho madylo 8 8 ZA1A 90 42 ye de aryyo 0 lt yo nrero TEATA 440 NO yedo9 dddslo dolsa 502 440 NO HO 1HdZLO0 yaad NdVTV gt 6L 1 2 yaNe d imd Sard ATA HB L3H ATA N9 110H 1v1d gt ZI amp ye ad dNAd dO1S3 de 9laN9 gt 91 5 55 5 q N9 dn ait SF EL 8 19 40159 21 521 u x amp mo va ea y9 13d 90159 501 a 5 g 28 N9 dn air IN 4 gt IM 1 2 2 5 zE e Yg 90N9 gt 9 8 28 r X8 NO H LOY 1 14 z ie e H8 9LQN5 55 z j noova 4 1 0
136. 652 Section Scheduled Maintenance Procedures September 2006 CHECKLIST B PROCEDURES B 21 Test the Primary Boom Self leveling The primary boom self leveling function is adjustable on machines with software revision 1 03 and lower This function is not adjustable on machines with a software revision higher than 1 03 Refer to Repair Procedure 6 1 How to Determine the Revision Level Automatic primary boom self leveling throughout the full cycle of secondary boom raising and lowering is essential for safe machine operation The primary boom is maintained level by the communication between the platform level sensor and the turntable level sensor If the platform becomes out of level the computer at the ground controls will open the appropriate solenoid valve s at the function manifold to maintain a level primary boom 1 Turn the key switch to ground control and pull out the red Emergency Stop buttons out to the on position at both the ground and platform controls 2 Push one of the LCD screen buttons shown 4 until primary boom angle is displayed 3 Start the engine and level the platform until the displays shows 0 DEGREES A TEREX COM REV C 4 Fully raise the secondary boom while watching the display at the ground controls Stop when the secondary boom just begins to extend Result The primary boom should remain level at all times to within 2 degrees If the pl
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138. 8 22 Test the Primary Boom Angle 3 39 B 23 Inspect the Fuel Tank Cap Venting Systems 3 40 B 24 Perform Engine 3 41 B 25 Perform Engine Maintenance Gasoline LPG Models 3 42 B Checklist C Procedures C 1 Perform Engine Maintenance Diesel Models 3 43 C 2 Grease the Platform Overload Mechanism if equipped 3 44 C 3 Testthe Platform Overload System if equipped 3 44 C 4 Replace the Engine Air 3 46 C 5 Replace the Fuel Filter Water Separator Diesel Models 3 47 C 6 Perform Engine Maintenance Gasoline LPG Models 3 49 B Checklist D Procedures D 1 Check the Boom Wear Pads nnns 3 50 0 2 Check the Free wheel Configuration pp 3 50 D 3 Check the Turntable Rotation Bearing Bolts 3 52 D 4 Inspect for Turntable Bearing Wear pp 3 53 D 5 Replace the Drive Hub Oil 3 55 D 6 Perform Engine Maintenance Diesel Models 3 57 D 7 Replace the Hydraulic Filter Elements pp 3 58 Checklist E Procedures E 1 Testor Replace the Hydraulic
139. Boom A Angle S Secondary Boom E Extend T Turntable Retract LS Limit switch 2 LS P RO IPANY Part No 88619 July 2006 Section 6 Schematics REV B LIMIT SWITCHES AND ANGLE SENSORS Limit Switch and Angle Sensor Legend PRIMARY BOOM ANGLE SENSOR LSP1RO LSS2AO LSP1AO BOOM a 1 y 1 re LSS2AS p LSS3AO TURNTABLE c re ANGLE SENSOR LSS1RS J Ez s LSS1AO DRIVE CHASSIS CONTROL BOX fy m LST1O LSA10S Limit switch Axle 1 Oscillating Operational LSS1RO Limit switch Secondary Boom 1 Retract Operational Activates the axle oscillate circuit on the right side Switch Secondary boom fully retracted 0 secondary boom down allowed LSA20S Limit switch Axle 2 Oscillating Operational Activates the axle oscillate circuit on the left side LSS1RS Limit switch Secondary Boom 1 Retract Safety Switch Secondary boom fully retracted LST10 Limit switch Operational Activates the drive enable secondary boom down allowed Backup switch for LSS1RO zone LSS1AO Limit switch Secondary Boom 1 Angle Operational Turntable Angle Sensor Measures the X axis and Y axis of Switch Open when the secondary boom is fully lowered closes the turntable The alarm sounds at 4 5 degrees when th
140. D 5 11 LEFT pu en ey ee UPS EN IEEE LBRAKE J 2 i TEST CDR COL i SPEED R2SPEED 000000000001 HYDRAULIC WELDER OPTION RBPAKE z Pc 1 COOLER 4 DRIVE oer i 10 e 89 ERE 0031 7 1 3 5 GPM G1 H TMTRA J B g 8 ir 1 12 5 KW GENERATOR Part No 88619 Z 80 60 6 40 July 2006 Section 6 Schematics Hydraulic Schematic 2 Wheel Drive with 4 Wheel Steer View 2 July 2006 Section 6 Schematics Hydraulic Schematic 4 Wheel Drive with 2 Wheel Steer View 1 Section 6 Schematics July 2006
141. E EXT RET BUTTONS Axle extend retract disabled display Power up controller with the problem message on LCD corrected CAN BUS Fault check Display message on LCD PowerUp Controller with ihe problem corrected Value at 5 0 V Value too high Limited speed and direction frozen at Power up controller with problem Value too low zero and neutral alarm sounds corrected Value at 0 V PRIMARY BOOM UP DOWN JOYSTICK TERES Not calibrated Joystick Speed and Direction frozen at Calibrate joystick zero and neutral Initiate one second beep of audible warning device Just calibrated Self clearing transient Value at 5 0 V Value too high Limited speed and direction frozen at Power up controller with problem Value too low zero and neutral alarm sounds corrected Value at 0 V Nat calibrated Joystick speed and direction frozen at Calibrate joystick zero and neutral Just calibrated nitas one Second beep DR Self clearing transient warning device Value at 5 0 V Value too high Limited speed and direction frozen at Power up controller with problem Value too low zero and neutral alarm sounds corrected SECONDARY BOOM JOYSTICK PRIMARY EXTEND RETRACT Value at 0 V JOYSTICK Not calibrated Joystick speed and direction frozen at Calibrate joystick zero and neutral Just calibrated Initiate one second beep Self clearing transient warning device as Continued on next Genie 22295 A TEREX COMPANY Part
142. ERY SIGNAL BOOM DWN RECOVERY SIGNAL BOOM EXT RET FC RECOVERY SIGNAL BOOM UP DWN FC RECOVERY SIGNAL P_30 P_22R P7R P10 Continued on View 5 ald OL J14 WHITE 35 PIN MANIFOLD HARN View 12 6 23 Genie 2 80 60 G Part No 88619 July 2006 Section 6 Schematics Electrical Schematic View 6 Ground Controls TCON July 2006 Section 6 Schematics Electrical Schematic View 7 July 2006 Section 6 Schematics REV Electrical Schematic View 7 Continued on View1 Continued on View 8 ser 1431 1 111050 9SA e 98r 1H9IH 31VTIIOSO ZSA 8 8 gt 51 202 gt 5 lt lt a 6 amp 1 8 5 8 2 RS 96 84 m E 2 ro 58 qd V Add9SS ay 2 5 2 okz TA NY9z8q HWHd9 OXVzzIA ES 23 ig 18 8 3 2 5 2 995 aly 5 aw HAT 2 5825 HNWH9 OXVZZLA 5 H9 OXVIZIA 2 5 9 ad B Add9sS sau 9 wee YHO OXVIZLA o H8 S o 0S2 995 lt 9 al x Gu v Aud9ss HM 2950 10 14 42
143. EX COMPANY Z 80 60 G 6 18 Section 6 Schematics July 2006 Electrical Schematic View 2 REV Platform Controls PCON PRI BOOM EXT RET SEC BOOM UP DWN DRIVE amp STEERING BOOM UP DWN amp PCON Continued on View 1 N CD LO N 2 o lt 3dAL1304 6 5 485 5 58 c 8 e e an 40153 NOOd HMd daals 4 lt O 3331 avuo 9 9 e ui 9334 uv3d S E NVO TA NY9z8d ed lt Y9 NVOI8G 9331 INOdd id HM NH90 e LNO ynaLHN LnoLtyo 8 lt 4 03398 zi IXY 2 s 8 gt EN e o 9334 ANIONS 5 Bah OL 6 8 5 Zed HIWQH AHd9Sd E L gr 6 9 gt sc 5 ld qd Add95S HMd
144. GENERATOR Part No 88619 Z 80 60 6 42 July 2006 Section 6 Schematics m1 Hydraulic Schematic 4 Wheel Drive with 2 Wheel Steer View 2 July 2006 Section 6 Schematics Hydraulic Schematic 4 Wheel Drive with 4 Wheel Steer View 1 Section 6 Schematics July 2006 Hydraulic Schematic REV 4 Wheel Drive with 4 Wheel Steer View 1 A B D E F G H J K L M N 1 TURNTABLE PRIMARY LIFT PRIMARY BOOM SECONDARY BOOM LIFT SECONDARY BOOM ROTATE 7 1 5 1 26 8 19 3 L min EXTEND RETRACT
145. HT NEUTRAL 1 120 gt AUTO SEE DETAIL C FOR 220VAC GENERATOR 1 Continued on View 10 2 Q SEPARATOR RESET CB W REGULATOR AND DETAIL FOR 120 Continued on View 12 2 GENERATOR W O REGULATOR L_ 22 1 15A 1 4 E 4 i eg __ 8 e 8 E 5 a C26TSR WT RD C25PSR WT BK B1ENG RD B1ENG RD P125SBLE WH RD P125SBLE WH RD P125SBLE WH RD P125SBLE WH RD P126SBLD WH BK P126SBLD WH BK P126SBLD WH BK P126SBLD WH BK V125SBLE WH RD V125SBLE WH RD V125SBLE WH RD V125SBLE WH RD 5 V126SBLD WH BK V126SBLD WH BK V126SBLD WH BK V126SBLD WH BK C21IGN WH 5 20 e P33STR BK P33STR BK P33STR BK F17 F17 TO J3 WHITE 70A 20 20 C35RPM BK RD 23 PIN ENGINE 55 1 22 dt ale m 1 DETAIL D 1 1 A 8743 OPTIONAL 120VAC W O REGULATOR P116HYD OR P116HYD OR J32 ENG HARNESS Lee ERE TUR 1 80 214 B1STAID RD B1STAID RD Lok CASGEN GRANH ASS d o 2186085 5 6 TROMBETTA WH PULL IN 3 2 SEE DETAIL TIME DELAY 5 2 BK e RD 220VAC GENERATOR CR1 80 256 ET or 8 g W REGULATOR AND SNELAY 87 85 2 a 8 DETAIL B 5 2 eee ate 2 2 2 1 12 WHT NEUTRAL GENERATOR W REGULATOR c 201 AUX 25 HORN m 2 5 C
146. LE 06 P11 BLACK 35 PIN VALVE VALVE PM PCON MODE 12 BLACK 35 PIN TCON J32 22 J32 16 SM NOT SLP MODE P21 BLACK 23 PIN RF STEER LEFT RR STEER LEFT PM SM TO P22 WHITE 23 PIN PCON VALVE VALVE FOOT SW PRI BM P34 DEUTSCH DTP 2 PIN CONN J32 21 J32 09 181 22 16 22 17 FC VALVEP P14 03 P18 DEUTSCH DTP 2 PIN CONN RF STEER RIGHT RR STEER RIGHT 8 BATT P6 R56FTS RD C56FTS RD TT ROT P31 BLACK 23 PIN DCON VALVE VALVE pean PLATFORM Bean FC VALVE P55 6 WAY DEUTSCH AT PLAT LEVEL SENSOR J32 18 J32 08 MANIFOLD c P14 04 PAUX HYD P17 16 WAY MOLEX IN TCON SPARE VALVE HARNESS RELAY J32 03 14 32 Safety Circuits P7R enie A TEREX COMPANY 6 36 Z 80 60 Part No 88619 REV July 2006 Section 6 Schematics Hydraulic Schematic 2 Wheel Drive with 2 Wheel Steer View 1 Section 6 Schematics July 2006 Hydraulic Schematic 2 Wheel Drive with 2 Wheel Steer View 1
147. LTI FUNCTION VLV RECOVERY SIGNAL PELOTON ESTP 7 BOOM RET RECOVERY SIGNAL 22 P_22 LLL Boo DWN RECOVERY SIGNAL 3 P_9B ert BOOM EXT RET FC RECOVERY SIGNAL OUT PWR ENABLE OUT PWRIENABLE OF 4 BOOM UP DWN RECOVERY SIGNAL P_6R2 SM AH TO MICRO P_30 P22R P22R P22R P 228 14 12 c bi 22 7 8 10 4 8 9 SM AH ESM AHP 7 87 719 PI amp SM AH BM 8 24 8 i E z 74HCOB 74HCOB E m o w x n 1 Vi 6 5 S Continued on View 4 4 4 smana SLP MODE SM Di 5 5 5 AUX HYD 2 1 FUNC ENABLE BOOM STOWED B a TCON MODE MODE TM 7 PI P7R P7R e e P6R1 P10 P10 Pn c c 6 14 G G 12V gt POWER PCON POWER GND 2 1 7 7 POR ANE a ue P6R1 e _11 8 5 5 gt TOMICRO To MICRO 7 5 lt 805 P Continued View 4 wre 2 z 5E ggg m c z mi Ec x XE lt EB 20192 2 3 52545 Ego Faqs 4 5 8 224 2 4 8 899 ees C t d 11 ZeseS2 045 500205 53006 ontinue on a
148. M CONTROLS Ramp Rate Specifications Ramp rate factory settings Primary boom and turntable rotate accelerate 4 seconds decelerate 1 second Primary boom extend retract accelerate 3 seconds decelerate 0 75 second Secondary boom up down accelerate 7 seconds decelerate 0 75 second Secondary boom extend retract accelerate 8 seconds decelerate 1 second Drive accelerate 2 5 seconds decelerate to neutral 0 75 second decelerate change of direction 0 75 second decelerate coasting 1 second decelerate braking 1 5 seconds decelerate shift from low to high speed 1 second decelerate shift from high to low speed 4 seconds 4 17 Part No 88619 Z 80 60 Section 4 Repair Procedures July 2006 Platform Components 2 1 Platform How to Remove the Platform 1 Separate the foot switch quick disconnect plug 2 Support the platform with an appropriate lifting device 3 Locate the cables that connect to the bottom of the control box Number each cable and its location at the platform control box 4 Disconnect the cables from the bottom of the platform control box 5 Remove the platform control box mounting fasteners Remove the platform control box and set it aside 6 Remove the air line to platform bracket retaining fasteners if equipped 7 Remove the weld cables from the platform if equipped 8 Remove the platform mounting fasteners and remove the platform from the machine Crushing haza
149. MARY EMERGENCY STOP Mem 2 Iw 7 AUXILIARY POWER HIGH SPEED FUNCTION ENABLE LOW SPEED FUNCTION ENABLE TCON TURNTABLE CONTROLLER J11 1 GNDPCON BR 2 P52PCON BL RD 3 C46HN WH 4 CA7OUT WH BK 5 P23PCON BK 6 S56PRV RD 7 P56PRV RD 8 WH RD 9 R49LP WH BK 10 D80 SHIELD 11 UNUSED 12 UNUSED 13 UNUSED 14 CAL FREQ 1 15 P97TET BK 16 CAL FREQ 2 17 D81CAN GR 18 D82CAN YL 19 UNUSED 20 TETFUNC WH 21 TETGND BR 22 P96TET RD 23 TCON TURNTABLE CONTROLLER J12 1 GNDDCON BR 2 P21DCON RD 3 P53LS WH BK 4 P54ENG BK WH 5 S56PRV RD 6 P21DCON RD 7 P58LS RD BK 8 S59SBE GR WH 9 S121PBU GR 10 P53LS WH BK 11 P53LS WH BK 12 5595 GR WH 13 C64LS OR BL 14 C65LOF BL WH 15 C66DREN BL 16 C73SBR BL RD 17 C68PBD RD 18 C64LS OR BL 19 C70PBR BL WH 20 C71PBE BL BK 21 C67SBD BL 22 C77SBU WH 23 V74PRLO RD 24 V75PRLO RD WH 25 SNSR GND BR 26 BOOM ANGLE PWR 27 G119SR BL 28 C124SBL RD BK 29 C77AS WH 30 C78PS WH BK 31 P56PRV RD 32 PRIMARY ANGLE SENSOR INPUT 33 SEC ANGLE SENSOR INPUT 34 P30 3
150. Manifold welder Option pp 4 85 8 10 Traction Manifold 2WD 4 4 86 8 11 Valve Adjustments 2WD Traction Manifold 4 88 8 12 Traction Manifold 4WD 4 4 90 8 13 Valve Adjustments 4WD Traction Manifold 4 92 8 14 4 94 B Turntable Rotation Components 9 1 Turntable Rotation 4 95 Axle Components 10 1 Hub and Bearings 2WD Models pp 4 97 10 2 Oscillating Axle Cylinders 4 99 Section5 Rev Fault Codes Introduction cette t Auden ed 5 1 A Control System Fault Codes eene nennen nnns 5 2 A Ford Engine ECM Fault Code 5 9 Part No 88619 Z 80 60 Xi September 2006 TABLE OF CONTENTS Section6 Rev Schematics 6 1 B Wire Circuit Legend de eee c te teen t tts 6 2 B Limit Switches and Angle Sensors Ne 6 8 B Drive Chassis and Platform Controller Pin Legend 6 10 B Engine Relay and Fuse Panel Legend pp 6 11 B Turntable Controller Pin Legend pp 6 13 Electrical Symbols Legend pp 6 14 B Hydraulic Symbols Legend pp 6 15 Electrical Schematic Legend pp 6 17 Electrical Schematic View 1 Drive Chassis Controller DCON 6 18 B
151. NYO 01 1 LON 31XV 60444 134 80 44 Zld 904 lt adAdd9ss lt 966 v0 Ld Luo d 616 4 HM NOGLZd GND 1044 e ZIO 200 gt N 55 gt 5 5 CD 9 ZIV O 2a tr 95 NY 14374331S 41 sz zd 541 JIH9IH HASLS 41 42 24 79 55795 e 14374331S 4 5zzd X8 18 S4H4 A e uMd HSNS 9331 0z zd HIWHO ONV60Ld A GND HSNS 4331S 1 t 9934 du 18 544 4 1481 daalS 21246 g 18 SH4 A e AU H331s 91 24 T8 SH 196A o E 2199 1 USNS 4331S H1 1 YO S4ILLLO HSNS 4331S JH erac YO SAYLLEO ARD USNS H331S H1 YHO SHTELLO A HSNS 9331 YO SHH LLO e Ks 1437 93215 uH X8 18 SHH4 A m 315 HH 80 zd TH SHH9 A e asuaAau xnv 70 2 90 24 lt GSMOLS aivriloso 50 24 N m ARD 9334 HOLOW HIN QH SIN6ZA E 2 JAYA 10 zd NH8 13HATA a N 11 14 9 Part No 88619 TER
152. No 88619 Z 80 60 5 3 Section 5 Fault Codes July 2006 CONTROL SYSTEM FAULT CODES REV A Error Source Error Type Effects Recovery Actions Value too high Limited speed and direction frozen at Power up controller with problem Value too low zero and neutral alarm sounds corrected STEER JOYSTICK ValeatoV at 0 ValueatoVv Not calibrated Joystick speed and direction frozen at Calibrate joystick zero and neutral Just calibrated second beet ot audible Self clearing transient warning device PRIMARY BOOM UP DOWN Fault Check both Primary boom up down disabled Power up controller with the problem SWITCHES ON TCON buttons pressed display message on LCD corrected SEC BOOM Secondary boom up extend and UP EXT DWN RET down retract disabled display message SWITCHES ON TCON LCD Power controller with the problem corrected PRIMARY BOOM EXT RET Fault Check both Primary boom extend retract disabled Power up controller with the problem SWITCHES ON TCON buttons pressed display message on LCD corrected PRIMARY BOOM LENGTH Fault check Display message on LCD Power up controller with the problem unknown length corrected Fault check Allow only primary boom retract and Power up controller with the problem PRIMARY BOOM ANGEE unknown angle down Display message on LCD corrected PRIMARY UP DOWN SPEED Not calibrated Display message on LCD and allow bore auto calibrate
153. Oil cooler fan Axle oscillate LEFT Axle oscillate RIGHT Primary boom angle signal operational Secondary boom angle signal operational Secondary boomlockout Ext Enable Secondary boom lockout Riser Down Enable ECU test switch Low engine speed A TEREX COMPANY Part No 88619 July 2006 REV Color Circuit and Primary function Section 6 Schematics WIRE CIRCUIT LEGEND Color Circuit and Primary function RD BK 129 Descent alarm BL WH 163 Pri extend retract signal WH RD 130 Travel alarm RD WH 164 Pri up down signal BL 131 Motion alarm WH RD 165 TT Rotate signal GR 132 Platform load input OR 166 Boom length signal safety GR WH 133 Platform load alarm OR BK 167 Boom length signal operational GR BK 134 Key switch power BL RD 168 Primary boom hydraulic valve BL WH 135 lockout RD 136 Power to safety module GN 169 Envelope active LED RD WH 137 Propel power P 38 WH RD 170 Load sense relay source RD BK 138 Priboom up sec boom dwn Ext WH BK 171 Load sense relay sink P 11 30 BL 172 flow control ground WH RD 139 Turntable rot FC safety P 39 BK 173 Ext Ret flow control ground OR RD 140 Boom envelope safety WH 174 Key switch power ground position RD 141 Primary boom angle signal safety WH BK 175 Load sensor signal operational OR 142 Secondary boom angle signal GN WH 176 Secondary extend retract safety BL RD 177 Extend retract lockout BL RD 143 Drive
154. Procedures REV B How to Install the Flex Plate 3 1 Install the flex plate onto the engine flywheel with the raised spline towards the pump 2 Ford models Torque the flex plate mounting 4 bolts in sequence to 14 ft lbs 19 Nm Then torque the flex plate mounting bolts in sequence to 20 ft lbs 27 Nm GM models Torque the flex plate mounting bolts in sequence to 22 ft lbs 30 Nm Then torque the flex plate mounting bolts in sequence to 31 ft lbs 42 Nm Deutz models Torque the flex plate mounting bolts in sequence to 26 ft lbs 35 Nm Then torque the flex plate mounting bolts in sequence to 37 ft lbs 51 Nm Perkins models Torque the flex plate mounting bolts in sequence to 13 ft lbs 18 Nm Then torque the flex plate mounting bolts in sequence to 19 ft Ibs 26 Nm pump pump shaft pump coupler flex plate with raised spline engine flywheel 0 185 inch 4 7 mm gap Deutz Engines 0 15 inch 3 8 mm gap GM Engines 0 25 inch 6 35 mm gap Ford Engine 0 25 inch 6 35 mm gap Perkins 804C 33 Engine 0 3 inch 7 6 mm gap Perkins 704 30 Engine TEREX COMPANY Part No 88619 Z 80 60 ENGINES Install the pump coupler onto the pump shaft with the set screw toward the pump Leave the appropriate gap between coupler and pump end plate for your engine Apply Loctite removable thread sealant to the pump coupler set screw Torque set screw to 61 ft lbs 83 Nm Install the
155. Procedures September 2006 CHECKLIST B PROCEDURES B 12 Test the Engine Idle Select Operation A properly operating engine idle select function is essential to good engine performance and safe machine operation There are three settings Low idle turtle symbol allows the operator to control multiple boom and or drive functions simultaneously though at reduced speed This setting maintains a consistent low idle High idle rabbit symbol allows the operator to control multiple boom and or drive functions simultaneously This setting maintains a consistent high idle Foot switch activated high idle rabbit and foot switch symbols should be used for normal machine operation This selection activates high idle only when the foot switch is pressed down 1 Turn the key switch to ground controls 2 Pull out the red Emergency Stop button to the on position at both the ground and platform controls 3 Start the engine from the ground controls 4 Push and release the rpm select button until high rpm is selected rabbit symbol Result The engine should change to high idle 5 Push and release the rpm select button until low rpm is selected turtle symbol Result The engine should return to low idle A TEREX COMI REV C 6 Turn the key switch to platform controls 7 Atthe platform controls press the engine idle select button until high idle rabbit symbol is selected Result The engine should cha
156. Proper engine maintenance following the engine manufacturer s maintenance schedule is essential to good engine performance and service life Failure to perform the maintenance procedures can lead to poor engine performance and component damage Deutz Models Required maintenance procedures and additional engine information are available in the Deutz BF4L2011 Operation Manual Deutz part number 0297 9929 Deutz BF4L2011 Operation Manual REV To access the engine 1 Remove the engine tray retaining fastener located under the engine tray Swing the engine tray out and away from the machine 2 Install the fastener that was just removed through the engine tray and into the engine tray anchor hole in the turntable AWARNING Crushing hazard Failure to install the fastener into the engine tray anchor hole to secure the engine tray from moving could result in death or serious injury Genie part number 84794 Genie 3 66 Z 80 60 Part No 88619 September 2006 Section 3 Scheduled Maintenance Procedures REV CHECKLIST E PROCEDURES E 7 E 8 Perform Engine Maintenance Deutz Models Engine specifications require that this procedure be performed every 6000 hours Proper engine maintenance following the engine manufacturer s maintenance schedule is essential to good engine performance and service life Failure to perform the maintenance procedures can lead to poor engine performance and component d
157. R17 86 n 30 86 2 lt 87 85 RELAY x ART ABS COOLER 235 39 ENGINE i COM 5 ub RELAY 2 1 RELAY fas 187 8 gh 187 185 ALTERNATOR J 4 5 CR5 2 8630 RELAY AUTO 5 S 500 5 5 lt Na 5 4 4 5 RESET CB 5 9 925 E amp 85 87 BLK 120VAC lt 4 i B 5 4 Y a 7 amp 2528 z Erw 8 rod WHITE 1 5 23PINENGINE 2 457 5 58 AAA 8 2 8 E 2 5 23 PINEN 5 2 12 Sg 8 5 EEC ES 424 g 8 P32 GENERATOR HARNESS Wa 3 DETAIL E cso P a Lr Bog NS OPT 220VAC W REGULATOR 1 2 5 5 27 PD 1 30 4 RD 12VDC RD weer c 87 1 F 2 8 CABGEN GRIWH gt wh 3 WH R4SGEN A ok WH 5 adz 3 BATGND BR en BRGND lt 53 BR 120 r 1 5 456 8 2 i o f ad 3 4 ABD K BIS BK E BK 1 i c a c c 1 GR 45 BKWH sz REGULATOR IND sl 5 5 1 a a 8 5 Hi 5 5 8 WH NEUTRAL gu t 9 1 lt lt lt lt 5 S 5 a 2 Ls 220VAC 1 SEE DETAILB 120VAC GENERATOR ogr E m 3 a x Zz ug Wray OZ gt
158. RY 0 4 arp PWR P52 PCON lt 52 PCON WH P7R 3 PLAT ROT CCW 856 RD P56PRV SEC COMP PRI COMP 22 23 55 05 55 06 22 15 21 07 02 11 07 17 10 CABLE CABLE P87PTS RD C88PTS RD BK P22 56PRV RD WH2 P56PRV RD WH gt gt gt ail PLATFORM PLATFORM TILT BLATEOBM PCON E MANIFOLD SENSOR MANIFOLD 74HC08 HARNESS HARNESS 5 11 BLACK 35 3 04 ROUND DEUTSCH CONN 8 WAY 2 5 P21 BLACK 23 PCON T 42 P22 WHITE 23 PIN PRI UP DN P55 6 WAY DEUTSCH AT PLAT LEVEL SENSOR rr VANE P17 16 WAY MOLEX IN TCON BATT J14 02 3 SM NOT SLP MODE SEC FC Safety Circuits P22 and P22R AH AUX HYD J14 06 RECOVERY SW Z TM TCON MODE SM AH 17 12 P17 09 15 FE FUNC ENABLE P7 4 7 TOON RECOVERY 6 TM FE PLD TCON P17 08 TO 7 21 SM AH P7 S56PRV RD RECOVERY BATT 74HC08 SW V 154 12 05 4 01 18 01 P31 06 To 7 gt o gt S56PRV RD WH WH S56PRV RD lt 2 gt SPARE VALVE TCON LOWER LIMIT ELECTRIC DRIVE 032 02 TCON SWITCH HARN ROTATOR CHASSIS 7 P31 05 To 11 06 01 21 04 FWD VALVE lt P7R LE STEERLEFT LR STEER LEFT S56PRV RD lt lt S56PRV RD P7 9 P13 05 VALVE VALVE REV VALVE 032 23 032 17 SEC COMP PRI COMP P13 06 LF STEER RIGHT LR STEER RIGHT TCON CABLE CAB
159. RY SIGNAL BOOM RET RECOVERY SIGNAL BOOM DWN RECOVERY SIGNAL BOOM DWN RECOVERY SIGNAL BOOM EXT RET FC RECOVERY SIGNAL BOOM EXT RET FC RECOVERY SIGNAL BOOM UP DWN FC RECOVERY SIGNAL BOOM UP DWN FC RECOVERY SIGNAL P15 ECU POWER P15 ECU POWER P_30 TO HORN BUTTON TO HORN BUTTON PWR TO TCON ESTOP PWR TO TCON ESTOP 22 22 22 P_9B OUT PWR ENABLE OUT PWR ENABLE P_6R2 P15 ECU POWER BOOM STOWED TCON MODE MODE TCON MODE P7 P7 TO HORN BUTTON P7R P7R P7R PWR TO TCON ESTOP P10 P10 PCON POWER PCON POWER PCON POWER OUT PWR ENABLE TCON MODE 7 P6R1 P6R1 e P6R1 22 P11 P11 5 11 5 a g P7R PCON POWER 38g 2 2 ate ae g beni 858 ele 2 a E E 9 7 615 2424 EJE 8 3 lt 855 oa sag 88 5 8 2 2 990909 coocuzmcmcuzzzmuurcco amp torzzt tx SSSSRSRSHEN FE SHEP 25000000 8 08 0 9999999935 gt J12 BLACK 35 PIN Jou elo e Jo fx fool ee o e mim T TITIN e NINI 188 N 100 192 eo Continued on View
160. Safety Circuits Section 6 Schematics July 2006 Electrical Schematic View 17 Safety Circuits 12 03 03 NCP 04 P20B 02 114 06 P114 08 P20B 03 P12 09 mE 1 P6R1 s P53LS WH BK BK WH S59SBE GR WH gt lt lt 1 gt A WH S12SBL BL WH P_11 gt WB MONITOR RD W WH RD P12 11 LSS1RS 3 EXT RD BK WH BK LOWER LIMIT ee P 30 ECU P14 YELLOW 18 19 CABLE PBAS 18 19 CABLE SW HARNESS E MONITOR P12 10 03 NCFOP 04 TCON ro TO P12 SEC EXT PRI UP VALVE TCON LOWER LIMIT LSS2AS RAISED VALVE J14 07 SW HARNESS PURPLE P12 BLACK 35 PIN TCON ong ee tere eM P20B 12 WAY DEUTSCH VALVEP J14 12 STARTER RELAY Safety Circuits P6R1 P14 P12 P11 AND P30 PITAT WAY DEUTSCH RBAS 013 09 20 01 114 04 114 02 P20B 12 01 NCP 02 P12 07 18 To P54ENG BK WH gt BK WH gt lt lt gt NX gt OR BK SJ1 WH RD 75 BR 5815 RD BK lt lt gt P_9B gt iGN FUEL RELAY 18 19 CABLE PBAS 18 19 CABLE LOWER LIMIT LSS1RS 2 EXT LOWER LIMIT J13 03 SW HARNESS SW HARNESS LOWER LIMIT YELLOW TCON SW HARNESS or 0 0 BRIK P12 BLACK 35 PIN TCON LSS2AS RAISED 3 P20B 12 WAY DEUTSCH PURPLE 114 12 WAY DEUTSCH PBAS Safety Circuits P6R2 P10 P18 AND P9B NOT SLEEP MODE AND FOOT SW PLAT DOWN gt JIB DOWN PLAT UP JIB UP 1 P11 02 04 PLAT ROT CW P17 08 RECOVE
161. Scheduled Maintenance Procedures September 2006 CHECKLIST A PROCEDURES A 7 Perform Engine Maintenance Engine specifications require that this procedure be performed every 100 hours GM Models Required maintenance procedures and additional engine information are available in the GM 3 0L Operator Handbook GM part number 36100007 GM 3 0L Operator Handbook Genie part number 77738 Perkins Models Required maintenance procedures and additional engine information are available in the Perkins 704 30 User s Handbook Perkins part number TPD 1336E OR the Perkins 804C 33 Operation and Maintenance Manual Perkins part number SEBU7853 00 Perkins 704 30 User s Handbook Genie part number 101840 Perkins 804C 33 Operation and Maintenance Manual Genie part number 111332 A TEREX COM REV C 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 84792 To access the engine 1 Remove the engine tray retaining fastener located under the engine tray Swing the engine tray out and away from the machine 2 Install the fastener that was just removed through the engine tray and into the engine tray anchor hole in the turntable AWARNING Crushing hazard Failure to install the fastener into the engine tray anchor hole to se
162. UEL 1 WH NEUTRAL ales 58 seg eg ae i 2 we T a 1 220VAC 7 m ALTERNATOR 6 1 2 02 2 8 1 AUTO 2 Be Sz 8 5 8 5 148 922458 8 RESET CB SEE DETAIL FOR i 25 002200220 120VAC GENERATOR W REGULATOR Q gt Bicazovac 5 x mn 0306 E a 2 STA H 99 5 5 i 5 IND 5 13 97115 112118 6 2423 5 3 ao a ToJ4 32 REGULATOR 2 AAAAAAAAAAAA WHITE 35 PIN FORD 42 PIN CONNECTOR oO 8 14 lol gt a 2 gt n n lt x t dua a ox 4 558 5248 208 of ou I aou 62 F xE E z2 8 B St t 254 lt b T xz 9 8 26 c 5 E x 5 G a E lt 5 lt 8 lt 8 o enie A TEREX COMPANY 6 34 Z 80 60 Part No 88619 July 2006 Section 6 Schematics REV A Electrical Schematic View 16 Hydraulic Generator Option N M L K J H G F E D C B A 1 PIN COLOR CKT COLOR 1 BR GND WH RD c 2 WH WH lt lt 3 WH BK C31EDC WH BK PCON as 4 BR GND BK RD 5 BR GND BURD Harness 6 WH C30EDC A RD 7 WHIBK C31EDC A RD BK N 8 BR GND OR RD c 2 9 GR WH C45GEN GR WH 10 GR BK V150HG GR BK
163. V B 9 Testall machine functions from the platform controls O Result All platform control functions should not operate 10 Turn the key switch to ground control 11 Test all machine functions from the ground controls O Result All ground control functions should not operate 12 Using a suitable lifting device lift the test weight off the platform floor Result The alarm should be off The platform overload indicator light should be off at the platform controls and there should be no error message on the LCD display at the ground controls There may be a 2 second delay before the overload indicator lights and alarm turn off 13 Test all machine functions from the ground controls O Result All ground control functions should operate normally 14 Turn the key switch to platform control 15 Test all machine functions from the platform controls O Result Only for software versions 1 03 and lower All ground control functions should not operate Refer to Repair Procedure 6 1 How to Determine the Revision Level O Result Only for software versions 1 04 and higher All ground control functions should still operate Refer to Repair Procedure 6 1 How to Determine the Revision Level Part No 88619 July 2006 Section 4 Repair Procedures Jib Boom Components 3 1 Jib Boom How to Remove the Jib Boom Perform this procedure with the boom in the stowed position When removing a hose ass
164. V46 Statoil Hydra Way Bio Pa 32 BP Biohyd SE S Fire resistant UCON Hydrolube HP 5046 Quintolubric 822 Mineral based Shell Tellus T32 Shell Tellus T46 Chevron Aviation 5606A Use Chevron Aviation A hydraulic oil when in ambient temperatures consistently below O F 17 C Use Shell Tellus T46 hydraulic oil when in ambient temperatures consistently exceed 205 F 96 C Genie specifications require additional equipment and special installation instructions for the approved optional fluids Consult the Genie Industries Service Department before use 2 4 Z 80 60 Part No 88619 September 2006 Section 2 Specifications REV SPECIFICATIONS Drive pump Auxiliary pump Type bi directional variable displacement piston pump Type two section fixed displacement gear pump Displacement 2 81 Displacement Section 1 inner 0 159 cu in 46 cc 2 61 cc Flow rate 2300 rpm 28 Flow rate 2687 rpm 1 7 gpm 106 L min 6 4 L min Drive pressure maximum 3625 psi Displacement Section 2 outer 0 051 cu in 250 bar 0 84 cc Charge pump Flow rate 2687 rpm 0 3 gpm 1 1 L min Type gerotor Function manifold Displacement 0 85 cu in 13 9 cc System relief pressure 3200 psi measured at PTEST port 220 6 bar Flow rate 2300 rpm 9 gpm 34 L min Primary boom down relief pressure 1300 psi measured at PTEST port 89 6 bar Charge pre
165. WARNING Crushing hazard Failure to install hydraulic oil can penetrate and the bolt into the engine tray to burn skin Loosen hydraulic secure it from moving could result connections very slowly to allow in death or serious injury the oil pressure to dissipate gradually Do not allow oil to squirt 6 Attach a lifting strap from an overhead crane to to the lug on the barrel end of the primary boom lift cylinder Raise the primary boom lift cylinder 3 Remove the engine tray retaining fastener to a vertical position 2 engine Ney Cutaway Tanne 7 Remove the pin retaining fastener from the primary boom rod end pivot pin a 8 Use slide hammer to remove the pin Remove the primary boom lift cylinder and linkage arms from the machine Crushing hazard The primary AWARNING boom lift cylinder and linkage arms could become unbalanced and fall if not properly supported when the pin is removed a engine tray anchor hole b engine tray retaining fastener 4 Locate the engine tray anchor hole at the pivot end of the engine tray A TEREX COMPANY Part No 88619 Z 80 60 4 43 Section 4 Repair Procedures September 2006 BOOM COMPONENTS 4 7 Secondary Boom Lift Cylinder How to Remove the Secondary Boom Lift Cylinder AWARNING Bodily injury hazard This procedure requires specific repair skills lifting equipment and a suitable workshop Attempting this procedure without these skills an
166. Xii Z 80 60 Part No 88619 September 2006 TABLE OF CONTENTS Section6 Rev Schematics continued Electrical Schematic View 17 Safety Circuits 00420 0 6 36 B Hydraulic Schematic 2 Wheel Drive with 2 Wheel Steer View 1 6 37 B Hydraulic Schematic 2 Wheel Drive with 2 Wheel Steer View 2 6 38 B Hydraulic Schematic 2 Wheel Drive with 4 Wheel Steer View 1 6 39 B Hydraulic Schematic 2 Wheel Drive with 4 Wheel Steer View 2 6 40 B Hydraulic Schematic 4 Wheel Drive with 2 Wheel Steer View 1 6 41 B Hydraulic Schematic 4 Wheel Drive with 2 Wheel Steer View 2 6 42 B Hydraulic Schematic 4 Wheel Drive with 4 Wheel Steer View 1 6 43 B Hydraulic Schematic 4 Wheel Drive with 4 Wheel Steer View 2 6 44 Part No 88619 Z 80 60 September 2006 SSS eS This page intentionally left blank 7 80 60 Part 88619 September 2006 Section 2 Specifications REV Machine Specifications Tires and wheels Tire size foam filled and non marking 18 625 FF Tire size Hi flotation 445D50 70 Tire ply rating foam filled and non marking 16 Tire ply rating Hi flotation 14 Overall tire diameter 40 7 in foam filled and non marking 103 3 cm Overal
167. YSTICK DEFAULTS is displayed Press the button to select ves then press the button 5 Do not start the engine 6 Locate the secondary boom up down and extend retract joystick 7 Genie Part No 88619 Z 80 60 Turn the key switch to the off position Press and hold the enter button on the ground control panel while turning the key switch to platform controls Press the minus button twice then press the enter button twice Use the scroll button to scroll through the menu until RESET PRIMARY BOOM UP DOWN JOYSTICK DEFAULTS is displayed Press the button to select ves then press the button Do not start the engine Locate the primary boom turntable rotate joystick Move the boom turntable rotate joystick full stroke in the up direction and hold for 5 seconds then return to the center or neutral position Section 4 Repair Procedures PLATFORM CONTROLS x Move the boom turntable rotate joystick full stroke in the down direction and hold for 5 seconds then return to the center or neutral position Result The alarm at the ground controls should sound for a successful calibration Result If the alarm does not sound repeat calibration procedure Turntable rotate functions 1 2 Turn the key switch to the off position Press hold the enter button on the ground control panel while turning the key switch to platform controls Press the
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170. amage Deutz Models Required maintenance procedures and additional engine information are available in the Deutz BF4L2011 Operation Manual Deutz part number 0297 9929 Perform Engine Maintenance Deutz Models Engine specifications require that this procedure be performed every 12000 hours Proper engine maintenance following the engine manufacturer s maintenance schedule is essential to good engine performance and service life Failure to perform the maintenance procedures can lead to poor engine performance and component damage Deutz Models Required maintenance procedures and additional engine information are available in the Deutz BF4L2011 Operation Manual Deutz part number 0297 9929 Deutz BF4L2011 Operation Manual Genie part number 84794 Deutz BF4L2011 Operation Manual Genie part number 84794 To access the engine 1 Remove the engine tray retaining fastener located under the engine tray Swing the engine tray out and away from the machine 2 Install the fastener that was just removed through the engine tray and into the engine tray anchor hole in the turntable AWARNING Crushing hazard Failure to install the fastener into the engine tray anchor hole to secure the engine tray from moving could result in death or serious injury A TEREX COMI Part No 88619 To access the engine 1 Remove the engine tray retaining fastener located under the engine tray Swing the engi
171. ar RR PCN Right Rear Steer Sensor RRS PEL RPM RPM PLD Secondary Boom Angle Sensor SBS PLF Secondary Boom Elevated SBL PLU Sec Boom Down SBD PRF Sec Boom Extend SBE PRC Sec Boom Extend Retract Flow Control SER PRL Sec Boom Retract SBR PRR Sec Boom Up SBU PWR Sec Boom Up Dwn Flow Control SUD PSL Secondary Boom SB PTA This list continues on the next page PTS Z 80 60 6 3 Section 6 Schematics July 2006 WIRE CIRCUIT LEGEND Definition Suffix Secondary Boom Lockout Valve Extend SLE Secondary Boom Lockout Valve Riser Down SLD REV Wire Coloring 1 All cylinder extension colors are solid and all Sensor SEN retract functions are striped black When using Spare SP black wire the stripe shall be white 5 P choke EA 2 Allrotations that are LEFT or CW are solid a 9 bab RIGHT or CCW are striped and black When the Starter STIR wire is black the stripe is white Steer Control Signal STC Steering Valve Clockwise SCW All proportional valve wiring is striped Steering Valve Counter Clockwise SCC Temp Sender TSR Temp Switches TS Wire Color Legend Tether TET BL Blue Tilt Alarm X axis TAX BL BK Blue Black Tilt Alarm Y axis TAY BL RD Blue Red Turntable or Ground Control Panel TCN BL WH Blue White Turntable Rotate Flow Control TRF BK Black Turntable Rotate Right CW TRR ac BK RD Black Red Turntable Rotate Signal TRS BK WH Black White Turntable Tilt Alarm TTA BR Brown Turntable Tilt Sensor TTS
172. ard When testing or replacing any hydraulic component always support the structure and secure it from movement AWARNING Electrocution hazard Contact with electrically charged circuits could result in death or serious injury Remove all rings watches and other jewelry AWARNING 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 Two persons will be required to safely perform some troubleshooting procedures Part No 88619 Z 80 60 5 1 Section 5 Fault Codes July 2006 Control System Fault Codes REVA ErrorSource Error Type 8 Recovery Actions Normal function except threshold for Not calibrated one or the other direction is zero Calibrate thresholds Display message on LCD Initiate one second beep of audible PRIMARY BOOM EXT RET warning device Value Too High Limited speed and direction frozen Power up controller with the at zero and neutral alarm sounds problem corrected Value Too Low Value at 0 V PRI BOOM EXT VALVE PRI BOOM RET VALVE Limited speed and direction frozen Power up controller with the Fault check PRI BOOM UP VALVE at zero and neutral alarm sounds problem corrected PRI BOOM DOWN VALVE Stop all secondary boom functions Fault check Power up controller with the problem corrected SEC BOOM
173. arrow in the display at the ground controls does not turn off Repeat this procedure beginning with step 1 22 Start the engine and activate the primary boom down function Release the function enable button when the digital level displays 40 Push in the red Emergency Stop button to the off position 23 Press and hold the enter button and pull out the red Emergency Stop button to the on position Section 4 Repair Procedures September 2006 BOOM COMPONENTS 24 Press and hold the enter button until the engine symbol appears in the display at the ground controls 25 Enter sensor calibration mode by pressing the buttons at the ground controls in the following sequence 26 Press the scroll button until PRIMARY BOOM ANGLE 40 is shown on the display 27 Press the plus button to select yes then press and hold the enter button to accept Result The alarm should not sound Result The alarm does sound Repeat this procedure beginning with step 1 28 Press the scroll button until Exit is shown on the display Press the plus button to select yes then press and hold the enter button to accept 29 Start the engine 30 Activate the boom up function until the digital level reads 65 Result The primary boom should stop Result The primary boom does not stop Immediately release the function enable button and lower the boom Repeat this procedure
174. ate independently functioning safety switch The mechanical type operational or safety switches are used to sense a positive displacement or movement of the limit switch actuator or arm as the machine moves through its range of operational functions Included in this group are envelope limit switches which sense the extended length and angle of the booms and rotational position of the turntable For example when the secondary boom is fully raised and the operational switch is activated it tells the ECM at the ground controls to start extending the secondary boom Another example is the drive enable limit switch which disables the drive function anytime the boom is rotated past the rear axles indicated by the circle end of the drive chassis In some cases the engine will be stopped if safety parameters are exceeded A TEREX REV B Limit Switch Numbering LSP1AO Primary boom angle stowed LSP1RO Primary boom length retracted LSP1EO Primary boom length fully extended LSS1AO Secondary boom angle fully stowed LSS2AO Secondary boom angle fully raised LSS3AO Secondary boom angle 25 to 30 LSS2AS Secondary boom angle safety LSS1RO Secondary boom fully retracted LSS1RS Secondary boom fully retracted safety LSJ1EO Platform level fully extended LST10 Drive enable mechanical LSA10S Oscillate axle right side LSA2OS Oscillate axle left side Numbering Legend Switch number J Jib boom D Down P Primary
175. atform becomes out of level the tilt alarm will sound and the platform not level indicator will turn on Level the platform until the indicator light turns off Part No 88619 September 2006 Section 3 Scheduled Maintenance Procedures REV B 22 Test the Primary Boom Angle Sensor A properly functioning primary boom angle sensor PBAS is essential to safe machine operation The primary boom angle sensor is used to limit the angle of the primary boom relative to the angle of the secondary boom and gravity The ECM at the ground controls TCON monitors the position and angle of the primary boom using the signal from PBAS The PBAS signal is used to control the ramping of the primary boom as well as velocity control limiting the speed of the primary boom to 1 3 feet 0 4 meters per second Perform this procedure on a firm level surface 1 Turn the key switch to ground control and pull out the red Emergency Stop buttons out to the on position at both the ground and platform controls TEREX COMPANY 2 Push one of the LCD screen buttons shown 4 el until primary boom angle is displayed Part No 88619 Z 80 60 CHECKLIST B PROCEDURES 3 Start the engine from the ground controls Raise the primary boom The display will begin showing a boom angle of 40 Continue raising the primary boom until the display shows 65 Result The primary boom should stop Result The primary
176. atform to the ground The ground control box contains a replaceable membrane decal with touch sensitive buttons for various machine functions The ground control box also contains two printed circuit boards The LCD Liquid Crystal Display circuit board is mounted to the inside of the control box lid which controls the LCD display screen The ECM circuit board is the main circuit board for the machine There are relays on the ECM circuit board that can be replaced All operating parameters and configuration of options for the machine are stored in the ECM memory The ECM circuit board inside the ground control box TCON cannot be replaced by itself If the ECM circuit board is faulty and needs to be replaced contact the Genie Industries Service Department When an ECM circuit board is replaced the proportional valves will need to be calibrated See 1 3 How to Calibrate a Joystick A TEREX COMI Part No 88619 Ground Controls How to Determine the Revision Level 1 Turn the key switch to ground controls and pull out the red Emergency Stop buttons to the on position at both platform and ground controls Result The revision level of the ECM will appear in the LED display window How to Remove the LCD Display Screen Circuit Board 1 Push in the red Emergency Stop button to the off position at both the ground and platform controls 2 Remove the ground control box lid fasteners Open the control box lid
177. ations 1 Start the engine from the ground controls 2 Raise the end of the boom to a comfortable working height chest high then extend the boom 1 foot 30 cm 3 Measure each wear pad Result Replace the wear pad if it is less than specification If the wear pad is still within specification shim as necessary to obtain zero clearance and zero drag Refer to Repair Procedure 4 2 How to Shim the Boom 4 Extend and retract the boom through the entire range of motion to check for tight spots that may cause binding or scraping of the boom Always maintain squareness between the outer and inner boom tubes A TEREX COM Proper use of the free wheel configuration is essential to safe machine operation The free wheel configuration is used primarily for towing A machine configured to free wheel without operator knowledge may cause death or serious injury and property damage AWARNING Collision hazard Select a work site that is firm and level Component damage hazard If the machine must be towed do not exceed 2 mph 3 2 km h CAUTION 1 Chock the steer wheels to prevent the machine from rolling 2 Center a lifting jack of ample capacity 20 000 Ibs 10 000 kg under the drive chassis between the wheels at the non steer end of the machine 3 Liftthe wheels off the ground and place blocks under the drive chassis for support 4 Disengage the drive hubs by turning over the drive hub disconnect caps on eac
178. ble lifting device place a test weight equal to that of the available capacity one of the locations shown Refer to Illustration 1 Result The platform overload indicator lights should be off at both the ground and platform controls and the alarm should not sound Result The platform overload indicator lights are on and the alarm is sounding Calibrate the platform overload system Refer to Repair Procedure 2 4 How to Calibrate the Platform Overload System if equipped Illustration 1 5 Carefully move the test weight to each remaining location Refer to Illustration 1 O Result The platform overload indicator lights should be off at both the ground and platform controls and the alarm should not sound Result The platform overload indicator lights are on and the alarm is sounding Calibrate the platform overload system Refer to Repair Procedure 2 4 How to Calibrate the Platform Overload System if equipped A TEREX Part No 88619 6 x x CHECKLIST C PROCEDURES Using a suitable lifting device place an additional 50 Ibs 23 kg of weight onto the platform Result The alarm should sound The platform overload indicator light should be flashing at the platform controls and PLATFORM OVERLOAD should be displayed on the LCD Screen at the ground controls Result The alarm is not sounding OR the platform overload indicator light is not flashing OR PLATFORM OVERLOAD is not dis
179. bol is selected 4 Press down the foot switch and raise the boom until the engine switches to low idle 5 Choose a point on the machine i e contact patch of a tire as a visual reference for use when crossing the start and finish lines 6 Bring the machine to top drive speed before reaching the start line Begin timing when your reference point on the machine crosses the start line A TEREX COMI Part No 88619 CHECKLIST B PROCEDURES 7 Continue at full speed and note the time when the machine reference point crosses the finish line Refer to Section 2 Specifications 8 Lower the boom to the stowed position 9 Extend the boom 4 feet 1 2 m 10 Choose a point on the machine i e contact patch of a tire as a visual reference for use when crossing the start and finish lines 11 Bring the machine to top drive speed before reaching the start line Begin timing when your reference point on the machine crosses the start line 12 Continue at top speed and note the time when the machine reference point crosses the finish line Refer to Section 2 Specifications Section Scheduled Maintenance Procedures September 2006 CHECKLIST B PROCEDURES B 17 Test the Alarm and Optional Flashing Beacon An alarm and optional flashing beacon are installed to alert operators and ground personnel of machine proximity and motion There are four alarm option modes that can be activated based on user preference or r
180. bolts lubricated Continuous improvement of our products is a Genie policy Product specifications are subject to change without notice Part No 88619 SPECIFICATIONS Manifold Component Specifications 640 ft lbs Plug torque 867Nm SAENo 2 50 in lbs 6 Nm 35 ft Ibs 47 5 Nm SAE No 4 14 ft lbs 18 9 Nm SAE No 6 23 ft lbs 31 2 Nm 180 ft lbs SAE No 8 36 ft lbs 48 8 Nm 244 Nm SAE No 10 62 ft lbs 84 1 Nm 80408 SAE No 12 84 ft lbs 113 9 Nm 108 4 Nm 280 ft lbs 379 Nm 210 ft lbs 284 Nm 160 ft lbs 217 Nm 110 ft lbs 149 Nm 80 ft lbs 108 4 Nm Z 80 60 2 15 Section 2 Specifications September 2006 SPECIFICATIONS Hydraulic Hose and Fitting Torque Specifications Your machine is equipped with Parker Seal Lok fittings and hose ends Genie specifications require that fittings and hose ends be torqued to specification when they are removed and installed or when new hoses or fittings are installed SAE O ring Boss Port tube fitting installed into Aluminum SAE Dash size Torque 4 14 ft lbs 18 9 Nm 6 23 ft lbs 31 2 Nm 8 36 ft lbs 48 8 Nm 10 62 ft lbs 84 1 Nm 12 84 ft lbs 113 9 Nm 16 125 ft lbs 169 5 Nm 20 151 ft lbs 204 7 Nm 24 184 ft lbs 250 Nm SAE O ring Boss Port REV C Seal Lok fittings 1 Replace the O ring The O ring must be replaced anytime the seal has been broken The O ring cannot be re used
181. boom does not stop Immediately release the function enable button and lower the boom Calibrate the limit switch Refer to Repair Procedure 4 7 How to Calibrate the Primary Boom Limit Switch Crushing hazard If the boom does not stop at 65 immediately release the function enable button and lower the primary boom Failure to lower the boom could cause the machine to tip over resulting in death or serious injury Section Scheduled Maintenance Procedures September 2006 CHECKLIST B PROCEDURES B 23 Inspect the Fuel and Hydraulic Tank Cap Venting Systems Genie requires that this procedure be performed every 250 hours or quarterly whichever comes first Perform this procedure more often if dusty conditions exist Free breathing fuel and hydraulic tank caps are essential for good machine performance and service life A dirty or clogged tank cap may cause the machine to perform poorly and continued use may cause component damage Extremely dirty conditions may require that the caps be inspected more often Explosion and fire hazard Engine fuels are combustible Perform this procedure in an open well ventilated area away from heaters sparks flames and lighted tobacco Always have an approved fire extinguisher within easy reach Perform this procedure with the engine off 1 Remove the cap from the fuel tank TEREX COMPANY REV C Check for proper venting Result Air passes through the fu
182. ch 12mm 2 7 Section 2 Specifications September 2006 SPECIFICATIONS Ford LRG 425 EFI Engine Displacement Number of cylinders Bore amp stroke Horsepower 153 cu in 2 5 liters 4 3 78 x 3 4 in 96 01 x 86 36 mm Continuous 60 2500 rpm 44 7 kW 2500 rpm Intermittent Firing order Low idle Frequency High idle Frequency Compression ratio 70 2500 rpm 52 kW 2500 rpm 1 3 4 2 1600 rpm 396 8 Hz 2500 rpm 620 Hz 9 4 1 Compression pressure Pressure psi or bar of lowest cylinder must be at least 75 of highest cylinder Valve clearances collapsed tappet Lubrication system 0 035 to 0 055 in 0 889 to 1 397 mm Oil pressure operating temp 2000 rpm 40 to 60 psi 2 75 to 4 1 bar Oil capacity including filter 5 quarts 4 7 liters REV Oil pressure switch specifications Torque 8 18 ft lbs 11 24 Nm Oil pressure switch point 3 5 psi 0 21 0 34 bar Starter motor Normal engine cranking speed 200 to 250 rpm Current draw normal load 140 200A Current draw maximum load 800A Current draw no load 70A Maximum circuit voltage drop 0 5V DC while starting normal temperature Battery Type 12V DC Group 34 78 Quantity 1 Cold cranking ampere 900A Reserve capacity 25A rate 200 minutes Electronic fuel pump Fuel pressure static 64 psi 4 4 bar Fuel flow rate 0 58 gpm 2 18 L mi
183. ck on the boom Cables on the boom and jib boom Jib boom platform rotate manifold Inside of the platform control box 13 Remove the engine tray retaining fastener from the engine tray anchor hole at the pivot end of the engine tray 14 Inspect for a liberal coating of dielectric grease at the following location All wire harness connectors to the platform control box Hydraulic manifold wiring 15 Swing the engine tray in towards the machine 16 Install the bolt that was just removed into the original hole to secure the engine tray AWARNING Crushing hazard Failure to install the bolt into the engine tray to secure it from moving could result in death or serious injury Part No 88619 September 2006 Section 3 Scheduled Maintenance Procedures REV B 3 Test the Key Switch Proper key switch action and response is essential to safe machine operation The machine can be operated from the ground or platform controls and the activation of one or the other is accomplished with the key switch Failure of the key switch to activate the appropriate control panel could cause a hazardous operating situation 1 Pull out the red Emergency Stop button to the on position at both the ground and platform controls 2 Turn the key switch to ground control start the engine and then turn the key switch to platform control 3 Check all machine function from the ground controls Result All machine functions
184. crease the rpm Tighten the low idle lock nut and confirm the rpm Skip to step 4 if the low idle rpm is correct Be sure the solenoid fully retracts when activating high idle solenoid boot a b high idle adjustment nut yoke lock nut d yoke e low idle adjustment screw f low idle lock nut A TEREX COMPANY Part No 88619 Z 80 60 3 35 Section Scheduled Maintenance Procedures September 2006 CHECKLIST B PROCEDURES B 20 Test the Safety Envelope and Circuits Testing the machine safety envelope is critical to safe machine operation If the boom is allowed to operate when a safety switch is not functioning correctly the machine stability is compromised and may tip over Refer to Section 6 for limit switch and angle sensor information Secondary Boom 1 Angle Safety Limit Switch LSS2AS 1 Turn the key switch to ground control and pull out the red Emergency Stop buttons out to the on position at both the ground and platform controls Start the engine from the ground controls 3 Simultaneously push the LCD screen buttons shown to activate status mode 4 Push one of the LCD screen buttons shown 4 until secondary boom status is displayed 5 Fully raise the secondary boom and extend the secondary boom approximately 2 feet 61 cm 6 Remove the fasteners from the turntable riser cover at the pivot end of the secondary boom Remo
185. croll through the menu until the function valve that needs to be reset is displayed Press the button to select ves then press the button July 2006 Section 4 Repair Procedures REV B How to Set the Function Thresholds and Default Functions Speeds Before the threshold and default function speeds can be set the boom function proportional valve coil defaults must be set first See 1 3 How to Reset a Proportional Valve Coil Default If a boom function proportional valve coil has not been replaced and just want to reset the function speed to original factory settings begin with step 10 Perform this procedure with the machine parked on a firm level surface which is free of obstructions 1 Start the engine from the platform controls 2 Press down the foot switch Be sure the engine rpm is set to foot switch activated high idle Function threshold 3 Select a joystick controlled function that needs to have the threshold set 4 Slowly move the joystick off center in either direction just until the machine function starts to move then move the joystick very slowly towards the neutral or center position just before the machine function stops Do not let go of the joystick A TEREX Part No 88619 5 8 PLATFORM CONTROLS While holding the joystick in position press the engine start button v at the platform controls to set the joystick controller threshold Re
186. cs Erie LS LXXX Electrical Schematic View 14 Perkins 704 30 Engine before serial number 329 REV B July 2006 C Electrical Schematic View 14 Perkins 704 30 Engine before serial number 329 Section 6 Schematics N SSS SS Ses TEET EET eT T d 5 5 E 5 1 2 1 5 9 00 2 oc 1 u 512 gt ibo PSP QE ius 355 O zo 1 gt 27 28 50 0 e orzamco 3 8 5 1 E 5 1 So8 lt fe 88108 8 BD 9 8 9 i E 2 1 8 x 1 808 g H ag 92555 i BEA i 52 uz ES rzo 2 o zu 22 Omm fo bo 3Hnlydadna L B 29
187. ction 6 Schematics WIRE CIRCUIT LEGEND Color Circuit and Primary function WH BK WH RD BK BK WH BK RD BL BL BK BL WH BL RD OR OR BK OR RD GR GR BK GR WH WH WH BK WH RD WH BK BL BL WH BL RD WH BK BK WH GR BK RD RD WH RD BK GR WH GR WH Reverse EDC B Brake Start Start aid glow plug or choke High engine speed select Steer clockwise Steer counterclockwise Gas LP Limit switch signal stowed RPM signal Boom retracted signal Jib up Jib down AC Generator Drive horn Output power enable Work lamp Motion lamp Auxiliary boom Auxiliary steer Auxiliary platform Boom envelope safety valve cutoff Power to safety interlock switches engine Axle oscillation Foot switch TCON estop power Boom down safety interlock Safety interlock to engine Chain break circuit Axle extend Axle retract Boom stowed safety Power to boom envelope safety switch This list continues on the next page Section 6 Schematics WIRE CIRCUIT LEGEND Color Circuit and Primary function OR BK 64 Power for operational switches BL WH 65 Low fuel indication BL 66 Drive enable BL 67 Secondary boom not stowed RD 68 Primary boom lowered operational BL 69 Primary boom 1 extended BL WH 70 Primary boom 2 retracted BL BK 71 Primary boom 2 extended GN 72 Secondary boom extend GN BK 73 Secondary boom retract RD 74 Primary 1 Lockout RD WH
188. cure the engine tray from moving could result in death or serious injury Part No 88619 September 2006 Section 3 Scheduled Maintenance Procedures REV A 8 Grease the Turntable Rotation Bearing and Rotate Gear Genie specifications require that this procedure be performed every 100 hours of operation Perform this procedure more often if dusty conditions exist Frequent application of lubrication to the turntable bearing and rotate gear is essential to good machine performance and service life Continued use of an improperly greased bearing and gear will result in component damage 1 Locate the grease fitting next to the ground control box 2 Pump grease into the turntable rotation bearing Rotate the turntable in increments of to 5 inches 10 to 13 cm at a time and repeat this step until the entire bearing has been greased 3 Apply grease to each tooth of the drive gear located under the turntable Grease Specification Chevron Ultra duty grease EP NLGI 2 lithium based or equivalent A TEREX COMI Part No 88619 CHECKLIST A PROCEDURES A 9 Inspect the Fuel Filter Water Separator Diesel Models Genie specifications require that this procedure be performed every 100 hours or monthly whichever comes first Proper maintenance of the fuel filter water separator is essential for good engine performance Failure to perform this procedure can lead to poor engine performance and or
189. d tools could result in death or serious injury and significant component damage Dealer service is strongly recommended 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 2 Hydraulic Hose and Fitting Torque Specifications 1 Lower the secondary boom to the stowed position 2 Tag disconnect secure and remove the wire harnesses connecting the batteries Remove battery fasteners and hooks from battery tray Remove the batteries and store them in a safe and secure location away from the unit Electrocution hazard Contact with AWARNING electrically charged circuits could result in death or serious injury Remove all rings watches and other jewelry A TEREX REV 3 Remove the retaining fasteners securing the upper and lower turntable covers from the turntable at the platform end Remove the covers 4 Remove the engine tray retaining fastener Swing the engine tray out away from the machine _ AREA Aceh rere 2 m a ae esi 22 UH b a engine tray anchor hole b engine tray retaining fastener 5 Locate the engine tray anchor hole at the pivot end of the engine tray 6 Install the bolt that was just removed into the anchor hole to secure the engine tray from moving AWARNING Crushing hazard Failure to install the bolt into the
190. d Emergency Stop button out to the on position at the platform controls Press the fuel select button to LPG mode Start the engine and allow it to run at low idle 10 Press down the foot switch to allow the engine the gasoline and LPG fuel levels and warming the engine to normal operating temperature 1 Turn the key switch to platform controls and pull out the red Emergency Stop buttons out to the on position at both the ground and platform controls Press the fuel select button to gasoline mode allow the engine to run at low idle At the platform controls press the engine idle Start the engine from the platform controls and select button until foot switch activated high idle rabbit and foot switch symbol is selected Part No 88619 TEREX COMPANY to run at high idle Result The engine should start promptly and operate smoothly in low and high idle The engine may hesitate momentarily and then continue to run on the selected fuel if the fuel source is switched while the engine is running Section 3 Scheduled Maintenance Procedures September 2006 CHECKLIST B PROCEDURES B 14 Test the Drive Brakes Proper brake action is essential to safe machine operation The drive brake function should operate smoothly free of hesitation jerking and unusual noise Hydraulically released individual wheel brakes can appear to operate normally when they are actually not fully operationa
191. d bolt b ventplug c drain plug d filter bowl e separator head 4 Loosen the drain plug located at the bottom of the bowl Allow the water to drain into a suitable container until fuel starts to come out Immediately tighten the drain plug TEREX COMPANY 3 14 Z 80 60 Part No 88619 September 2006 Section 3 Scheduled Maintenance Procedures REV A 10 Perform Engine Maintenance Deutz Models Engine specifications require that this procedure be performed every 125 hours Proper engine maintenance following the engine manufacturer s maintenance schedule is essential to good engine performance and service life Failure to perform the maintenance procedures can lead to poor engine performance and component damage Deutz Models Required maintenance procedures and additional engine information are available in the Deutz 913 Operation Manual Deutz part number 0297 7341 Deutz 913 Operation Manual CHECKLIST A PROCEDURES A 11 Replace the Drive Hub Oil Manufacturer drive hub specifications require that this one time procedure be performed after the first 150 hours Replacing the drive hub oil is essential for good machine performance and service life Failure to replace the torque hub oil after the first 150 hours of use may cause the machine to perform poorly and continued use may cause component damage Drive Hubs 1 Select the drive hub to be serviced Drive the machine until
192. d the secondary boom up extend button with the secondary boom fully raised and extended Observe the pressure reading on the pressure gauge Refer to Section 2 Specifications Section 4 Repair Procedures July 2006 MANIFOLDS 4 Turn the engine off Use a wrench to hold the relief valve and remove the cap item Q 5 Adjust the internal hex socket Turn it clockwise to increase the pressure or counterclockwise to decrease the pressure Install the relief valve cap AWARNING Tip over hazard Do not adjust the relief valve higher than specified 6 Repeat steps 2 through 5 to confirm relief valve pressure 7 Remove the pressure gauge How to Adjust the Platform Manifold Relief Valve Perform this procedure with the boom in the stowed position 1 Connect 0 to 5000 psi 0 to 350 bar pressure gauge to the 2 port on the function manifold Start the engine from the ground controls 3 Simultaneously push and hold the function enable high speed button and the jib boom down button with the jib boom fully lowered Observe the reading on the pressure gauge Refer to Section 2 Specifications A TEREX COMI REV C 4 Turn the engine off Use a wrench to hold the relief valve and remove the cap item AG 5 Adjust the internal hex socket Turn it clockwise to increase the pressure or counterclockwise to decrease the pressure Install the relief valve cap AWARNING Tip over hazard Do not adjust t
193. dary boom extend speed Secondary boom retract speed Turntable rotate speed retracted Turntable rotate speed extended Jib boom up down speed 120 max and 50 min 100 default 120 max and 50 min 100 default 120 max and 50 min 100 default 120 max and 50 min 100 default 120 max and 50 min 100 default 120 max and 50 min 100 default 120 max and 50 min 100 default 120 max and 50 min 100 default 120 max and 50 min 100 default 120 max and 50 min 100 default 120 max and 50 min 100 default 120 max and 50 min 100 default 120 max and 50 min 100 default 120 max and 50 min 100 default Part No 88619 TEREX COMPANY Section 4 Repair Procedures Ss DISPLAY MODULE July 2006 REV B and press Primary boom extend retract ramp acceleration Primary boom extend retract ramp deceleration Secondary boom ramp acceleration Secondary boom ramp deceleration Turntable rotate ramp acceleration Turntable rotate ramp deceleration Jib boom up down ramp deceleration Screen or Procedure Description Range Menu Lift With the key switch OFF Primary boom up down 150 max and 50 min Function press and hold the ramp acceleration 96 100 default Ramp button and turn the key switch to the ON position Primary boom up down 150 max and 50
194. der on the blocks AWARNING Crushing hazard The primary boom could become unbalanced and fall if not properly supported when the pivot pin is removed 9 Attach a lifting strap from an overhead crane to the upper primary boom lift cylinder linkage arm Support the arm 10 Remove the pin retaining fasteners from the upper primary boom lift cylinder linkage arm where it connects to the primary boom A TEREX REV 11 Use a soft metal drift to remove the upper primary boom lift cylinder linkage arm pivot pin Crushing hazard The upper ACAUTION primary boom lift cylinder linkage arm will fall if not properly supported when the pivot pin is removed 12 Attach a 5 ton 5000 kg overhead crane to the center point of the primary boom 13 Remove the pin retaining fastener from the primary boom pivot pin 14 Use a soft metal drift to remove the primary boom pivot pin AWARNING Crushing hazard The primary boom could become unbalanced and fall if not properly supported when the pivot pin is removed 15 Carefully remove the primary boom from the machine and place it on a structure capable of supporting it AWARNING Crushing hazard The primary boom could become unbalanced and fall if not properly supported when removed from the machine When the primary boom is installed the primary boom angle sensor will need to be calibrated Part No 88619 September 2006 Section 4 Repair Procedures REV
195. djusted is displayed Press the plus button to increase the speed or press the minus button to decrease the speed Press the enter button to save the setting in memory Perform this procedure until the machine function speed meets specification Part No 88619 July 2006 REV B How to Adjust the Function Ramp Rate Setting The ramp rate setting of a joystick controls the time at which it takes for the joystick to reach maximum output when moved out of the neutral position The ramp rate settings of a joystick can be changed to compensate for hydraulic pump wear to maintain peak performance from the machine Refer to Section 2 Specifications Perform this procedure with the boom in the stowed position 1 Pull out the red Emergency Stop button to the on position at both the ground and platform controls 2 Press and hold the enter button on the ground control panel while turning the key Switch to ground controls 3 Press the plus button twice then press the scroll button twice 4 Press the scroll button until the function to be adjusted is displayed 5 Press the plus button to increase the ramp rate or press the minus button to decrease the ramp rate 6 Press the enter button a to save the setting in memory 7 Perform this procedure until the machine function speed meets specification A TEREX COMI Section 4 Repair Procedures PLATFOR
196. e and pilot ratio 2 position 2 way solenoid valve Directional valve pilot operated 2 position 2 way MESA Solenoid operated 3 position 4 way directional valve d 2 position 3 way shuttle valve Hydraulic oil cooler Brake A TEREX COMPANY Z 80 60 Section 6 Schematics July 2006 This page intentionally left blank A TEREX COMPANY 6 16 Z 80 60 Part No 88619 REV Deutz BF4L 2011 View 10 Limit Switches f E R ee i View 14 2 Perkins 804 C33 July 2006 Section 6 Schematics View 11 Deutz F4L 913 View 15 Ford LRG 425 Electrical Schematic Legend View 12 View 16 Hydraulic Generator Option Part No 88619 A TEREX COMPANY July 2006 Section 6 Schematics Electrical Schematic Layout July 2006 Section 6 Schematics Electrical Schematic View 1 Drive Chassis Controller DCON REV July 2006 Electrical Schematic View 1 Drive Chassis Controller DCON Section 6 Schematics HMd 1X3 LON GND 61 14 Nvo sra TA NVOZ8Q Y NY Continued on View 2 SIS 1X3 LON 31XY srtd lt 1008 siia 21 14
197. e boom is raised out of the stowed position This switch limits the drive speed and disables the drive motor destroke The other contacts close when the boom is fully lowered allowing the platform to be tucked underneath the mast for transport Primary Boom Angle Sensor PBS Measures the Y axis angle of the primary boom The operational range shall be 33 degrees to 73 degrees The safety cutouts are set at 70 degrees and will disable boom up and stop the engine LSP1AO Limit Switch Primary Boom 1 Angle Operational One side closes when the primary boom is raised from the stowed position disabling the drive motor destroke and limiting the drive speed The other side of the switch closes when the boom is fully lowered allowing the platform to be tucked underneath the mast for transport Platform Angle Sensor Measures the angle of the platform The range of measurement is 20 degrees The safety cutout is set at 10 degrees from gravity and will disable the primary and secondary boom up down functions and the platform level up down functions LSS2AO Limit switch Secondary Boom 2 Angle Operational Switch Secondary boom angle full extension angle up all the way secondary boom extend allowed LSJ1EO Limit Switch Jib Boom 1 Closes when the platform leveling cylinder is fully extended disabling the primary boom down function LSS3AO Limit switch Secondary Boom 3 Angle Operational Switch Secondary boom elevated to
198. e changes to high idle 6 Simultaneously push and hold the function enable high speed button and the primary boom retract button with the primary boom fully retracted Observe the reading on the pressure gauge Refer to Section 2 Specifications A TEREX COMI REV C 7 Turn the engine off Use a wrench to hold the relief valve and remove the cap item AJ 8 Adjust the internal hex socket Turn it clockwise to increase the pressure or counterclockwise to decrease the pressure Install the relief valve cap AWARNING Tip over hazard Do not adjust the relief valve higher than specified 9 Repeat steps 4 through 8 confirm the relief valve pressure 10 Remove the pressure gauge 11 Remove the wire jumpers from the limit switch connector 12 Securely install the LSP1RO pig tail into the wire harness How to Adjust the Primary Boom Down Relief Valve Perform this procedure with the boom in the stowed position 1 Connect a 0 to 5000 psi 0 to 350 bar pressure gauge to the Ls port on the function manifold 2 Start the engine from the ground controls 3 Press and release the rpm select button until the engine changes to high idle 4 Raise the primary boom approximately 5 feet 1 5 m Part No 88619 July 2006 Section 4 Repair Procedures REV MANIFOLDS 5 Place a 4x 4 inch 10 x 10 cm block on the How to Adjust the Primary Boom primary boom rest pad Lower the primary boom onto the block
199. e disc 0 031 inch 0 79 mm Delays shift to drive 35 40 ft lbs 47 54 Nm 4 Relief valve 270 psi 3 5 18 6 bar 13 2 44442211 CBD Charge pressure circuit 35 40 ft lbs 47 54 Nm 5 Check valve CBE Prevents oil flowing into generator 35 40 ft lbs 47 54 Nm CBE Part No 88619 Section 4 Repair Procedures July 2006 MANIFOLDS REV 8 10 Traction Manifold 2WD The 2WD traction manifold is mounted inside the drive chassis at the circle end of the machine Index Schematic No Description Item Function Torque 1 Check valve 5 psi 0 34 bar EA i uu Drive motor anti cavitation 30 35 ft lbs 41 47 Nm 2 Check valve 5 psi 0 34 bar EB Drive motor anti cavitation 30 35 ft lbs 41 47 Nm 3 Orifice 0 031 in 0 79 mm EG Brake and 2 speed circuit 4 Check valve ED Keeps brakes released in case of temporary loss of charge pressure 20 25 ft Ibs 27 34 Nm 5 Solenoid valve 2 position way EE Brake 26 30 ft lbs 35 41 Nm 6 Solenoid valve 2 position 3 way 2 drive motor shift 26 30 ft lbs 35 41 Nm 7 Relief valve 250 psi 17 2
200. e machine which could result in death or serious injury AWARNING Crushing hazard The drive hub could become unbalanced and fall if not properly supported by the overhead crane or lifting device when removed from the machine When installing a turntable rotation assembly the rotation gear backlash must be adjusted See 9 1 Adjust the Turntable Rotation Gear Backlash Section 4 Repair Procedures July 2006 TURNTABLE ROTATION COMPONENTS How to Adjust the Turntable 7 Rotation Gear Backlash The turntable rotation drive hub is mounted on an adjustable plate that controls the gap between the rotation motor pinion gear and the turntable 8 bearing ring gear Perform this procedure with the platform between the circle end tires and with the machine ona firm level surface 1 Secure the turntable from rotating with the turntable rotation lock pin 2 Loosen the backlash pivot plate mounting fasteners 3 Push the backlash pivot plate towards the turntable as far as possible this will push the rotation gear into the turntable bearing ring gear 4 Loosen the lock nut on the adjustment bolt 5 Turn the adjustment bolt clockwise until it contacts the backlash pivot plate 6 Turn the adjustment bolt 1 2 turn counterclockwise Tighten the lock nut on the adjustment bolt A TEREX COMPANY REV B Rotate the backlash pivot plate away from the turntable until it contacts the adjustment bolt Torque the mount
201. e reading taken in step 5 Turn How to Adjust the Charge it clockwise to increase the pressure or Pressure Relief Valve counterclockwise to decrease the pressure Install the valve cap Perform this procedure with the hydraulic oil temperature must be 100 F to 150 F 38 C to 65 5 C gauge 12 Turn the engine off and remove the pressure 1 Connect a 0 to 600 psi O to 50 bar pressure gauge to the test port on the drive pump 2 Use a wrench to hold the charge pressure relief valve and remove the cap item FF 3 Turn the internal hex socket fully in a clockwise direction until it stops Install the cap 4 Start the engine from the ground controls 5 Press and hold the function enable high rpm select button rabbit symbol position Note the reading on the pressure gauge 6 Turn the engine off 7 Remove the pressure gauge from the drive pump Connect the gauge to the test port located on the drive manifold 8 Use wrench to hold the charge pressure relief valve and remove the cap from the valve item FF 9 Start the engine from the ground controls TEREX COMPANY 4 92 Z 80 60 Part No 88619 July 2006 Section 4 Repair Procedures REV 8 14 Valve Coils How to Test a Coil A properly functioning coil provides an electromotive force which operates the solenoid valve Critical to normal operation is continuity within the coil that provides this force field AWARNING Electrocution hazard
202. eal into the hub by pressing it evenly into the hub until it is flush Always replace the bearing grease seal when removing the hub 17 Slide the hub onto the yoke spindle CAUTION Component damage hazard Do not apply excessive force or damage to the lip of the seal may occur 18 Place the outer bearing into the hub 19 Install the washer and castle nut 20 Tighten the slotted nut to 35 ft lbs 47 Nm to seat the bearings 21 Fully loosen the castle nut then re tighten to 8 ft lbs 11 Nm 22 Install a new cotter pin Bend the cotter pin to lock it in Always replace the cotter pin with a new one when removing the castle nut or when checking the torque of the castle nut 23 Install the dust cap then the tire and wheel assembly Torque the wheel lug nuts to specification Refer to Section 2 Specifications 24 Repeat this procedure for the other wheels beginning with step 4 A TEREX COMI Part No 88619 CHECKLIST E PROCEDURES E 3 Perform Engine Maintenance Engine specifications require that this procedure be performed every 2000 hours Proper engine maintenance following the engine manufacturer s maintenance schedule is essential to good engine performance and service life Failure to perform the maintenance procedures can lead to poor engine performance and component damage Deutz Models Required maintenance procedures and additional engine information are available in the Deutz 913 Operat
203. econd delay before the platform overload indicator lights and alarm responds Section 4 Repair Procedures July 2006 PLATFORM COMPONENTS 7 Move the platform up and down by hand so it bounces approximately 2 5 to 5 cm 1 to 2 inches Allow the platform to settle O Result The alarm should be off The platform overload indicator light should be off at the platform controls and there should be no error message on the LCD display at the ground controls Proceed to step 8 Result The overload indicator lights are flashing at the platform and ground controls and the alarm is sounding Repeat this procedure beginning with step 5 There may be a 2 second delay before the platform overload indicator light and alarm responds 8 Addan additional 10 Ib 4 5 kg test weight to the platform Result The alarm should be sounding The platform overload indicator light should be flashing at the platform controls and PLATFORM OVERLOAD should be displayed on the LCD screen at the ground controls Proceed to step 9 Result The alarm should be off The platform overload indicator light should be off at the platform controls and there should be no error message on the LCD display at the ground controls Remove the additional 10 Ib 4 5 kg test weight Repeat this procedure beginning with step 6 There may be a 2 second delay before the platform overload indicator light and alarm responds A TEREX COMI RE
204. edures and additional engine information are available in the Perkins 704 30 User s Handbook Perkins part number TPD 1336E OR the Perkins 804C 33 Operation and Maintenance Manual Perkins part number SEBU7853 00 Perkins 704 30 User s Handbook Genie part number 101840 Perkins 804C 33 Operation and Maintenance Manual Genie part number 111332 Part No 88619 Z 80 60 CHECKLIST B PROCEDURES To access the engine Remove the engine tray retaining fastener located under the engine tray Swing the engine tray out and away from the machine Install the fastener that was just removed through the engine tray and into the engine tray anchor hole in the turntable AWARNING Crushing hazard Failure to install the fastener into the engine tray anchor hole to secure the engine tray from moving could result in death or serious injury Section Scheduled Maintenance Procedures September 2006 CHECKLIST B PROCEDURES B 25 Perform Engine Maintenance Gasoline LPG Models Engine specifications require that this procedure be performed every 400 hours Proper engine maintenance following the engine manufacturer s maintenance schedule is essential to good engine performance and service life Failure to perform the maintenance procedures can lead to poor engine performance and component damage GM Models Required maintenance procedures and additional engine information are available in the GM 3 0L
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206. el tank cap Proceed to step 4 Result If air does not pass through the cap clean or replace the cap Proceed to step 3 When checking for positive tank cap venting air should pass freely through the cap Using a mild solvent carefully wash the cap venting system Dry using low pressure compressed air Repeat this procedure beginning with step 2 Install the fuel tank cap onto the fuel tank Remove the breather cap from the hydraulic tank Check for proper venting Result Air passes through the hydraulic tank cap Proceed to step 8 Result If air does not pass through the cap clean or replace the cap Proceed to step 7 When checking for positive tank cap venting air should pass freely through the cap Using a mild solvent carefully wash the cap venting system Dry using low pressure compressed air Repeat this procedure beginning with step 6 Install the breather cap onto the hydraulic tank Part No 88619 September 2006 Section 3 Scheduled Maintenance Procedures REV B 24 Perform Engine Maintenance 1 Engine specifications require that this procedure be performed quarterly or every 250 hours whichever comes first Deutz Models Required maintenance procedures and additional engine information are available in the Deutz 913 Operation Manual Deutz part number 0297 7341 Deutz 913 Operation Manual Genie part number 62446 Perkins Models Required maintenance proc
207. elivery The inspection is designed to discover if anything is apparently wrong with a machine before it is put into service A damaged or modified machine must never be used If damage or any variation from factory delivered condition is discovered the machine must be tagged and removed from service Repairs to the machine may only be made by a qualified service technician according to the manufacturer s specifications Scheduled maintenance inspections shall be performed by qualified service technicians according to the manufacturer s specifications and the requirements listed in the responsibilities manual enig A TEREX COMPANY Genie Industries USA 18340 NE 76th Street PO Box 97030 Redmond WA 98073 9730 425 881 1800 Genie UK The Maltings Wharf Road Grantham Lincolnshire NG31 6BH England 44 1476 584333 Copyright 2002 by Genie Industries Genie is a registered trademark of Genie Industries Rev B Instructions Use the operators manual on your machine The Pre delivery Preparation consists of completing the Pre operation Inspection the Maintenance items and the Function Tests Use this form to record the results Place a check in the appropriate box after each part is completed Follow the instructions in the operator s manual If any inspection receives an N remove the machine from service repair and re inspect it After repair place a check in the R box Legend Y yes completed
208. elow the acceptable level Repair exhaust leaks OR there is an emissions compliance issue Contact Ford Power Products for assistance 135 NG cat monitor There are exhaust leaks OR the catalyst system efficiency is below the acceptable level Repair exhaust leaks OR there is an emissions compliance issue Contact Ford Power Products for assistance Adaptive Lean Fault High Limit Gasoline 141 Heated Oxygen Sensor wiring and or connections open or shorted OR sensor is faulty OR there are vacuum or exhaust leaks OR one or more fuel injectors faulty or stuck closed OR fuel quality is poor OR fuel pressure is too low Repair heated oxygen sensor wiring and or connections OR replace sensor OR repair vacuum and exhaust leaks OR test the fuel pressure OR clean or replace the fuel injectors Adaptive Rich Fault Low Limit Gasoline 142 MAP IAT or ECT sensors not in correct position OR wiring and or connections for sensors open or shorted OR sensor is faulty OR one or more fuel injectors are stuck closed OR there is electro magnetic interference from a faulty crankshaft and or camshaft position sensor Adjust or replace sensors OR clean or repair fuel injectors 143 Adaptive Learn High LPG Heated Oxygen Sensor wiring and or connections open or shorted OR sensor is faulty OR there are vacuum leaks or exhaust leaks OR fuel quality is poor OR fuel system components may be faulty Repair wiring
209. embly 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 2 Hydraulic Hose and Fitting Torque Specifications 1 Remove the platform mounting weldment and the platform rotator See 2 3 How to Remove the Platform Rotator 2 Remove the hose and cable cover retaining fasteners from the jib boom Remove the hose and cable cover from the machine 3 Attach a lifting strap from an overhead crane to the jib boom 4 Tag disconnect and plug the jib boom lift cylinder hydraulic hoses Cap the fittings on the cylinder AWARNING 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 TEREX COMPANY Part No 88619 Z 80 60 jib boom platform rotator upper pivot pin platform rotator lower pivot pin jib boom leveling arm jib cylinder pivot pin jib boom cylinder primary boom lower pivot pin primary boom upper pivot pin Section 4 Repair Procedures July 2006 JIB BOOM COMPONENTS 5 Support the barrel end of the cylinder with another suitable lifting device 6 Remove the pin retaining fastener from the jib boom lift cylinder barrel end pivot pin 7 Use a soft metal drift to remove the pin and let the cylinder hang down AWARNING Cushing hazard The jib boom could become u
210. en at Power up controller with problem Value too low zero and neutral alarm sounds corrected TURNTABLE ROTATE VaueatoV ato V JOYSTICK Joystick speed and direction frozen at Not calibrated y P Calibrate joystick zero and neutral Just calibrated second beep or audible Self clearing transient warning device TURNTABLE ROTATE Fault Check both Turntable rotate disabled display Power up controller with the problem BUTTONS buttons pressed message on LCD corrected TURNTABLE ROTATE Display message on LCD and allow SPEED Not calibrated oooratipn atd tault speed Perform auto calibrate procedure Normal function except threshold for Not calibrated one or the other direction is zero Calibrate thresholds Display message on LCD Initiate one second beep of audible TURNTABLE ROTATE FLOW Just calibrated Self clearing transient VALVE Value at 5 0 V Value Too High Limited speed and direction frozen at Power up controller with the problem Value Too Low zero and neutral alarm sounds corrected Value at 0 V TURNTABLE ROTATE CW Fault check Limited speed and direction frozen at Power up controller with the problem TURNTABLE ROTATE CCW zero and neutral alarm sounds corrected TURNTABLE LEVEL TURNTABLE LEVEL Display message on LCD and sound Y DIRECTION A TEREX COMPANY 5 6 Z 80 60 Part No 88619 July 2006 Section 5 Fault Codes REV A CONTROL SYSTEM FAULT CODES Error Source Error
211. enable left BK 178 Control module status light BL WH 144 Drive enable right GN 179 Drive power relay RD WH 145 Calibrate BK 180 Lift power relay BL 146 Jib bellcrank up FC OR 181 48 Volt alternator field or battery BL BK 147 Jibbellcrank down FC RD 182 24 Volt battery BL WH 148 Jib bellcrank sensor BL 183 Envelope or load sense recovery GR WH 149 Jib Up Down FC WH 184 Program setup enable GR BK 150 Hydraulic generator bypass WH 185 Encode GR 151 Hydraulic EDCoutput BL 186 Encode B BK 152 Injector retard BL 187 Bootstrap or program enable BK 153 Jib extend GR 188 Safety cross check BK WH 154 Jibretract BK 189 Data receive OR RD 155 Pressure comp enable BK WH 190 Data transmit GN WH 156 Jib Up Down WH RD 191 Multi Function pressure relief BK RD 157 Jib Ext Ret WH BK 192 Jib rotate left BL RD 158 Spare WH RD 193 Jib rotate right BL WH 159 Steer joystick signal WH RD 194 Speed select input WH RD 160 Propel joystick signal OR RD 195 Electric brake source WH BK 161 Sec boom joystick signal YL 196 2 5V Sensor power OR 162 Joystick 5 VDC power BR N A Ground or return Part No 88619 Z 80 60 6 7 Section 6 Schematics July 2006 Limit Switches and Angle Sensors Types of Limit Switches There are two types of limit switches found in various locations throughout the machine mechanical type operational or safety switches As in aircraft which features redundant safety systems each mechanical operational switch is backed up with a separ
212. engine tray to secure it from moving could result in death or serious injury 7 Remove the fuel tank filler cap Part No 88619 September 2006 Section 4 Repair Procedures REV 8 Using an approved hand operated pump drain the fuel tank into a suitable container Refer to Section 2 Specifications Explosion and fire hazard Engine fuels are combustible Perform this procedure in an open well ventilated area away from heaters sparks flames and lighted tobacco Always have an approved fire extinguisher within easy reach Explosion and fire hazard When transferring fuel connect a grounding wire between the machine and pump or container Be sure to only use a hand operated pump suitable for use with gasoline and diesel fuels 9 Tag and disconnect the wire harness from the fuel level sending unit 10 Tag disconnect and plug the fuel hoses from the fuel tank 11 Clean up any fuel that may have spilled 12 Remove the fuel tank mounting fasteners Carefully remove the fuel tank from the machine CAUTION Component damage hazard The fuel tank is plastic and may become damaged if allowed to fall Clean the fuel tank and inspect for cracks and other damage before installing it onto the machine A TEREX COMI Part No 88619 BOOM COMPONENTS 13 Tag disconnect and plug the hydraulic hoses from the secondary boom lift cylinder AWARNING Bodily injury hazard Spraying hydraulic oil can penet
213. eplace ECM Genie Part No 88619 A TEREX COMPANY Z 80 60 Section 5 Fault Codes July 2006 This page intentionally left blank 5 14 Z 80 60 Part No 88619 July 2006 Section 6 Schematics Schematics About This Section There are two groups of schematics in this section An illustration legend precedes each group of drawings Electrical Schematics Observe and Obey Electrocution hazard Contact with y AWARNING electrically charged circuits could Troubleshooting and repair procedures shall be result in death or serious injury completed by a person trained and qualified on Remove all rings watches and the repair of this machine other jewelry Immediately tag and remove from service a Hydraulic Schematics damaged or malfunctioning machine AWARNING Bodily injury hazard Spraying Repair any machine damage or malfunction hydraulic oil can penetrate and before operating the machine burn skin Loosen hydraulic connections very slowly to allow Before Troubleshooting the oil pressure to dissipate gradually Do not allow oil to squirt Read understand and obey the safety rules and or spray operating instructions printed in the 4 t General Repair Process Operator s Manual on your machine Be sure that all necessary tools and test equipment are available and ready for use Malfunction Identity discovered symptoms Troubleshoot problem Still exi
214. equirement Refer to Display Module in the Repair Section for information 1 Turn the key switch to ground control and pull out the red Emergency Stop button to the on position at both the ground and platform controls Result The alarm should sound twice The flashing beacon if equipped should be on and flashing A TEREX REV B 18 Perform Hydraulic Oil Analysis Replacement or testing of the hydraulic oil is essential for good machine performance and service life Dirty oil and a clogged suction strainer may cause the machine to perform poorly and continued use may cause component damage Extremely dirty conditions may require oil changes to be performed more often Before replacing the hydraulic oil the oil may be tested by an oil distributor for specific levels of contamination to verify that changing the oil is necessary If the hydraulic oil is not replaced at the two year inspection test the oil quarterly Replace the oil when it fails the test See E 1 Test or Replace the Hydraulic Oil Part No 88619 September 2006 Section 3 Scheduled Maintenance Procedures REV B 19 Check and Adjust the Engine RPM Maintaining the engine rpm at the proper setting for both low and high idle is essential to good engine performance and service life The machine will not operate properly if the rpm is incorrect and continued use may cause component damage GM models The engine rpm is co
215. er Turntable rotate functions Move the joystick full stroke in either the left or right direction When the alarm sounds move the joystick in the opposite direction full stroke until the alarm sounds again Return the joystick to center 13 Once the function speeds have been set press and hold the engine start button NI until the engine shuts off Do not press the red Emergency Stop button Approximately 3 seconds after the engine shuts off the alarm at the ground controls will sound to indicate the speed settings are being saved in memory Release the button 14 At the ground controls turn the key switch to the off position wait three seconds and then turn the key switch to platform controls 15 Inspect the display at the ground controls to be sure there are no calibration faults There should be no calibration faults shown on the display If calibration faults exist repeat this procedure TEREX REV How to Adjust the Function Speeds Perform this procedure with the boom in the stowed position Refer to Section 2 Specifications Pull out the red Emergency Stop button to the on position at both the ground and platform controls Press and hold the enter button on the ground control panel while turning the key Switch to ground controls Press the plus button twice then press the minus button twice Press the scroll button until the function to be a
216. er engine maintenance following the engine manufacturer s maintenance schedule is essential to good engine performance and service life Failure to perform the maintenance procedures can lead to poor engine performance and component damage 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 84792 To access the engine 1 Remove the engine tray retaining fastener located under the engine tray Swing the engine tray out and away from the machine 2 Install the fastener that was just removed through the engine tray and into the engine tray anchor hole in the turntable AWARNING Crushing hazard Failure to install the fastener into the engine tray anchor hole to secure the engine tray from moving could result in death or serious injury Part No 88619 September 2006 Section 3 Scheduled Maintenance Procedures REV E 5 Perform Engine Maintenance Diesel Models Engine specifications require that this procedure be performed every 3000 hours Proper engine maintenance following the engine manufacturer s maintenance schedule is essential to good engine performance and service life Failure to perform the maintenance procedures can lead to poor engine performance and component damage Deutz Models Required maintenance procedure
217. eration Inspection Completing a pre operation inspection is essential to safe machine operation The pre operation inspection is a visual inspection performed by the operator prior to each work shift The inspection is designed to discover if anything is apparently wrong with a machine before the operator performs the function tests The pre operation inspection also serves to determine if routine maintenance procedures are required Complete information to perform this procedure is available in the appropriate operator s manual Refer to the Operator s Manual on your machine A TEREX COMI REV A 3 Perform Function Tests Completing the function tests is essential to safe machine operation Function tests are designed to discover any malfunctions before the machine is put into service A malfunctioning machine must never be used If malfunctions are discovered the machine must be tagged and removed from service Complete information to perform this procedure is available in the appropriate operator s manual Refer to the Operator s Manual on your machine Part No 88619 September 2006 Section 3 Scheduled Maintenance Procedures REV A 4 Perform Engine Maintenance Engine specifications require that this procedure be performed daily or every 8 hours whichever comes first Deutz Models Required maintenance procedures and additional engine information are available in the Deutz 913 Operation Ma
218. ersonnel to operate the machine from the ground controls whether or not the Emergency Stop button on the platform controls is in the on or OFF position This function is particularly useful if the operator at the platform controls cannot return the boom to the stowed position 1 Push in the platform red Emergency Stop button to the off position 2 Start the engine from the ground controls 3 Atthe ground controls operate each boom function through a partial cycle Result All boom functions should operate a drive hub b plug 2 f necessary add oil until the oil level is even with the bottom of the plug hole opening 3 Apply pipe thread sealant to the plug and install the plug in the drive hub TEREX COMPANY 3 26 Z 80 60 Part No 88619 September 2006 Section 3 Scheduled Maintenance Procedures REV B 11 Test the Platform Self leveling Automatic platform self leveling throughout the full cycle of primary boom raising and lowering is essential for safe machine operation The platform is maintained level by the communication between the platform level sensor and the turntable level sensor If the platform becomes out of level the computer at the ground controls will open the appropriate solenoid valve s at the platform manifold to maintain a level platform A platform self leveling failure creates an unsafe working condition for platform and ground personnel 1 Start the eng
219. essential to safe operation and good performance Tire and or wheel failure could result in a machine tip over Component damage may also result if problems are not discovered and repaired in a timely fashion The tires on this machine are foam filled and do not need air added to them 1 Check all tire treads and sidewalls for cuts cracks punctures and unusual wear 2 Check each wheel for damage bends and cracked welds 3 Check each lug nut for proper torque Refer to Section 2 Specifications A TEREX COMI REV C B 8 Confirm the Proper Brake Configuration Proper brake configuration is essential to safe operation and good machine performance Hydrostatic brakes and hydraulically released spring applied individual wheel brakes can appear to operate normally when they are actually not fully operational 1 Check each drive hub disconnect cap to be sure it is in the engaged position disengaged position EE arf arg er engaged position 2 Be sure the free wheel valve on the drive pump is closed clockwise The free wheel valve is located on the drive pump a drive pump b screwdriver lift pump d free wheel valve The free wheel valve should always remain closed Part No 88619 September 2006 Section 3 Scheduled Maintenance Procedures REV CHECKLIST B PROCEDURES B 9 2 Remove the plug located at 90 degrees and heck the oil level Check the Drive Hub Oil Level
220. ew platform controls decal over the membrane decal Perform this procedure with the 10 Open the control box lid and carefully connect engine off the ribbon cables from the membrane decal to the membrane circuit board Drive functions 1 Turn the key switch to the off position 2 Press and hold the enter button a on the ground control panel while turning the key switch to platform controls 3 Press the minus button twice then press the enter button twice TEREX COMPANY Part No 88619 Section 4 Repair Procedures July 2006 PLATFORM CONTROLS 4 Use the scroll button to scroll through the menu until RESET DRIVE JOYSTICK DEFAULTS S displayed Press the button to select yes then press the button Do not start the engine Locate the drive steer joystick 7 Move the drive steer joystick full stroke in the forward direction and hold for 5 seconds then return to the center or neutral position 8 Move the drive steer joystick full stroke in the reverse direction and hold for 5 seconds then return to the center or neutral position Result The alarm at the ground controls shou sound for a successful calibration Steer functions 1 Turn the key switch to the off position 2 Press and hold the enter button on the ground control panel while turning the key switch to platform controls 3 Press the minus button twice then press the enter
221. from moving when not steering Solenoid valve 2 position 3 way Oscillate cylinder left side Solenoid valve 2 position way GE us Oscillate cylinder right side Check valve 65 psi 4 5 bar Prevents steer cylinder from moving when not steering 8 Relief valve 750 to 860 psi 51 71 to 59 3 bar CH Oscillate 9 Flow regulator valve 2 3 8 7 L min Circle end left side steer cylinder extend circuit 10 Flow regulator valve 1 2 4 5 L min before software revision 1 04 1 5 5 7 L min after software revision 1 03 CJ Circle end left side steer cylinder retract circuit 11 Flow regulator valve 1 2 gpm 4 5 L min before software revision 1 04 1 5 gpm 5 7 L min after software revision 1 03 Circle end right side steer cylinder retract circuit 12 Flow regulator valve 2 3 gpm 8 7 L min 2 Circle end right side steer cylinder extend circuit 13 Check valve OM Load sensing circuit circle end left side steer cylinder retract 14 Check valve
222. ft blank A TEREX COMPANY 4 100 Z 80 60 Part No 88619 July 2006 Section 5 Fault Codes Observe and Obey Troubleshooting and repair procedures shall be completed by a person trained and qualified on the repair of this machine Immediately tag and remove from service damaged or malfunctioning machine Repair any machine damage or malfunction before operating the machine Unless otherwise specified perform each repair procedure with the machine in the following configuration Machine parked on a firm level surface Boom in stowed position Turntable rotated with the boom between the circle end yellow arrow wheels Turntable secured with the turntable rotation lock pin Key switch in the off position with the key removed Welder disconnected from the machine if equipped with the weld cable to platform option Wheels chocked All external AC power supply disconnected from the machine A TEREX Fault Codes Before Troubleshooting Read understand and obey the safety rules and operating instructions printed in the Operator s Manual on your machine Be sure that all necessary tools and test equipment are available and ready for use Read each appropriate fault code thoroughly Attempting shortcuts may produce hazardous conditions aware of the following hazards and follow generally accepted safe workshop practices Crushing haz
223. gine Do not remove the elbow from the air intake tube 6 Support the drive pump with an appropriate lifting device Remove all of the bell housing to engine fasteners 7 Carefully pull the pump and bell housing assembly away from the engine and secure it from moving Component damage hazard CAUTION Hoses can be damaged if they are kinked or pinched 8 Remove the flex plate mounting fasteners and remove the flex plate from the engine flywheel A TEREX COMI REV B Perkins 804C 33 Models 5 Tagand disconnect the wiring from the bell housing 6 Remove the exhaust pipe clamp at the muffler ACAUTION Burn hazard Hot engine parts can cause severe burns 7 Remove the muffler mounting bracket fasteners Remove the muffler and bracket assembly from the engine 8 Remove the hose clamps from the air cleaner elbow and the engine intake manifold 9 Remove the air cleaner mounting bracket fasteners Remove the air cleaner and bracket assembly from the engine 10 Support the drive pump with an appropriate lifting device Remove all of the remaining bell housing to engine fasteners 11 Carefully pull the pump and bell housing assembly away from the engine and secure it from moving Component damage hazard CAUTION Hoses can be damaged if they are kinked or pinched 12 Remove the flex plate mounting fasteners and remove the flex plate from the engine flywheel Part No 88619 July 2006 Section 4 Repair
224. gine specifications require that this procedure be performed every 1000 hours Deutz Models Required maintenance procedures and additional engine information are available in the Deutz 913 Operation Manual Deutz part number 0297 7341 OR the Deutz BF4L2011 Operation Manual Deutz part number 0297 9929 Deutz 913 Operation Manual CHECKLIST D PROCEDURES Perkins Models Required maintenance procedures and additional engine information are available in the Perkins 704 30 User s Handbook Perkins part number TPD 1336E OR the Perkins 804C 33 Operation and Maintenance Manual Perkins part number SEBU7853 00 Perkins 704 30 User s Handbook Genie part number 101840 Perkins 804C 33 Operation and Maintenance Manual Genie part number 111332 To access the engine 1 Remove the engine tray retaining fastener located under the engine tray Swing the engine tray out and away from the machine Genie part number 62446 2 Install the fastener that was just removed through the engine tray and into the engine tray Deutz BF4L2011 Operation Manual anchor hole in the turntable Genie part number 84794 AWARNING Crushing hazard Failure to install the fastener into the engine tray anchor hole to secure the engine tray from moving could result in death or serious injury Genie Part No 88619 Z 80 60 3 57 Section Scheduled Maintenance Procedures September 2006 CHECKLIST D PROCEDURES REV D 7 3 Rem
225. gine tray out away from the machine E a XE 2 2 52 a engine tray anchor hole b engine tray retaining fastener 3 Locate the engine tray anchor hole at the pivot end of the engine tray Section Scheduled Maintenance Procedures September 2006 CHECKLIST B PROCEDURES 4 Install the bolt that was just removed into the anchor hole to secure the engine tray from moving AWARNING Crushing hazard Failure to install the bolt into the engine tray to secure it from moving could result in death or serious injury 5 Inspect the following areas for burnt chafed corroded pinched and loose wires Engine wiring harness Battery area wiring 6 Open the ground controls side turntable cover 7 Inspect the following areas for burnt chafed corroded pinched and loose wires Inside of the ground control box Hydraulic manifold wiring Hydraulic oil cooler wiring 8 Inspect for a liberal coating of dielectric grease atthe following location All wire harness connectors to the ground control box Hydraulic manifold wiring 9 Start the engine from the ground controls and raise the secondary boom above the turntable covers 10 Inspect the turntable area for burnt chafed and pinched cables A TEREX REV C 11 Lower the secondary boom to the stowed position and turn the engine off 12 Inspect the following areas for burnt chafed corroded pinched and loose wires Cable tra
226. h non steer wheel hub o disengaged position arf arg engaged position Part No 88619 September 2006 Section Scheduled Maintenance Procedures REV 5 Manually rotate each non steer wheel Result Each non steer wheel should rotate with minimum effort 6 Re engage the drive hubs by turning over the hub disconnect caps Rotate each wheel to check for engagement Lift the machine and remove the blocks AWARNING CUllision hazard Failure to re engage the drive hubs could result in death or serious injury and property damage 4WD models 7 Chockthe non steering wheels to prevent the machine from rolling 8 Center a lifting jack with a minimum capacity of 25 000 Ibs 12000 kg under the drive chassis between the steer wheels 9 Liftthe wheels off the ground and then place blocks under the drive chassis for support 10 Disengage the drive hubs by turning over the drive hub disconnect caps on each steer wheel hub iR disengaged position A rz 2 engaged position A TEREX COMI Part No 88619 CHECKLIST D PROCEDURES 11 Manually rotate each steer wheel Result Each steer wheel should rotate with minimum effort 12 Re engage the drive hubs by turning over the drive hub disconnect caps Rotate each wheel to check for engagement Lift the machine and remove the blocks llision h AWARNING Collision hazard Failure to re engage the dri
227. he engine tray anchor hole to secure the engine tray from moving could result in death or serious injury Genie Part No 88619 Z 80 60 3 9 Section Scheduled Maintenance Procedures September 2006 CHECKLIST A PROCEDURES A 5 Check the Hydraulic Filter Condition Indicators Maintaining the hydraulic filters in good condition is essential to good system performance and safe machine operation The filter condition indicators will show when the hydraulic flow is bypassing a clogged filter If the filters are not frequently checked and replaced impurities will remain in the hydraulic system and cause component damage There are four hydraulic filters on the machine one tank return filter one medium pressure filter and two high pressure filters All the filters have condition indicators on them except the medium pressure filter 1 Start the engine from the ground controls 2 Press and release the engine idle select button to change the engine rpm to high idle A TEREX COM REV C Tank return filter 3 Open the ground control side turntable cover and inspect the filter condition indicator gauge Result The needle on the gauge should be operating in the green area If the needle is in the red area this indicates that the hydraulic filter is being bypassed and the filter needs to be replaced See D 7 Replace the Hyaraulic Filter Elements filter condition indicator gauge Pa
228. he hub into a container of adequate capacity Refer to Section 2 Specifications Install the drive hub Torque the drive hub mounting bolts to specification Refer to Section 2 Specifications Install the brake and motor onto the drive hub Torque the motor brake mounting bolts to specification Refer to Section 2 Specifications Fill the hub with oil from the side hole until the oil level is even with the bottom of the hole Apply pipe thread sealant to the plug Install the plug Adjust turntable rotation gear backlash Refer to Repair Procedure 9 1 How to Adjust the Turntable Rotation Gear Backlash Part No 88619 September 2006 Section 3 Scheduled Maintenance Procedures REV C CHECKLIST A PROCEDURES A 12 Ford Models Perform Engine Maintenance Gasoline LPG Models Engine specifications require that this procedure be performed every 200 hours Proper engine maintenance following the engine manufacturer s maintenance schedule is essential to good engine performance and service life Failure to perform the maintenance procedures can lead to poor engine performance and component damage GM Models Required maintenance procedures and additional engine information are available in the GM 3 0L Operator Handbook GM part number 36100007 GM 3 0L Operator Handbook Required maintenance procedures and additional engine information are available in the Ford LRG 425 EFI Operator Handbook Ford
229. he post cat oxygen sensor Closed Loop Multiplier High Gasoline 121 Heated Oxygen Sensor wiring and or connections open or shorted OR sensor is faulty OR there are vacuum leaks or exhaust leaks OR fuel pressure is low OR the fuel injectors need cleaning or replacing Repair wiring and or connections OR replace sensor OR repair any vacuum and exhaust leaks OR test the fuel pressure OR clean or replace the fuel injectors Closed Loop Multiplier Low Gasoline 122 MAP IAT or ECT sensors not in correct position OR wiring and or connections for sensors open or shorted OR sensor is faulty OR one or more fuel injectors are stuck open OR there is electro magnetic interference from a faulty crankshaft and or camshaft position sensor Adjust or replace sensors OR clean or repair fuel injectors Closed Loop Multiplier Low LPG 124 Heated Oxygen Sensor wiring and or connections open or shorted OR sensor is faulty OR fuel quality is poor OR fuel system components may be faulty Repair wiring and or connections OR replace sensor OR replace fuel OR test and repair the fuel system components 133 Gasoline cat monitor There are exhaust leaks OR the catalyst system efficiency is below the acceptable level Repair exhaust leaks OR there is an emissions compliance issue Contact Ford Power Products for assistance 134 LPG cat monitor There are exhaust leaks OR the catalyst system efficiency is b
230. he relief valve higher than specified 6 Repeat steps 2 through 3 to confirm relief valve pressure 7 Remove the pressure gauge Part No 88619 July 2006 Section 4 Repair Procedures REV MANIFOLDS This page intentionally left blank A TEREX COMPANY Part No 88619 Z 80 60 4 69 Section 4 Repair Procedures July 2006 2 MANIFOLDS REV 8 4 Platform Manifold The platform Manifold is mounted to the platform mounting weldment Index Schematic No Description Item Function Torque 1 Check valve GA aus Platform level circuit 2 Proportional solenoid valve position 4 GB Jib boom up down Cote TUBS en 5 7 5 9 ft lbs 10 12 Nm Core 3 7 4 5 ft lbs 5 6 Nm 3 7 4 5 ft lbs 5 6 Nm Hand Tighten Only 3 Check GC uu Jib boom circuit Accumulator 500 psi 34 5 bar GD Hydraulic dampening 23 ft lbs 31 Nm Differential sensing valve N O GE 2 Jib boom differential sensing circuit pp 23 25 ft lbs 31 34 Nm 6 Differential sensing valve N O GE Platform level differential sensing circuit pp 23 25 ft lbs 31 34 Nm 7 Differential sensing valve N O GH Platform rotate differe
231. high idle 4 Raise the secondary boom approximately 12 inches 30 cm 5 Placea4x4 inch 10 x 10 cm block on the secondary boom rest pad Lower the secondary boom onto the block AWARNING Crushing hazard Keep hands clear of the block when lowering the secondary boom 6 Simultaneously push and hold the function enable high speed button and the secondary boom down button Observe the reading on the pressure gauge Refer to Section 2 Specifications 7 Turn the engine off Use a wrench to hold the relief valve and remove the cap item D A TEREX COM Part No 88619 MANIFOLDS 8 Adjust the internal hex socket Turn it clockwise to increase the pressure or counterclockwise to decrease the pressure Install the relief valve cap AWARNING Tip over hazard Do not adjust the relief valve higher than specified 9 Start the engine and repeat step to confirm relief valve pressure 10 Start the engine and raise the secondary boom approximately 12 inches 30 cm Remove the block and lower the secondary boom to the stowed position 11 Turn the engine off and remove the pressure gauge How to Adjust the Secondary Boom Extend Relief Valve Perform this procedure with the secondary boom fully raised 1 Connect a 0 to 5000 psi 0 to 350 bar pressure gauge to the LS port on the function manifold 2 Startthe engine from the ground controls 3 Simultaneously push and hold the function enable high speed button an
232. hone 65 98 480 775 Fax 65 67 533 544 Genie Phone 34 93 579 5042 Fax 34 93 579 5059 Genie G rmany Phone 49 0 4202 88520 Fax 49 0 4202 8852 20 Genie Japan Phone 81 3 3453 6082 Fax 81 3 3453 6083 Genie Korea Phone 82 25 587 267 Fax 82 25 583 910 Genie U K Phone 44 0 1476 584333 Fax 44 0 1476 584334 Genie Brasil Phone 55 11 41 665 755 Fax 55 11 41 665 754 Genie Mexico City Phone 52 55 5666 5242 Fax 52 55 5666 3241 Genie Holland Phone 31 183 581 102 Fax 31 183 581 566 Service Manual Z 80 60 from serial number 101 Part No 88619 Rev B1 G enie G A TEREX COMPANY
233. hrottle is sticking open OR there are air leaks between the throttle body and cylinder head Re program ECM OR repair binding throttle operation OR repair any air leaks between the throttle body and cylinder head 552 Fuel Rev Limit ECM needs to be re programmed OR throttle is sticking open OR there are air leaks between the throttle body and cylinder head Re program ECM OR repair binding throttle operation OR repair any air leaks between the throttle body and cylinder head 553 Spark Rev Limit ECM needs to be re programmed OR throttle is sticking open OR there are air leaks between the throttle body and cylinder head Re program ECM OR repair binding throttle operation OR repair any air leaks between the throttle body and cylinder head 611 COP Failure Loose wire connections to ECM OR ECM is faulty Locate and repair any engine harness wiring damage or shorts to ECM to be sure they are secure OR replace ECM 612 Invalid Interrupt Loose wire connections to ECM OR ECM is faulty Locate and repair any engine harness wiring damage or shorts to ECM to be sure they are secure OR replace ECM Loose wire connections to ECM OR ECM is Locate and repair any engine harness wiring faulty 613 A D Loss faul damage or shorts to ECM to be sure they y are secure OR replace ECM 3 Locate and repair engine harness wiring 614 RTI 1 Loss Loose wine connections to ECM S da
234. hten the wing nut to welded bracket Tighten the jam nut to welded bracket Tighten the PBAS fasteners to boom Result The ground control box display should read amp P11 raurr 13 Push in the red Emergency Stop button to the off position Wait until display turns off before proceeding 14 Press and hold the enter button and pull out the red Emergency Stop button to the on position 15 Turn the key switch to ground control and pull out the red Emergency Stop buttons out to the on position at both the ground and platform controls A TEREX COMI Part No 88619 BOOM COMPONENTS 16 Press and hold the enter button until the engine symbol appears the display at the ground control box 17 Enter sensor calibration mode by pressing the buttons at the ground controls in the following sequence 1 18 Press the scroll button PRIMARY BOOM ANGLE 70 is shown on the display 19 Press the plus button to select yes then press and hold the enter button 44 to accept 20 Press the scroll button until Exit is shown the display Press the plus button to select yes then press and hold the enter button to accept 21 At the ground controls use auxiliary power and lower the boom until the faults are no longer shown on the display Result The flashing arrow in the display at the ground controls will turn off Result The flashing
235. id Petroleum Gas LPG tank by turning it clockwise if equipped 11 Tag and disconnect the wiring from the LPG solenoid 12 Remove the engine starter retaining fasteners and remove the starter from the engine Do not disconnect the wiring 13 Remove the dipstick tube bracket fasteners 14 Attach a lifting strap from an overhead crane to the lifting eyes on the engine 15 Remove the bell housing engine tray fasteners 16 Raise the engine slightly using the overhead crane Do not apply any lifting pressure 17 Support the drive pump with an appropriate lifting device Remove all of the remaining bell housing engine fasteners 18 Carefully pull the pump and bell housing assembly away from the engine and secure it from moving Component damage hazard CAUTION Hoses can be damaged if they are kinked or pinched 19 Remove the flex plate mounting fasteners Remove the flex plate from the engine fly wheel Part No 88619 July 2006 Section 4 Repair Procedures REV Deutz F4L 913 models 5 Tag and disconnect the wiring from the bell housing 6 Remove the exhaust tailpipe and air inlet tube U bolts from the air cleaner mounting bracket ACAUTION Burn hazard Hot engine parts can cause severe burns 7 Remove the fuel filter water separator retaining fasteners Remove the filter separator from the engine Do not disconnect the fuel hoses 8 Remove the air cleaner mounting bracket fasteners Remove the a
236. ids Use approved container Please be environmentally safe Used to indicate operation or maintenance information Be sure that your workshop or work area 4 3 is properly ventilated and well lit Genie vi Z 80 60 Part No 88619 September 2006 Introduction Section 1 Section2 Rev C Section 3 Rev Table of Contents Important Information li Serial Number Legend ete ed sp ten dete tn iii Safety Rules General Safety Rules pp Specifications Machine Specifications nnns 2 1 Performance Specifications Nt 2 2 Function Speeds Specifications 2 3 Hydraulic Specifications 2 4 Manifold Component Specifications 444 400 2 6 GMS OL EFL ENJIN E 2 7 Ford LRG 425 Engine 2 eed beeen 2 8 Deutz F4L 913 ENGINE rta o ordre Re een te eed ete epe t geb elena 2 10 Deutz BF4L 2011 Engine 2 11 Perkins 704 30 2 13 Perkins 804 33 00 44 00 00000 11 00 abon a VN 2 14 Machine Torque Specifications 01000 2 15 Manifold Component Specifications
237. if the fitting or hose end has been tightened beyond finger tight The O rings used in the Parker Seal LokQ fittings and hose ends are custom size O rings They are not standard SAE size O rings They are available in the O ring field service kit Genie part number 49612 2 Lubricate the O ring before installation 3 Be sure that the face seal O ring is seated and retained properly 4 Position the tube and nut squarely on the face seal end of the fitting and tighten the nut finger tight 5 Tighten the nut or fitting to the appropriate torque per given size as shown in the table 6 Operate all machine functions and inspect the hoses and fittings and related components to confirm that there are no leaks Seal Loke Fittings tube fitting installed into Steel hose end SAE Dash size Torque SAE Dash size Torque 4 15 ft lbs 20 3 Nm 4 18 ft lbs 24 4 Nm 6 35 ft lbs 47 5 Nm 6 30 ft lbs 40 Nm 8 60 ft lbs 81 3 Nm 8 40 ft lbs 55 Nm 10 100 ft lbs 135 6 Nm 10 60 ft lbs 80 Nm 12 135 ft lbs 183 Nm 12 85 ft lbs 115 Nm 16 200 ft lbs 271 Nm 16 110 ft lbs 150 Nm 20 250 ft lbs 334 Nm 20 140 ft lbs 190 Nm 24 305 ft lbs 414 Nm 24 180 ft lbs 245 Nm A TEREX COMI Part No 88619 September 2006 Section 2 Specifications REV SPECIFICATIONS SAE FASTENER TORQUE CHART This chart is to be used as a guide only unless noted
238. ine from the ground controls 2 Press and hold a function enable speed select button and fully retract the primary boom 3 Push one of the LCD Screen buttons shown until 4 platform angle is displayed 4 Press and hold a function enable speed select button and adjust the platform to zero degrees using the platform level up down buttons TEREX COMPAR Part No 88619 Z 80 60 CHECKLIST B PROCEDURES Push and hold a function enable speed select button and fully raise the primary boom while observing the platform angle shown on the LCD display Result The platform should remain level at all times to within 2 degrees If the platform becomes out of level the tilt alarm will sound and the Platform Not Level Indicator will flash at the ground controls The platform level up down buttons will only work in the direction that will level the platform Level the platform until the indicator light turns off Push and hold a function enable speed select button and fully lower the primary boom Result The platform should remain level at all times to within 2 degrees If the platform becomes out of level the tilt alarm will sound and the Platform Not Level Indicator will flash at the ground controls The platform level up down buttons will only work in the direction that will level the platform Level the platform until the indicator light turns off Section Scheduled Maintenance
239. ing fasteners on the backlash pivot plate to specification Refer to Section 2 Specifications Rotate the turntable through an entire rotation Check for tight spots that could cause binding Readjust if necessary Part No 88619 September 2006 Section 4 Repair Procedures REV C 10 1 Hub and Bearings 2WD Models How to Remove the Hub and Bearings 2WD Models 1 Loosen the wheel lug nuts Do not remove them 2 Block the non steer wheels 3 Center a lifting jack with a minimum capacity of 25 000 Ibs 12000 kg under the drive chassis between the steer wheels 4 Raise the machine 6 inches 15 cm and place blocks under the chassis for support Crushing hazard The machine ACAUTION may fall if not properly supported 5 Remove the lug nuts Remove the tire and wheel assembly 6 Remove the dust cap cotter pin and castle nut Always use a new cotter pin when installing a castle nut 7 Pull the hub off the spindle The washer and outer bearing should fall loose from the hub 8 Place the hub on a flat surface and gently pry the bearing seal out of the hub 9 Remove the rear bearing A TEREX Part No 88619 Axle Components How to Install the Hub and Bearings 2WD Models When replacing a wheel bearing both the inner and outer bearings including the pressed in races must be replaced 1 Be sure that both bearings are packed with clean fresh grease 2 Place the large inner bea
240. ing soda and water 1 Puton protective clothing and eye wear 2 Be sure that the battery cable connections are free of corrosion Adding terminal protectors and a corrosion preventative sealant will help eliminate corrosion on the battery terminals and cables 3 Be sure that the battery hold downs and cable connections are tight TEREX COMPANY REV C Be sure that the battery separator wire connections are tight Fully charge the batteries and allow them to rest at least 6 hours Remove the battery vent caps and check the specific gravity of each battery cell with a hydrometer Note the results Check the ambient air temperature and adjust the specific gravity reading for each cell as follows Add 0 004 to the reading of each cell for every 10 5 5 C above 80 F 26 7 C Subtract 0 004 from the reading of each cell for every 10 5 5 C below 80 F 26 7 C Result All battery cells display an adjusted specific gravity of 1 277 or higher The battery is fully charged Proceed to step 11 Result One or more battery cells display a specific gravity of 1 217 or below Proceed to step 8 Perform an equalizing charge OR fully charge the batteries and allow them to rest at least 6 hours Remove the battery vent caps and check the specific gravity of each battery cell with a hydrometer Note the results Part No 88619 September 2006 Section 3 Scheduled Maintenance Procedures
241. ion Manual Deutz part number 0297 7341 Deutz 913 Operation Manual Genie part number 62446 Perkins Models Required maintenance procedures and additional engine information are available in the Perkins 704 30 User s Handbook Perkins part number TPD 1336E OR the Perkins 804C 33 Operation and Maintenance Manual Perkins part number SEBU7853 00 Perkins 704 30 User s Handbook Genie part number 101840 Perkins 804C 33 Operation and Maintenance Manual Genie part number 111332 Section Scheduled Maintenance Procedures September 2006 CHECKLIST E PROCEDURES 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 84792 To access the engine 1 Remove the engine tray retaining fastener located under the engine tray Swing the engine tray out and away from the machine 2 Install the fastener that was just removed through the engine tray and into the engine tray anchor hole in the turntable AWARNING Crushing hazard Failure to install the fastener into the engine tray anchor hole to secure the engine tray from moving could result in death or serious injury A TEREX COMI REV C E 4 Perform Engine Maintenance Ford Models Engine specifications require that this procedure be performed every 2400 hours Prop
242. ir cleaner and bracket assembly from the engine 9 Support the drive pump with an appropriate lifting device Remove all of the remaining bell housing to engine fasteners 10 Carefully pull the pump and bell housing assembly away from the engine and secure it from moving Component damage hazard CAUTION Hoses can be damaged if they are kinked or pinched 11 Remove the flex plate mounting fasteners and remove the flex plate from the engine flywheel A TEREX COMI Part No 88619 ENGINES Deutz BF4L 2011 models 5 Tag and disconnect the wiring from the bell housing 6 Remove the U bolt from the exhaust flex pipe at the muffler ACAUTION Burn hazard Hot engine parts can cause severe burns 7 Remove the muffler bracket retaining fasteners from bell housing Remove the muffler and bracket assembly from the engine 8 Support the drive pump with an appropriate lifting device Remove all of the remaining bell housing engine fasteners 9 Carefully pull the pump and bell housing assembly away from the engine and secure it from moving Component damage hazard CAUTION Hoses can be damaged if they are kinked or pinched 10 Remove the flex plate mounting fasteners and remove the flex plate from the engine flywheel Section 4 Repair Procedures July 2006 ENGINES Perkins 704 30 Models 5 Remove the clamp securing the air intake elbow to the air cleaner assembly Remove the air intake tube from the en
243. iring and or connections to fuel injector 1 OR replace fuel injector 1 OR replace the ECM Injector Driver 1 Shorted 312 Wiring and or connections to fuel injector 1 shorted OR fuel injector 1 is faulty OR ECM is faulty Repair wiring and or connections to fuel injector 1 OR replace fuel injector 1 OR replace the ECM Injector Driver 2 Open 313 Open wiring and or connections to fuel injector 2 OR fuel injector 2 is faulty OR ECM is faulty Repair wiring and or connections to fuel injector 2 OR replace fuel injector 2 OR replace the ECM Injector Driver 2 Shorted 314 Wiring and or connections to fuel injector 2 shorted OR fuel injector 2 is faulty OR ECM is faulty Repair wiring and or connections to fuel injector 2 OR replace fuel injector 2 OR replace the ECM 315 Injector Driver 3 Open Open wiring and or connections to fuel injector 3 OR fuel injector 3 is faulty OR ECM is faulty Repair wiring and or connections to fuel injector 3 OR replace fuel injector 3 OR replace the ECM 316 Injector Driver 3 Shorted Wiring and or connections to fuel injector 3 shorted OR fuel injector 3 is faulty OR ECM is faulty Repair wiring and or connections to fuel injector 3 OR replace fuel injector 3 OR replace the ECM 321 Injector Driver 4 Open Open wiring and or connections to fuel injector 4 OR fuel injector 4 is faulty OR ECM is faulty Repair wiri
244. isible ao oo Move the platform rotate switch to the left and then to the right through two platform rotation cycles continue holding the switch to the right until the platform is fully rotated to the right TEREX COMPANY Part No 88619 Z 80 60 4 21 Section 4 Repair Procedures July 2006 PLATFORM COMPONENTS 3 Open the top bleed valve but do not remove it 4 Move the platform rotate switch to the left until the platform is fully rotated to the left Continue holding the switch until air stops coming out of the bleed valve Close the bleed valve AWARNING Crushing hazard Keep clear of the platform during rotation 5 Connect the clear hose to the bottom bleed valve Open the bottom bleed valve but do not remove it 6 Hold the platform rotate switch to the right until the platform is fully rotated to the right Continue holding the switch until air stops coming out of the bleed valve Close the bleed valve AWARNING Cushing hazard Keep clear of the platform during rotation 7 Remove the hose from the bleed valve and clean up any hydraulic oil that may have spilled 8 Rotate the platform full right then full left and inspect the bleed valves for leaks After serial number 228 1 Rotate the platform full right then full left until air is completely out of the rotator Bleeding the valve is not necessary AWARNING Crushing hazard Keep clear of the platform during rotation A TEREX COMI
245. itting the O ring on the fitting and or hose end must be replaced and then torqued to specification during installation Refer to Section 2 Hydraulic Hose and Fitting Torque Specifications 1 Remove the platform See 2 1 How to Remove the Platform A TEREX REV B 2 Disconnect the wire harness from the platform angle sensor 3 Tag disconnect and plug the hydraulic hoses from the platform rotator manifold Cap the fittings on the manifold AWARNING 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 Remove the hose and cable clamp from the platform support Remove the platform manifold mounting fasteners Lay the platform manifold to the side Component damage hazard CAUTION Cables can be damaged if they are kinked or pinched Remove the power to platform electrical outlet box bracket mounting fasteners Remove the power to platform electrical outlet box from the platform and lay it to the side Remove the weld cable from the platform if equipped AWARNING Electrocution hazard Contact with electrically charged circuits could result in death or serious injury Remove all rings watches and other jewelry Part No 88619 July 2006 Section 4 Repair Procedures REV B PLATFORM COMPONENTS 9 Support the platform mounting weldment
246. l AWARNING Collision hazard Be sure that the machine is not in free wheel or partial free wheel configuration See B 8 Confirm the Proper Brake Configuration Select a test area that is firm level and free of obstructions 1 Mark a test line on the ground for reference 2 the engine from the platform controls 3 Press the engine rpm select button until the foot switch activated high idle rabbit and foot switch symbol is selected then lower the boom into the stowed position 4 Choose a point on the machine i e contact patch of a tire as a visual reference for use when crossing the test line 5 Bring the machine to top drive speed before reaching the test line Release the drive controller when your reference point on the machine crosses the test line 6 Measure the distance between the test line and your machine reference point Refer to Section 2 Specifications The brakes must be able to hold the machine on any slope it is able to climb A TEREX COMI REV C B 15 Test the Drive Speed Stowed Position Proper drive function movement is essential to safe machine operation The drive function should respond quickly and smoothly to operator control Drive performance should also be free of hesitation jerking and unusual noise over the entire proportionally controlled speed range Select a test area that is firm level and free of obstructions Perform this procedure with the boom in the sto
247. l tire diameter 45 47 in Hi flotation 115 5 cm Wheel diameter 24 5 in foam filled and non marking 62 2 cm Wheel diameter 28 in Hi flotation 71 1 cm Wheel width 15 in foam filled non marking and Hi flotation 38 1 Wheel lugs 10 3 4 16 Lug nut torque dry 420 ft lbs 570 Nm Lug nut torque lubricated 320 ft lbs 434 Nm Continuous improvement of our products is a Genie policy Product specifications are subject to change without notice Part No 88619 A TEREX COMPANY Specifications Fluid capacities Fuel tank 40 gallons 151 4 liters LPG tank 33 5 16 15 2 kg Hydraulic tank 45 gallons 170 liters Hydraulic system 55 gallons including tank 208 liters Drive hubs 50 7 fl oz 1 5 liters Turntable rotation drive hub 17 fl oz 0 5 liters Drive hub oil type EP 80 90W gear oil API Service Classification GL5 For operational specification refer to the Operator s Manual Section 2 Specifications September 2006 SPECIFICATIONS REV Performance Specifications Drive speed maximum models with rough terrain tires Stowed position 3 mph 4 8 km h 40 ft 9 1 sec 12 2 m 9 1 sec Raised or extended position 0 7 mph 1 1 km h 40 ft 40 sec 12 2 m 40 sec Drive speed maximum models with Hi flotation tires Stowed position 2 mph 3 1 km h 40 ft 14 sec 12 2 14 sec Raised or extended position 0 4 mph 0 7 km h 40 ft 66
248. l viscosity requirements Units ship with 15W 40 Extreme operating temperatures my require the use of alternative engine oils For oil requirements refer to the Engine Operator Handbook on your machine A TEREX COMI REV C Injection system Injection pump make Zexel 10641 3932 Injection pump pressure 1707 to 1849 psi 117 7 to 127 5 bar Injector opening pressure 2000 psi 138 bar Fuel Requirement For fuel requirements refer to the engine Operator s Manual on your machine Engine coolant Capacity 12 5 quarts 11 8 liters Batteries Type 12V DC Group 31 Quantity 2 Cold cranking ampere 1000A Reserve capacity 25A rate 200 minutes Alternator output 90A 12V DC Fan belt deflection 3 8 to 1 2 in 9 to 12 mm Continuous improvement of our products is a Genie policy Product specifications are subject to change without notice Part No 88619 September 2006 Section 2 Specifications REV Machine Torque Specifications Platform rotator 1 8 center bolt Gr 5 dry 3 8 16 bolts Gr 8 use blue thread locking compound Turntable rotate assembly Rotate bearing mounting bolts lubricated Rotate drive hub mounting bolts lubricated Backlash plate mounting bolts lubricated Drive motor and hubs Drive hub mounting bolts dry Drive hub mounting bolts lubricated Drive motor mounting bolts dry Drive motor mounting
249. ld operate 13 Using a suitable lifting device lift the additional test weight from the platform Result The platform overload indicator lights should turn off at both the ground and platform controls and the alarm should not sound There may be an 2 second delay before the overload indicator lights and alarm turn off 14 Start the engine and test all machine functions from the ground controls Result All ground control functions should operate normally 15 Turn the key switch to platform control 16 Test all machine functions from the platform controls Result All platform control functions should operate If the platform overload system is not operating properly Refer to 2 4 How to Calibrate the Platform Overload System if equipped 17 Using a suitable lifting device remove the remaining test weights from the platform A TEREX COMI REV C C 4 Replace the Engine Air Filter Engine specifications require that this procedure be performed every 500 hours or 6 months whichever comes first Maintaining the engine air filter in good condition is essential to good engine performance and service life Failure to perform this procedure can lead to poor engine performance and component damage Perform this procedure with the engine off 1 Open the engine side cover Empty the dust discharge valve by pressing together the sides of the discharge slot Clean the discharge slot as needed
250. lt codes are displayed the check engine light will blink a code 123 times After the fault codes the check engine light will blink a code 123 three times again indicating the end of the stored codes 6 Refer to Section 5 Fault Codes for definition of engine fault codes How to Clear Engine Fault Codes from the ECM Perform this procedure with the engine off and the key switch in the off position 1 Open the engine side turntable cover and locate the battery 2 Disconnect the negative battery cable from the battery for a minimum of 5 minutes AWARNING 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 Part No 88619 July 2006 Section 4 Repair Procedures REVA 6 1 Circuit Boards The ground control box TCON is the communication and operations center for the machine The ground control box contains two key switches The key switch towards the top of the control box is for selection of ground or platform controls The key switch at the bottom of the control box is the Service Bypass key switch It is used to correct an out of level platform If the machine trips an envelope safety switch the operator at the ground controls can turn and hold the Service Bypass key switch in the RECOVER position which will automatically retract the boom and lower the pl
251. lter mounted on the hydraulic tank 2 Place suitable container under the hydraulic tank return filter high pressure filters b medium pressure filter TEREX COMPANY 3 58 Z 80 60 Part No 88619 September 2006 Section 3 Scheduled Maintenance Procedures REV CHECKLIST D PROCEDURES 8 Place a suitable container under the filters 9 Remove the filter housing by using a wrench on the nut provided on the bottom of the housing 10 Remove the filter element from the housing 11 Inspect the housing seal and replace it if necessary 12 Install the new medium and high pressure filter elements into the housings and tighten them securely 13 Clean up any oil that may have spilled during the installation procedure 14 Use a permanent ink marker to write the date and number of hours from the hour meter on the oil filter housings 15 Start the engine from the ground controls 16 Inspect the filter housings and related components to be sure that there are no leaks A TEREX COMPANY Part No 88619 Z 80 60 3 59 Section Scheduled Maintenance Procedures September 2006 Checklist E Procedures E 1 Test or Replace the Hydraulic Oil Replacement or testing of the hydraulic oil is essential for good machine performance and service life Dirty oil and suction strainers may cause the machine to perform poorly and continued use may cause component damage Extremely dirty c
252. m 5 lt P P E C O ee __ J15 BLACK 4 PIN 5 J13 WHITE 23 cilia 51 lal o 5 5 519 5 8 E Xm ses S SS POWER HARN amp amp ENGINE HARN al a a a enie A TEREX COMPANY 6 22 Z 80 60 Part No 88619 Section 6 Schematics Ground Controls TCON Electrical Schematic View 6 July 2006 REV No woog No e dn air e e WOOS e quuni oe e 93S e dN 4 e 1 woog lt 2 9 A NMOG Noog 2 7 138 woog e dn oas e e AUVITIXQV e 9334 9N3 e avsvo e NOLLn8 THOS e dmouos 1SSV 1815 5 Nonna 0 21 l v OL e 51 SI Old eee ee eS Ee ee ur 3 4 5 6 7 8 OHOIIN at 5 lt re zit DAS NMOG 235 4 lt OLN ATA 1 DAS 4 3 WOO 295 E vd
253. m Calibrate CAL stowed and BST stands for Boom Stowed CAN Signal CAN P 48 LP P stands for power 48 is the circuit number for work CAN Shield SHD lamps and LP stands for Lamp CATS Module CAT 48 LP stands for relay In this case it is the wire that Chain Break CNK feeds the relay coil for the work lamp All other numbers remain Data High DTH the same Data Low DTL Drive Chassis Controller DCN Circuit prefix Drive Enable DE Control Drive Enable Left DEL Data Drive Enable Right DER Electrical Displacement Control EDC E s Engine Envelope Light ENV G Gauges Engine Speed Select ESP Neutral Engine Status Lamp ESL Envelope Lockout ENL rat Extend retract Lockout ERL Relay Output Filter Restricted FLR S Safety Filter Switch FLT Valve Flashing Beacon FB Float Switch FS Footswitch Signal FTS Forward FWD Fuel Pump FP Fuel Select gas LP FL Fuel Solenoid FSL 6 2 Z 80 60 Part No 88619 July 2006 REV Definition Function Enable Ground Control Ground Horn High RPM Hydraulic Generator Ignition Jib Bellcrank Down Jib Bellcrank Up Jib Sensor Jib U D Control Jib Down Jib Up Down Flow Control Jib Select Valve Jib Up Jib E R Control Jib Ext Jib Ret Jib Rotate Left CCW Jib Rotate Right CW Joystick 5 VDC Power Lamps Left Front Left Front Steer Sensor Left Rear Left Rear Steer Sensor Limit Switch Lift Speed Reduction Load Sensor
254. m is not operating properly OR MegaJector is faulty Check fuel pressure OR repair LPG lockoff OR repair the line between the MegaJector and carburetor OR repair engine cooling system OR replace the MegaJector MegaJector communication lost 355 The ECM doesn t get any response from the MegaJector or an incorrect response for 500ms period or longer Check CAN circuits for continuity and shorts to power or ground and for continuity and repair as necessary OR replace the MegaJector MegaJector voltage supply high 361 Megavector detects voltage greater than 18 volts for 5 seconds anytime the engine is cranking or running Repair charging system OR replace the Megadector MegaJector voltage supply low 362 Megavector detects voltage less than 9 5 volts for 5 seconds anytime the engine is cranking or running Repair VBAT power or ground circuit to ECM and MegaJector OR replace battery OR repair charging system OR replace the MegaJector Part No 88619 Continued on next page Z 80 60 5 11 Section 5 Fault Codes July 2006 m sri FORD ECM FAULT CODE CHART REV A Code Problem Cause Solution 363 Megajector internal actuator fault detection The Megavector detects an internal fault Open or short in power ground or CAN circuits s Check Power Ground and CAN circuits at MegaJector and all connections and repair as
255. machine A TEREX COMI Part No 88619 SPECIFICATIONS Injection system Injection pump make Zexel PFR KX Injection pump pressure 2755 psi 190 bar Injector opening pressure 3626 psi 250 bar Fuel Requirement For fuel requirements refer to the engine Operator s Manual on your machine Engine coolant Capacity 11 5 quarts 10 9 liters Batteries Type 12V DC Group 31 Quantity 2 Cold cranking ampere 1000A Reserve capacity 25A rate 200 minutes Alternator output 65A 12V DC Fan belt deflection 3 8 10 mm Continuous improvement of our products is a Genie policy Product specifications are subject to change without notice Section 2 Specifications September 2006 SPECIFICATIONS Perkins 804C 33 Engine Displacement 201 cu in 3 3 liters Number of cylinders 4 Bore and stroke 3 70 x 4 72 inches 94 x 120 mm Horsepower 63 2600 rpm 47 kW 2600 rpm Firing order 1 3 4 2 Compression ratio 22 1 Compression pressure 300 to 500 psi 20 7 to 34 5 bar Pressure psi or bar of lowest cylinder must be within 50 psi 3 45 bar of highest cylinder Low idle 1650 rpm Frequency 335 5 Hz High idle 2300 rpm Frequency 467 7 Hz Governor mechanical all speed Valve clearance cold Intake 0 0098 in 0 25 mm Exhaust 0 0098 in 0 25 mm Lubrication system Oil pressure 2000 rpm 40 60 psi 2 8 4 1 bar Oil capacity 10 6 quarts including filter 10 liters Ci
256. mage or shorts to ECM to be sure they are secure OR replace ECM 615 Flash Checksum Invalid Loose wire connections to ECM OR ECM is faulty Locate and repair any engine harness wiring damage or shorts to ECM to be sure they are secure OR replace ECM 616 RAM Failure Loose wire connections to ECM OR ECM is faulty Locate and repair any engine harness wiring damage or shorts to ECM to be sure they are secure OR replace ECM 631 External 5V DC Ref Lower than Expected Engine harness wiring and or connections open or shorted to ground OR there is a faulty engine sensor OR ECM is faulty Locate and repair any engine harness wiring damage or shorts OR locate and troubleshoot or repair faulty engine sensor OR replace ECM 632 External 5V DC Ref Higher than Expected Engine harness wiring and or connections open or shorted to ground OR there is a faulty engine sensor OR ECM is faulty Locate and repair any engine harness wiring damage or shorts OR locate and troubleshoot or repair faulty engine sensor OR replace ECM Loose wire connections to ECM OR ECM is Locate and repair any engine harness wiring faulty S 655 RTI 2 Loss fault damage or shorts to ECM to be sure they secure OR replace Locate and repair any engine harness wiring 656 RTI 3 Loss 1 0089 Wire OR damage or shorts to ECM to be sure they are secure OR r
257. mation An illegible decal will fail to alert personnel of a procedure or hazard and could result in unsafe operating conditions 1 Check to make sure that the operator s and safety manuals are present and complete in the storage container on the platform 2 Examine the pages of each manual to be sure that they are legible and in good condition Result The operator s manual is appropriate for the machine and all manuals are legible and in good condition W Result The operator s manual is not appropriate for the machine or all manuals are not in good condition or is illegible Remove the machine from service until the manual is replaced A TEREX COM Part No 88619 Checklist A Procedures 3 Open the operator s manual to the decals inspection section Carefully and thoroughly inspect all decals on the machine for legibility and damage Result The machine is equipped with all required decals and all decals are legible and in good condition Result The machine is not equipped with all required decals or one or more decals are illegible or in poor condition Remove the machine from service until the decals are replaced 4 Always return the manuals to the storage container after use Contact your authorized Genie distributor or Genie Industries if replacement manuals or decals are needed Section Scheduled Maintenance Procedures September 2006 CHECKLIST A PROCEDURES A 2 Perform Pre op
258. minus button twice then press the enter button twice Use the scroll button to scroll through the menu until RESET TURNTABLE ROTATE LEFT RIGHT JOYSTICK DEFAULTS is displayed Press the button to select ves then press the button Do not start the engine Locate the primary boom turntable rotate joystick Move the boom turntable joystick full stroke in the left direction and hold for 5 seconds then return to the center or neutral position A TEREX COMI Z 80 60 Part No 88619 July 2006 REV B 8 Move the boom turntable joystick full stroke in the right direction and hold for 5 seconds then return to the center or neutral position O Result The alarm at the ground controls should sound for a successful calibration W Result If the alarm does not sound repeat calibration procedure How to Reset a Proportional Valve Coil Default This procedure only needs to be performed if a proportional valve has been replaced After the valve coil defaults have been set each machine function threshold and default function Speed must be set See 1 3 How to Set the Function Thresholds and Default Function Speeds 1 Turn the key switch to the off position 2 Press and hold the enter button on the ground control panel while turning the key switch to platform controls 3 Press the minus button twice then press the enter button twice 4 Use the scroll button to s
259. mit switches are located inside the drive chassis above the axle 4 Place a digital level on the turntable rotate bearing plate Start the engine and level the drive chassis Press down the foot switch and manually activate the oscillate limit switches until the machine is completely level TEREX COMPANY REV C Loosely install the limit switches Using a feeler gauge establish a gap of 0 015 0 030 inches 0 381 0 762 mm between the limit switch plunger and the top of the axle Carefully hold the position of each limit switch and tighten the limit switch mounting fasteners Verify the gap is 0 015 0 030 inches 0 381 0 762 mm between the limit switch plunger and the top of the axle Measure the distance between the drive chassis and the axle on both sides from the inside of the drive chassis Result The measurements should be equal If the distance is not equal and the adjustment to the limit switches was completed with the ground and drive chassis level consult Genie Industries Service Department Part No 88619 September 2006 Section 4 Repair Procedures REV C 10 2 Oscillating Axle Cylinders The oscillating axle cylinders extend and retract between the drive chassis and the oscillating axle The cylinders are equipped with counterbalance valves to prevent movement in the event of a hydraulic line failure The valves are not adjustable How to Remove an Oscillating Axle C
260. n Indicates that a specific result is expected after performing a series of steps W Indicates that an incorrect result has occurred after performing a series of steps Section 4 Repair Procedures July 2006 Display Module REV B This table lists the various screens and menu options of the operating software Some display menus are for informational purpose only while others can be used to change the machine operating parameters The key switch must be in the off position before entering the programming mode Screen or Procedure Description Range Menu Operator Default Hour meter Engine speed Engine oil pressure PSI Engine oil pressure kPa Engine temperature F Engine temperature C Primary boom angle sensor Turntable level sensor X Turntable level sensor Y Platform angle Battery voltage Machine With key switch ON Hydraulic pressure PSI 0 4500 PSI Status press the Hydraulic pressure kPa 0 31000 kPa at the same Primary boom angle 0 65 DEG time Primary boom length 0 gt 0 222 Secondary boom angle 0 DEG gt 0 DEG 65 DEG Secondary boom length OFT gt Unit of With the key switch Metric English measurements English German French Measure OFF press and hold Language selection Spanish Portuguese Italian the button and turn Dutch and Swedish the key switch to the Language on position Release the button and press
261. n Fuel requirement For fuel requirements refer to the engine Operator s Oil viscosity requirements Extreme operating temperatures may require the use of alternative engine oils For oil requirements refer to the Engine Operator Handbook on your machine Continuous improvement of our products is a Genie policy Product specifications are subject to change without notice A TEREX COMI Manual on your machine Ignition system Spark plug type Motorcraft AWSF 52C 0 042 to 0 046 in 1 07 to 1 18 mm Spark plug gap 5 to 10 ft lbs 7 to 14 Nm Spark plug torque Part No 88619 September 2006 Section 2 Specifications m REV C SPECIFICATIONS Engine coolant Capacity 11 5 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 13 8V DC Continuous improvement of our products is a Genie policy Product specifications are subject to change without notice A TEREX COMPANY Part No 88619 Z 80 60 2 9 Section 2 Specifications September 2006 SPECIFICATIONS Deutz F4L 913 Engine Displacement 249 3 cu in 4 085 liters Number of cylinders 4 4 02 x 4 92 inches 102 1 x 125 mm Bore and stroke Horsepower 76 2300 rpm 56 6 kW 2300 rpm Firing order 1 3 4 2 Compression ratio 18 1 Compression pressure Pressure psi or bar of the lowest cylinder must be at leas
262. n are available in the GM 3 0L Operator Handbook GM part number 36100007 GM 3 0L Operator Handbook Genie part number 77738 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 CHECKLIST C PROCEDURES To access the engine 1 Remove the engine tray retaining fastener located under the engine tray Swing the engine tray out and away from the machine 2 Install the fastener that was just removed through the engine tray and into the engine tray anchor hole in the turntable AWARNING Crushing hazard Failure to install the fastener into the engine tray anchor hole to secure the engine tray from moving could result in death or serious injury Genie part number 84792 Genie Part No 88619 Z 80 60 3 49 Section 3 Scheduled Maintenance Procedures September 2006 Checklist D Procedures D 1 D 2 Check the Boom Wear Pads Check the Free wheel Configuration Maintaining the boom wear pads in good condition is essential to safe machine operation Wear pads are placed on boom tube surfaces to provide a low friction replaceable wear pad between moving parts Improperly shimmed wear pads or continued use of extremely worn wear pads may result in component damage and unsafe operating conditions Refer to Section 2 Specifications for Boom Wear Pad Specific
263. nbalanced and fall if not properly supported when the jib boom lift cylinder barrel end pivot pin is removed 8 Secure the jib boom bellcrank to prevent it from moving 9 Remove the hose and cable clamp from the jib boom pivot pin 10 Remove the pin retaining fastener from the jib boom pivot pin Do not remove the pin 11 Place blocks under the platform leveling cylinder for support 12 Use a soft metal drift to remove the pin Carefully remove the jib boom from the primary boom AWARNING Crushing hazard The jib boom could become unbalanced and fall if not properly supported when removed from the machine A TEREX COMI REV B 13 Remove the pin retaining fasteners from the jib boom lift cylinder rod end pivot pin Do not remove the pin 14 Slide both of the jib boom leveling arms off of the jib boom cylinder rod end pivot pin and lay them off to the side 15 Attach a lifting strap from an overhead crane to the lug on the rod end of the jib boom lift cylinder 16 Attach a lifting strap from a second overhead crane to the jib boom bellcrank 17 Use a soft metal drift to remove the jib boom lift cylinder rod end pivot pin Remove the jib boom lift cylinder and jib boom bellcrank from the machine AWARNING Crushing hazard The jib boom lift cylinder and jib boom bellcrank could become unbalanced and fall if not properly supported when they are removed from the machine ACAUTION Cushing hazard The platfo
264. ne tray out and away from the machine 2 Install the fastener that was just removed through the engine tray and into the engine tray anchor hole in the turntable AWARNING Crushing hazard Failure to install the fastener into the engine tray anchor hole to secure the engine tray from moving could result in death or serious injury Section Scheduled Maintenance Procedures September 2006 This page intentionally left blank A TEREX COMPANY 3 68 Z 80 60 Part No 88619 July 2006 Section 4 Repair Procedures Observe and Obey Repair procedures shall be completed by a person trained and qualified on the repair of this machine Immediately tag and remove from service damaged or malfunctioning machine Repair any machine damage or malfunction before operating the machine Before Repairs Start Read understand and obey the safety rules and operating instructions in the Operator s Manual on your machine Be sure that all necessary tools and parts are available and ready for use Read each procedure completely and adhere to the instructions Attempting shortcuts may produce hazardous conditions Unless otherwise specified perform each repair procedure with the machine in the following configuration Machine parked on a firm level surface Boomin the stowed position Turntable rotated with the boom between the circle end yellow arrow wheels Turntable sec
265. necessary OR MegaJector has internal fault Contact Ford Power Products for assistance 364 Megajector internal circuitry fault detection The Megavector detects an internal circuitry failure Open or short in power ground or CAN circuits Check Power Ground and CAN circuits at MegaJector and all connections and repair as necessary OR Megavector has internal fault Contact Ford Power Products for assistance 365 MegaJector internal communication fault detection The Megavector detects an internal communications failure Open or short in power ground or CAN circuits Check Power Ground and CAN circuits at MegaJector and all connections and repair as necessary OR MegaJector has an internal fault Contact Ford Power Products for assistance 411 Coil Driver 1 Open Open wiring and or connections to ignition coil 1 OR ignition coil 1 is faulty Repair wiring and or connections to ignition coil 1 OR replace ignition coil 1 412 Coil Driver 1 Shorted Wiring and or connections to ignition coil 1 shorted OR ignition coil 1 is faulty Repair wiring and or connections to ignition coil 1 OR replace ignition coil 1 413 Coil Driver 2 Open Open wiring and or connections to ignition coil 2 OR ignition coil 2 is faulty Repair wiring and or connections to ignition coil 1 OR replace ignition coil 1 414 Coil Driver 2 Shorted Wiring and or connections to igni
266. ng 8 Remove the external snap rings from the extension cylinder rod end pivot pin at the platform end of the extension tube Crushing hazard The extension AWARNING cylinder could become unbalanced and fall if not properly supported when removed from primary boom extension tube 9 Use a soft metal drift to remove the pin AWARNING Crushing hazard The extension cylinder could become unbalanced and fall if not properly supported when removed from primary boom extension tube 10 Attach a lifting strap from an overhead crane to the extension cylinder Section 4 Repair Procedures September 2006 BOOM COMPONENTS 11 Working at the end of the extension boom tube opposite the jib boom mount support and slide the extension cylinder out of the extension boom tube AWARNING Crushing hazard The extension cylinder could become unbalanced and fall if not properly supported when removed from primary boom extension tube During removal the overhead crane strap will need to be carefully adjusted for proper balancing A TEREX REV 4 3 Primary Boom Lift Cylinder The primary boom lift cylinder raises and lowers the primary boom The primary boom lift cylinder is equipped with a counterbalance valve to prevent movement in the event of a hydraulic line failure How to Remove the Primary Boom Lift Cylinder AWARNING Bodiy injury hazard This procedure requires specific repair skills lifting equipment
267. ng and or connections to fuel injector 4 OR replace fuel injector 4 OR replace the ECM 322 Injector Driver 4 Shorted Wiring and or connections to fuel injector 4 shorted OR fuel injector 4 is faulty OR ECM is faulty Repair wiring and or connections to fuel injector 4 OR replace fuel injector 4 OR replace the ECM Fuel Pump Loop Open or High Side Short To Ground 351 Open wiring and or connections to fuel pump OR fuel pump power shorted to ground OR fuel pump is faulty Repair wiring and or connections to fuel pump OR replace fuel pump Fuel Pump High Side Shorted To Power 352 Wiring and or connections to fuel pump shorted to power OR fuel pump is faulty Repair wiring and or connections to fuel pump OR replace fuel pump MegaJector delivery pressure higher than expected 353 Fuel pressure too high OR LPG lockoff not sealing correctly OR the line between the MegaJector and carburetor is kinked or restricted or is leaking OR engine cooling system is not operating properly OR MegaJector is faulty Check fuel pressure OR repair LPG lockoff OR repair the line between the MegaJector and carburetor OR repair engine cooling system OR replace MegaJector Megajector delivery pressure lower than expected 354 Fuel pressure too low OR LPG lockoff not opening completely OR the line between the MegaJector and carburetor is kinked or restricted or is leaking OR engine cooling syste
268. nge to high idle a foot switch activated high idle indicator light b low idle indicator light c high idle indicator light d engine rpm select button 8 Press the engine idle select button until low idle turtle symbol is selected O Result The engine should change to low idle 9 Press the engine idle select button until the foot Switch activated high idle rabbit and foot switch symbol is selected O Result The engine should not change to high idle 10 Press down the foot switch O Result The engine should change to high idle Part No 88619 September 2006 Section 3 Scheduled Maintenance Procedures REV B 13 Test the Fuel Select Operation Gasoline LPG Models The ability to select and switch between gasoline and LPG fuels as needed is essential to safe machine operation A fuel selection can be made whether the engine is running or not Switching malfunctions and or the failure of the engine to start and run properly in both fuel modes and through all idle speeds can indicate fuel system problems that could develop into a hazardous situation Perform this test after checking 8 9 CHECKLIST B PROCEDURES Press down the foot switch to allow the engine to run at high idle Result The engine should start promptly and operate smoothly in low and high idle Release the foot switch and shut the engine off by pushing the red Emergency Stop button in to the off position Pull the re
269. ntial sensing circuit pe 23 25 ft lbs 31 34 Nm 8 Shuttle valve pe Gli Jib boom load sense circuit 7 5 9 ft Ibs 10 12 Nm 9 Orifice plug 0 030 inch 0 762 mm GJ Platform rotate left circuit 10 Orifice plug 0 030 inch 0 762 mm GK Platform rotate right circuit 11 Shuttle valve pp GL Platform level load sense circuit 7 5 9 ft lbs 10 12 Nm 12 Diagnostic nipple GM Testing 13 Shuttle valve GN Platform rotate load sense circuit 7 5 9 ft lbs 10 12 Nm 14 Differential sensing valve N C GO Directs flow to functions 23 25 ft lbs 31 34 Nm 15 Proportional solenoid valve position 4 way pp Platform rotate left right Core Tube 7 5 9 ft lbs 10 12 Nm Core T be Bottom iecit ede vec 3 7 4 5 ft Ibs 5 6 Nm IE 3 7 4 5 ft lbs 5 6 Nm Hand Tighten Only 16 Proportional solenoid valve position 4 way pp GQ Platform level up down Core Tube Son 7 5 9 ft lbs 10 12 Nm Core Tube Bottom pe 3 7 4 5 ft lbs 5 6 Nm eoim
270. ntrolled by the ECM and can only be adjusted by re programming the ECM If rpm adjustment or service is required please contact the Genie Industries Service Department or your local GM dealer 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 913 models 1 Start the engine from the ground controls 2 Push one of the LCD Screen buttons shown until 4 el engine rpm is displayed Refer to Section 2 Specifications Skip to step 11 if the low idle rpm is correct A TEREX COMI Part No 88619 CHECKLIST B PROCEDURES 3 Remove the secondary idle adjustment screw cap from the secondary idle adjustment screw on the injection pump Loosen the locknut Cd y N i NS TE G 5 Ast a idle adjustment screw b secondary idle adjustment screw 4 Turn the secondary adjustment screw counterclockwise until the adjustment screw is loose Tighten the locknut Be sure the adjustment screw is loosened until there is no spring tension felt 5 Remove the primary idle adjustment screw cap from the primary idle adjustment screw on the injection pump Loosen the locknut 6 Adjust the primary idle adjustment screw until low
271. nual Deutz part number 0297 7341 OR the Deutz BF4L2011 Operation Manual Deutz part number 0297 9929 Deutz 913 Operation Manual Genie part number 62446 Deutz BF4L2011 Operation Manual Genie part number 84794 GM Models Required maintenance procedures and additional engine information are available in the GM 3 0L Operator Handbook GM part number 36100007 GM 3 0L Operator Handbook CHECKLIST A PROCEDURES Perkins Models Required maintenance procedures and additional engine information are available in the Perkins 704 30 User s Handbook Perkins part number TPD 1336E OR the Perkins 804C 33 Operation and Maintenance Manual Perkins part number SEBU7853 00 Perkins 704 30 User s Handbook Genie part number 101840 Perkins 804C 33 Operation and Maintenance Manual Genie part number 111332 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 84792 To access the engine 1 Remove the engine tray retaining fastener located under the engine tray Swing the engine tray out and away from the machine 2 Install the fastener that was just removed through the engine tray and into the engine tray anchor hole in the turntable Genie part number 77738 AWARNING Crushing hazard Failure to install the fastener into t
272. oid valve 10V DC 4 5 to 6 50 schematic items H J V X Z AA BC BD CE CF EE EF FB and FC Section 4 Repair Procedures July 2006 MANIFOLDS 2 Connect a 100 resistor to the negative terminal of a known good 9V DC battery Connect the other end of the resistor to a terminal on the coil Resistor 10Q Genie part number 27287 The battery should read 9V DC or more when measured across the terminals ot 5 100 9V RESISTOR BATTERY 2 OM uj Lon XX eee led i l tet P Ads Ah pia ly E POL bo 1011 multimeter 9V DC battery 10Q resistor coil Note Dotted lines in illustration indicate a reversed connection as specified in step 6 REV Set a multimeter to read DC current The multimeter when set to read DC current should be capable of reading up to 800 mA Connect the negative lead to the other terminal on the coil Momentarily connect the positive lead from the multimeter to the positive terminal on the 9V DC battery Note and record the current reading At the battery or coil terminals reverse the connections Note and record the current reading Result Both current readings are greater than 0 mA and are different by a minimum of 20 The coil is good Result If one or both of the current readings are 0 mA or if the two current readings do not differ by
273. om service R repaired Checklist A Rev C Y N Checklist B Rev B YN R A 1 Inspect the manuals B 1 Batteries and decals B 2 Electrical wiring A 2 Pre operation B 3 Key switch a B 4 Exhaust system ze Los Mos B 5 Engine Air Filter 4 Engine maintenance B 6 Engine maintenance A 5 Hydraulic filter B7 L T condition indicators Perform after 40 hours ESOS Brake configuration B 9 Drive hub maintenance A 6 30 Day Service Perform every 100 hours A 7 Engine maintenance A 8 Rotation bearing 9 Filter separator Perform every 125 hours A 10 Engine maintenance Perform after 150 hours A 11 Replace drive hub oil Perform every 200 hours A 12 Engine maintenance Comments Part No 88619 B 10 Ground control override B 11 Platform self leveling B 12 Engine idle select B 13 Fuel select operation B 14 Drive brakes B 15 Drive speed stowed B 16 Drive speed raised or extended B 17 Alarm and beacon B 18 Hydraulic oil analysis B 19 Engine RPM B 20 Safety envelope and circuits B 21 Primary boom self leveling B 22 Primary boom angle sensor B 23 Fuel and hydraulic tank cap venting system B 24 Engine maintenance Perform every 400 hours B 25 Engine maintenance A TEREX COMPANY
274. onditions may require oil changes to be performed more often Before replacing the hydraulic oil the oil may be tested by an oil distributor for specific levels of contamination to verify that changing the oil is necessary If the hydraulic oil is not replaced at the two year inspection test the oil quarterly Replace the oil when it fails the test Perform this procedure with the boom in the stowed position 1 GM and Ford models Turn the valve on the LPG tank clockwise to the off position if equipped Then slowly disconnect the hose from the LPG tank 2 GM and Ford models Open the clamps from the LPG tank straps and remove the LPG tank from the machine if equipped 3 Models with hydraulic tank shut off valves Locate the two hydraulic tank valves at the hydraulic tank through the access hole underneath the turntable Close the valves A TEREX REV C 4 Place a suitable container underneath the hydraulic tank 5 Remove the drain plug from the hydraulic tank and completely drain the tank into a suitable container Refer to Section 2 Specifications 6 Tag disconnect and plug the two suction hoses and supply hose for the auxiliary pump from the hydraulic tank Cap the fittings on the tank The hoses can be accessed through the access hole under the turntable 7 Tag disconnect and plug the return filter hydraulic hose at the return filter Cap the fitting on the filter housing 8 Remove the ground
275. oss them TEREX COMPANY REV Part No 88619 July 2006 Section 4 Repair Procedures 2 Engines 5 1 How to Remove the Flex Plate RPM Adjustment Refer to Maintenance Procedure B 20 Check and Adjust the Engine RPM 5 2 Flex Plate The flex plate acts as a coupler between the engine and the pump It is bolted to the engine flywheel and has a splined center to drive the pump pump pump shaft pump coupler flex plate with raised spline engine flywheel 0 185 inch 4 7 mm gap Deutz Engines 0 15 inch 3 8 mm gap GM Engines 0 25 inch 6 35 mm gap Ford Engine 0 9 0 25 inch 6 35 mm gap Perkins 804C 33 Engine 0 3 inch 7 6 mm gap Perkins 704 30 Engine A TEREX Part No 88619 Perform this procedure with the engine off and cool to the touch 1 Open the engine side turntable cover 2 Tag and disconnect the battery cables from the batteries AWARNING Electrocution hazard Contact with electrically charged circuits could result in death or serious injury Remove all rings watches and other jewelry 3 Remove the engine tray retaining fastener Swing the engine tray out away from the machine aa aS t M M j ale em a engine tray anchor hole b engine tray retaining fastener 4 Tag and disconnect the wiring plug at the electronic displacement controller EDC located on the drive pump Section 4
276. other jewelry Component damage hazard Electrostatic discharge ESD can damage printed circuit board components Maintain firm contact with a metal part of the machine that is grounded at all times when handling printed circuit boards OR use a grounded wrist strap CAUTION 4 Carefully tag and disconnect the two ribbon cables from the membrane circuit board 5 Remove the LED circuit board retaining fasteners 6 Carefully remove the LED circuit board from the platform control box lid A TEREX REV B 1 2 Membrane Decal How to Replace the Membrane Decal The membrane decal is a special decal that consists of a decal with an electronic membrane on the backside The membrane contains touch sensitive areas that when pushed activates the machine functions The membrane buttons activate machine functions similar to toggle switches but do not have any moving parts 1 Push in the red Emergency Stop button to the off position at both the ground and platform controls 2 Remove the platform control box lid retaining fasteners Open the control box lid 3 Carefully tag and disconnect the two ribbon cables from the membrane circuit board AWARNING Electrocution hazard Contact with electrically charged circuits could result in death or serious injury Remove all rings watches and other jewelry Component damage hazard Electrostatic discharge ESD can damage printed circuit board components Maintain firm
277. ove the filter element 4 Clean the inside of the canister and the gasket with a damp cloth 5 Inspect the air filter element If needed blow from the inside out using low pressure dry compressed air or carefully tap out dust Install the filter element 7 Install the air filter canister end cap and connect the end cap retaining clamp A TEREX COMI Part No 88619 CHECKLIST B PROCEDURES B 6 Perform Engine Maintenance Deutz Models Engine specifications require that this procedure be performed every 250 hours Deutz Models Required maintenance procedures and additional engine information are available in the Deutz 913 Operation Manual Deutz part number 0297 7341 Deutz 913 Operation Manual Genie part number 62446 To access the engine 1 Remove the engine tray retaining fastener located under the engine tray Swing the engine tray out and away from the machine 2 Install the fastener that was just removed through the engine tray and into the engine tray anchor hole in the turntable AWARNING Crushing hazard Failure to install the fastener into the engine tray anchor hole to secure the engine tray from moving could result in death or serious injury Section Scheduled Maintenance Procedures September 2006 CHECKLIST B PROCEDURES B 7 Check the Tires Wheels and Lug Nut Torque Maintaining the tires and wheels in good condition including proper wheel fastener torque is
278. ove the filter with an oil filter wrench Replace the Hydraulic Filter 4 Apply a thin layer of fresh oil to the gasket of Elements the new oil filter 5 Install the new hydraulic return filter element 1647 and tighten it securely by hand Clean up any oil that may have spilled during the installation Genie requires that this procedure be performed annually or every 6 Use a permanent ink marker to write the date 1000 hours whichever comes and number of hours from the hour meter on first Perform this procedure more the oil filter often if dusty conditions exist Medium and high pressure filters Replacement of the hydraulic filters is essential for good machine performance and service life A dirty The medium pressure filter is for or clogged filter may cause the machine to perform the charge pump One high poorly and continued use may cause component pressure filter is for all boom and damage Extremely dirty conditions may require steer functions The other high that the filter be replaced more often pressure filter is for the oscillating axle circuit and platform manifold Bodily injury hazard Beware of ACAUTION hot oil Contact with hot oil may cause severe burns 7 Openthe engine side turntable cover and locate the three filters mounted to the bulkhead Perform this procedure with the engine off Hydraulic return filter 1 Open the ground controls side turntable cover and locate the hydraulic return fi
279. ower the opposite leveling arm Do not remove the pin ACAUTION Cushing hazard The jib boom lift cylinder may fall if not supported when the rod end pivot pin is removed 5 Support the jib boom lift cylinder with a suitable lifting device 6 Remove the pin retaining fastener from the jib boom lift cylinder barrel end pivot pin Use a soft metal drift to remove the barrel end pivot pin and let the cylinder hang down AWARNING Crushing hazard The platform and jib boom lift cylinder could become unbalanced and fall if not properly supported when the jib boom lift cylinder barrel end lift pivot pin is removed 7 Place blocks under the platform leveling cylinder for support 8 Use a soft metal drift to remove the jib boom lift cylinder rod end pivot pin Remove the jib boom lift cylinder from the machine AWARNING Crushing hazard The jib boom lift cylinder could become unbalanced and fall if not properly supported when removed from the machine Section 4 Repair Procedures September 2006 Boom Components REV primary boom lift cylinder link arm primary boom lift cylinder primary boom primary extension boom platform leveling cylinder upper turntable cover lower turntable cover secondary boom lift cylinder secondary boom secondary extension boom secondary boom hose cover primary
280. part number FPP 194 302 Ford LRG 425 EFI Operator Handbook Genie part number 84792 To access the engine 1 Remove the engine tray retaining fastener located under the engine tray Swing the engine tray out and away from the machine 2 Install the fastener that was just removed through the engine tray and into the engine tray anchor hole in the turntable AWARNING Crushing hazard Failure to install the fastener into the engine tray anchor hole to secure the engine tray from moving could result in death or serious injury Genie part number 77738 Genie Part No 88619 Z 80 60 3 17 Section Scheduled Maintenance Procedures September 2006 Checklist B Procedures B 1 Inspect the Batteries Proper battery condition is essential to good engine performance and operational safety Improper fluid levels or damaged cables and connections can result in engine component damage and hazardous conditions There are 2 batteries on this machine One is used in starting the engine and the other is used to power the control system and auxiliary power unit Both batteries are charged by the alternator through a battery separator AWARNING Electrocution hazard Contact with hot or live circuits could result in death or serious injury Remove all rings watches and other jewelry AWARNING Bodily injury hazard Batteries contain acid Avoid spilling or contacting battery acid Neutralize battery acid spills with bak
281. peat steps 3 through 5 for each joystick controlled machine function primary boom up down and turntable rotate left right primary boom extend retract secondary up down and extend retract drive forward reverse and steer left right Once the threshold has been set press and hold the engine start button until the engine shuts off Do not press the red Emergency Stop button Approximately 3 seconds after the engine shuts off the alarm at the ground controls will sound to indicate the threshold settings are being saved in memory Release the button At the ground controls turn the key switch to the off position wait a moment and then turn the key switch to platform controls Check the display at the ground controls to be sure there are no calibration faults Result There should be no calibration faults shown on the display If calibration faults exist repeat this procedure Function speeds Be sure the machine is in the stowed position and the boom is rotated between the square end tires Section 4 Repair Procedures July 2006 PLATFORM CONTROLS 10 Start the engine from the platform controls 11 Select a boom function that needs the function speed set 12 Boom up down and extend retract functions Move the joystick full stroke in the up or extend direction When the alarm sounds move the joystick in the opposite direction full stroke until the alarm sounds again Return the joystick to cent
282. pecification connections very slowly to allow the oil pressure to dissipate gradually Do not allow oil to squirt or spray during installation Refer to 3 Remove the pump mounting fasteners Section 2 Hydraulic Hose and Fitting Torque Specifications 1 Models without hydraulic tank shutoff valves Remove the drain plug from the hydraulic tank and completely drain the tank into a suitable container Refer to Section 2 Specifications Models with hydraulic tank shutoff valves Close the two hydraulic tank valves located at the hydraulic tank Component damage hazard The CAUTION engine must not be started with the hydraulic tank shutoff valves in the closed position or component damage will occur If the tank valves are closed remove the key from the key switch and tag the machine to inform personnel of the condition open closed TEREX COMPANY Part No 88619 Z 80 60 Carefully remove the pump CAUTION Component damage hazard Be sure to open the two hydraulic tank valves if equipped and prime the pump after installing the pump See 7 2 How to Prime the Pump Section 4 Repair Procedures July 2006 HYDRAULIC PUMPS 7 2 Drive Pump The drive pump is a bi directional variable displacement piston pump The pump output is controlled by the electronic displacement controller EDC located on the pump Any internal service to the pump should only be performed at an authorized Sauer Danfoss
283. peed and direction frozen at Power up controller with the problem Value Too Low zero and neutral alarm sounds corrected Value at 0 V Continued on next Genie 2395 A TEREX COMPANY Part No 88619 Z 80 60 5 7 Section 5 Fault Codes July 2006 CONTROL SYSTEM FAULT CODES REV A Error Source Error Type Effects Recovery Actions Limited speed and direction frozen at Power up controller with the problem Fault MN aa does corrected contacts closed message on LCD corrected Value at 5 0 V Value too high Limited speed and direction frozen at Power up controller with problem Value too low zero and neutral alarm sounds corrected STEERING JOYSTICK Value at 0 V Not calibrated Joystick speed and direction frozen at Calibrate joystick zero and neutral Just calibrated Initiate second besp oF audible Self clearing transient warning device Value at 5 0 V Value too high Limited speed and direction frozen at Power up controller with problem Value too low zero and neutral alarm sounds corrected Value at 0 V Value at 5 0 V Value too high Limited speed and direction frozen at Power up controller with problem Value too low zero and neutral alarm sounds corrected Value at 0 Value at 5 0 V Value too high Limited speed and direction frozen at Power up controller with problem Value too low zero and neutral alarm sounds corrected Value at 0 V Value at 5 0 V Value too high
284. place and secure OR repair wiring and or connections to sensor OR replace sensor 243 Never Crank Synced At Start Crankshaft position sensor wiring and or connections open or shorted OR there is a poor system ground connection OR sensor is faulty Be sure system ground connections are in place and secure OR repair wiring and or connections to sensor OR replace sensor A TEREX COMPANY Z 80 60 Part No 88619 July 2006 Section 5 Fault Codes REVA FORD ECM FAULT CODE CHART Code Problem Cause Solution 245 Camshaft Sensor Noise Camshaft position sensor wiring and or connections open or shorted OR there is a poor system ground connection OR sensor is faulty Be sure system ground connections are in place and secure OR repair wiring and or connections to sensor OR replace sensor 253 Knock Sensor Open Knock sensor wiring and or connections open or shorted OR sensor is faulty Repair wiring and or connections to knock sensor OR replace knock sensor 254 Excessive Knock Signal Knock sensor wiring and or connections open or shorted OR there is excessive engine vibration OR sensor is faulty Check for excessive engine vibration OR repair wiring and or connections to knock sensor OR replace knock sensor Injector Driver 1 Open 311 Open wiring and or connections to fuel injector 1 OR fuel injector 1 is faulty OR ECM is faulty Repair w
285. played on the LCD screen at the ground controls Calibrate the platform overload system Refer to Repair Procedure 2 4 How to Calibrate the Platform Overload System if equipped There may be a 2 second delay before the overload indicator lights flash and the alarm sounds Carefully move the test weights to each remaining location on the platform Refer to Illustration 1 Result The alarm should sound The platform overload indicator lights should be flashing at both the ground and platform controls Result The alarm does not sound and the platform overload indicator lights are not flashing Calibrate the platform overload system Refer to Repair Procedure 2 4 How to Calibrate the Platform Overload System if equipped There may be a 2 second delay before the overload indicator lights flash and the alarm sounds Test all machine functions from the platform controls Result All platform control functions should not operate Section 3 Scheduled Maintenance Procedures September 2006 CHECKLIST C PROCEDURES 9 Turn the key switch to ground control 10 Test all machine functions from the ground controls Result All ground control functions should not operate 11 Press and hold the auxiliary power button The engine will turn off when the auxiliary power is activated 12 Using auxiliary power test all machine functions from the ground controls Result All ground control functions shou
286. position 3 way uu Brake release 26 30 ft lbs 35 41 Nm 4 Check valve Keeps brakes released in case of temporary loss of charge pressure 20 25 ft lbs 27 34 Nm 5 Shuttle valve 3 position way Charge pressure circuit that directs hot oil out of low pressure side of drive pump 30 35 ft lbs 41 47 Nm 6 Relief valve 250 psi 17 2 bar EF uu Charge pressure circuit 20 25 ft lbs 27 34 Nm 7 Orifice 0 030 in 0 76 mm FG uus Brake and 2 speed circuit 8 Check valeres ERs east Drive motor anti cavitation 20 25 ft lbs 27 34 Nm 9 Check valve Drive motor anti cavitation 30 35 ft Ibs 41 47 Nm 10 Flow divider combiner valve EJ Controls flow to square end drive motors in forward and reverse 90 100 ft Ibs 122 136 Nm 11 Check valve 5 psi 0 34 bar Drive motor anti cavitation 20 25 ft lbs 27 34 Nm 12 Bi directional flow control valve 2 GPM 7 6 EL uus Equalizes pressure on both sides of divider combiner valve FJ 30 35 ft Ibs 41 47 Nm 13 Bi directional flow control valve 2 GPM 7 6
287. procedure operation at default speed PRIMARY Display message on LCD and allow EXTEND RETRACT SPEED Not calibrated operation at default speed Perform auto calibrate procedure Normal function except threshold for Not calibrated one or the other direction is zero Calibrate thresholds Display message on LCD Initiate one second beep of audible PRIMARY BOOM UP DOWN Just calibrated warming doviba Self clearing transient FLOW VALVE 50 at 50 OV Value Too High Limited speed and direction frozen at Power up controller with the problem Value Too Low zero and neutral alarm sounds corrected Value at 0 V A TEREX COMPANY 5 4 Z 80 60 Part No 88619 July 2006 Section 5 Fault Codes REV A CONTROL SYSTEM FAULT CODES ErrorSource Error Type Effects Recovery Actions UT UNES SAFETY SWITCH P6R1 SAFETY SWITCH P6R2 eem SAFETY SWITCH P7R 200 SAFETY SWITCH P10 Fault check PowerUp ed thie problem ae Gee SAFETY SWITCH P22R SENSOR BOOM EE OVERLOAD Fault check if active Display message on LCD BOOM DOWN OVERLOAD SHUT DOWN MODE Continued on next Genie 2295 A TEREX COMPANY Part No 88619 Z 80 60 5 5 Section 5 Fault Codes July 2006 CONTROL SYSTEM FAULT CODES REV A Error Source Error Type Effects Recovery Actions Value at 5 0 V Value too high Limited speed and direction froz
288. procedure be performed more often Explosion and fire hazard Engine fuels are combustible Perform this procedure in an open well ventilated area away from heaters sparks flames and lighted tobacco Always have an approved fire extinguisher within easy reach Perform this procedure with the engine off 1 Open the engine side turntable cover and locate the fuel filter water separator The fuel filter water separator is located near the hydraulic pump Section 3 Scheduled Maintenance Procedures September 2006 CHECKLIST C PROCEDURES 2 Disconnect and plug the fuel supply hose from the fuel tank to the fuel filter water separator head 3 Loosen the vent plug located on the fuel filter water separator head vent plug b drain plug c filter bowl d separator head 4 Place a suitable container under the filter bowl Loosen the drain plug located at the bottom of the bowl Completely drain the fuel 5 Rotate the filter bowl counterclockwise and remove it from the element 6 Rotate the filter element counterclockwise and remove it from the filter head 7 Install the filter bowl onto the new filter element A TEREX REV C 8 Apply a thin layer of oil onto the element gasket Install the filter bowl assembly onto the filter head Tighten the drain plug and vent plug CAUTION Component damage hazard The drain plug and vent plug can be damaged if they are overtightened 9 Install the
289. r death Used to indicate the presence of an imminently hazardous situation which if not avoided will result in death or serious injury Used to indicate the presence of a potentially hazardous situation which if not avoided could result in death or serious injury Safety alert symbol used to indicate the presence of a potentially hazardous situation which if not avoided may result in minor or moderate injury Without safety alert symbol used to indicate the presence of a potentially hazardous situation which if not avoided may result in property damage Used to indicate operation or maintenance information Indicates that a specific result is expected after performing a series of steps Indicates that an incorrect result has occurred after performing a series of steps Part No 88619 Z 80 60 Section 3 Scheduled Maintenance Procedures July 2006 SCHEDULED MAINTENANCE PROCEDURES Maintenance Symbols Legend The following symbols have been used in this manual to help communicate the intent of the instructions When one or more of the symbols appear at the beginning of a maintenance procedure it conveys the meaning below Indicates that tools will be required to perform this procedure Indicates that new parts will be required to perform this procedure Indicates that a cold engine will be required to perform this procedure Indicates that a warm engine will be required to perform
290. r machine Starter motor Current draw normal load 140 200A Cranking speed 200 250 rpm Battery Engine starting and control system Type 12V DC Group 31 Quantity 2 Cold cranking ampere 1000 Reserve capacity 25A rate 200 minutes Alternator output 80A 14V DC Fan belt deflection 3 8 to 1 2 inch 9 to 12 mm Continuous improvement of our products is a Genie policy Product specifications are subject to change without notice A TEREX COMPANY 2 12 Z 80 60 Part No 88619 September 2006 Section 2 Specifications REV Perkins 704 30 Engine Displacement 183 cu in 3 liters Number of cylinders 4 Bore and stroke 3 82 x 3 94 inches 97 x 100 mm Horsepower 61 2300 rpm 45 5 kW 2500 rpm Firing order 1 3 4 2 Compression ratio 17 5 1 Compression pressure 300 to 500 psi 20 7 to 34 5 bar Pressure psi or bar of lowest cylinder must be within 50 psi 3 45 bar of highest cylinder Low idle 1600 rpm Frequency 246 7 Hz High idle 2300 rpm Frequency 385 4 Hz Governor centrifugal mechanical Valve clearance cold Intake 0 014 in 0 35 mm Exhaust 0 014 in 0 35 mm Lubrication system Oil pressure 2300 rpm 41 psi 2 8 bar Oil capacity 7 4 quarts including filter 7 liters Oil viscosity requirements Units ship with 15W 40 Extreme operating temperatures my require the use of alternative engine oils For oil requirements refer to the Engine Operator Handbook on your
291. rate and burn skin Loosen hydraulic connections very slowly to allow the oil pressure to dissipate gradually Do not allow oil to squirt or spray 14 Place blocks under each end of the secondary boom lift cylinder for support 15 Remove the pin retaining fasteners from the secondary boom lift cylinder rod end pivot pin 16 Use a soft metal drift to remove the pin AWARNING Crushing hazard The secondary boom lift cylinder could become unbalanced and fall if not properly supported when removed from the machine 17 Remove the pin retaining fastener from the secondary boom lift cylinder barrel end pivot pin 18 Use a soft metal drift to remove the pin AWARNING Cushing hazard The secondary boom lift cylinder could become unbalanced and fall if not properly supported when removed from the machine Section 4 Repair Procedures September 2006 BOOM COMPONENTS 19 Remove the secondary boom lift cylinder from the machine by pulling it through the platform end of the secondary boom AWARNING Crushing hazard The secondary boom lift cylinder could become unbalanced and fall if not properly supported when removed from the machine Component damage hazard CAUTION When removing the secondary boom lift cylinder from the machine be careful not to damage the counterbalance valves at the barrel end of the cylinder Component damage hazard CAUTION Cables and hoses can be damaged if the cylinder is pulled acr
292. rd The platform AWARNING could become unbalanced and fall when it is removed from the machine if it is not properly supported A TEREX COMI REV B 2 2 Platform Leveling Cylinder The platform leveling cylinder maintains platform leveling through the entire range of boom motion This allows the platform to be level with the turntable The ECM at the ground controls compares the difference in readings between the platform angle sensor and the turntable level sensor The ECM at the ground controls sends a signal to the platform controls to open or close the appropriate platform level proportional valve on the platform manifold to maintain a level platform The platform leveling cylinder is equipped with counterbalance valves to prevent movement in the event of a hydraulic line failure How to Remove the Platform Leveling 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 2 Hydraulic Hose and Fitting Torque Specifications 1 Extend the boom until the platform leveling cylinder barrel end pivot pin is accessible 2 Raise the jib boom slightly and place blocks under the platform Part No 88619 July 2006 Section 4 Repair Procedures REV 3 Lower the jib boom until the platform is resting on the blocks just enough to support the platform Do not rest the entire weight of the
293. re gauge Refer to Section 2 Specifications 10 Start the engine and raise the primary boom approximately 12 inches 30 cm Remove the 9 Turn the engine off Use a wrench to hold the block and lower the primary boom to the relief valve and remove the cap item U stowed position 11 Turn the engine off and remove the pressure gauge A TEREX COMPANY Part No 88619 Z 80 60 4 65 Section 4 Repair Procedures July 2006 MANIFOLDS 10 Adjust the internal hex socket Turn it clockwise to increase the pressure or counterclockwise to decrease the pressure Install the relief valve cap AWARNING Tip over hazard Do not adjust the relief valve higher than specified 11 Repeat steps 7 through 8 to confirm relief valve pressure 12 Start the engine and fully retract the primary boom Turn the engine off 13 Install the limit switch and bracket assembly to the primary boom 14 Remove the pressure gauge How to Adjust the Secondary Boom Up Relief Valve 1 Remove the cover retaining fasteners from the secondary boom end cover Remove the cover from the machine 2 Locate the wire connector for secondary boom limit switch LSS2AO Disconnect the connector The secondary boom limit switch 582 is the upper limit switch located on the inside of the riser plate at the engine side of the machine 3 Install a jumper wire between pins 3 and 4 of the 662 Deutsch connector on the wire harness end
294. re OR repair wiring and or connections to sensor OR replace throttle position sensor 1 533 TPS2 Signal Voltage High The 2 throttle position sensor wiring and or connections open or shorted OR there is a poor system ground connection OR throttle position sensor 2 is faulty Be sure system ground connections are in place and secure OR repair wiring and or connections to sensor OR replace throttle position sensor 2 534 TPS2 Signal Voltage Low The 2 throttle position sensor wiring and or connections open or shorted OR there is a poor system ground connection OR throttle position sensor 2 is faulty Be sure system ground connections are in place and secure OR repair wiring and or connections to sensor OR replace throttle position sensor 2 363 Megajector internal actuator fault detection Megavector detects an internal fault Open or short in power ground or CAN circuits s Check Power Ground and CAN circuits at Megadector and all connections and repair as necessary OR Megavector has internal fault Contact Ford Power Products for assistance A TEREX COMPANY Z 80 60 Part No 88619 July 2006 Section 5 Fault Codes REV A FORD ECM FAULT CODE CHART Code Problem Cause Solution 535 TPS1 Higher than TPS2 The throttle position sensor wiring and or connections for either TPS1 or TPS2 open or
295. re should be no error message on the LCD display at the ground controls Proceed to step 6 Result The alarm is sounding The platform overload indicator light is flashing at the platform controls and PLATFORM OVERLOAD should is displayed on the LCD screen at the ground controls Slowly tighten overload indicator light should be off at the platform controls and there should be no error message on the LCD display at the ground controls Slowly loosen the load spring adjustment nut in a counterclockwise direction in 10 increments until the overload indicator light flashes at both the platform and ground controls and the alarm sounds Proceed to step 7 the load spring adjustment nut in a clockwise W Result The alarm should be sounding direction in 10 increments until the overload indicator light turns off and the alarm does not sound Proceed to step 8 The platform will need to be moved up and down and allowed to settle between each adjustment There may be a 2 second delay before the platform overload indicator light and alarm responds A TEREX COMPANY Part No 88619 Z 80 60 The platform overload indicator light should be flashing at the platform controls and PLATFORM OVERLOAD should be displayed on the LCD screen at the ground controls Repeat this procedure beginning with step 5 The platform will need to be moved up and down and allowed to settle between each adjustment There may be a 2 s
296. reater than 1000 rpm OR air intake system has leaks OR IAT sensor is faulty Check air intake system for damage and proper routing of air intake components OR replace the IAT sensor 214 IAT Higher Than Expected 2 Air intake temperature is greater than 210 F with the engine greater than 1000 rpm OR air intake system has leaks OR IAT sensor is faulty Check air intake system for damage and proper routing of air intake components OR replace the IAT sensor 215 Oil Pressure Low Faulty oil pressure sensor OR sensor wiring and or connections open or shorted OR engine oil level too low Replace oil pressure sensor OR repair sensor wiring and or connections OR fill engine oil level to specification 221 CHT ECT High Voltage Engine cooling system is malfunctioning OR sensor wires and or connections open or shorted OR sensor is faulty Repair engine cooling system problems OR repair open or shorted wiring to sensor OR replace sensor 222 CHT ECT Low Voltage Engine cooling system is malfunctioning and overheating the engine OR sensor wires and or connections open or shorted OR sensor is faulty OR coolant level is low Repair engine cooling system problems OR repair open or shorted wiring to sensor OR replace sensor OR fill engine coolant level to specification 223 CHT Higher Than Expected 1 Coolant temperature at the cylinder head is 240 F Engine cooling system is malfunctioning
297. ring into the rear of the hub 3 Press the bearing seal evenly into the hub until it is flush 4 Slide the hub onto the yoke spindle Component damage Do not CAUTION apply excessive force or damage to the lip of the seal may occur 5 Place the outer bearing into the hub 6 Install the washer and castle nut 7 Tighten the castle nut to 35 ft lbs 47 Nm to seat the bearing 8 Fully loosen the castle nut then re tighten to 8 ft lbs 11 Nm 9 Install a new cotter pin Bend the cotter pin to secure the castle nut 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 Section 4 Repair Procedures September 2006 AXLE COMPONENTS How to Adjust the Oscillate Limit Switches Tip over hazard Failure to perform this procedure on a firm level surface will compromise the stability of the machine and could cause the machine to tip over which could result in death or serious injury Perform this procedure with the machine on a firm level surface that is free of obstructions Use a digital level to confirm This procedure will require two people 1 Lower the boom to the stowed position 2 Remove the drive chassis cover from the circle end of the machine 3 Remove the oscillate axle limit switch mounting fasteners Remove the limit switches The oscillate axle li
298. rm leveling cylinder may fall if not supported when the rod end pivot pin is removed Part No 88619 July 2006 Section 4 Repair Procedures REV B 3 2 Jib Boom Lift Cylinder How to Remove the Jib Boom Lift Cylinder Perform this procedure with the boom in the stowed position 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 2 Hydraulic Hose and Fitting Torque Specifications 1 Raise the jib boom slightly and place blocks under the platform mounting weldment Lower the jib boom until the platform is resting on the blocks just enough to support the platform Do not rest the entire weight of the boom on the blocks 2 Tag disconnect and plug the jib boom lift cylinder hydraulic hoses Cap the fittings on the cylinder AWARNING 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 TEREX COMPANY Part No 88619 Z 80 60 JIB BOOM COMPONENTS 3 Remove the pin retaining fasteners from the jib boom lift cylinder rod end pivot pin Do not remove the pin 4 Use a soft metal drift to tap the jib boom lift cylinder rod end pivot pin half way out and lower one of the leveling arms to the ground Tap the pin the other direction and l
299. rocedures REV B 7 Move the primary boom extend retract joystick full stroke in the extend direction and hold for 5 seconds then return to the center or neutral position 8 Move the primary boom extend retract joystick full stroke in the retract direction and hold for 5 seconds then return to the center or neutral position Result The alarm at the ground controls should sound for a successful calibration Result If the alarm does not sound repeat calibration procedure Secondary boom up down and extend retract functions 1 Turn the key switch to the off position x PLATFORM CONTROLS Move the secondary boom up down and extend retract joystick full stroke in the up extend direction and hold for 5 seconds then return to the center or neutral position Move the secondary boom up down and extend retract joystick full stroke in the down retract direction and hold for 5 seconds then return to the center or neutral position Result The alarm at the ground controls should sound for a successful calibration Result If the alarm does not sound repeat calibration procedure Primary boom up down functions 1 2 2 Press and hold the enter button on the ground control panel while turning the key switch to platform controls r 3 Press the minus button twice then press the enter button twice 4 Use the scroll button to scroll through the menu until RESET SECONDARY BOOM JO
300. rol box lid retaining fasteners Open the control box lid 6 Locate the ALC 1000 circuit board mounted to the inside of the platform control box A TEREX COMI Part No 88619 PLATFORM CONTROLS 7 Attach a grounded wrist strap to the ground screw inside the platform control box AWARNING Electrocution hazard Contact with electrically charged circuits could result in death or serious injury Remove all rings watches and other jewelry Component damage hazard Electrostatic discharge ESD can damage printed circuit board components Maintain firm contact with a metal part of the machine that is grounded at all times when handling printed circuit boards OR use a grounded wrist strap CAUTION 8 Carefully disconnect the wire connectors from the circuit board 9 Remove the ALC 1000 circuit board mounting fasteners 10 Carefully remove the ALC 1000 circuit board from the platform control box How to Remove the LED Circuit Board 1 Push in the red Emergency Stop button to the off position at both the ground and platform controls 2 Remove the platform control box lid retaining fasteners Open the control box lid Section 4 Repair Procedures July 2006 PLATFORM CONTROLS 3 Locate the LED circuit board mounted to the inside of the platform control box lid AWARNING Electrocution hazard Contact with electrically charged circuits could result in death or serious injury Remove all rings watches and
301. rom the primary boom lift cylinder rod end pivot pin 8 Use a soft metal drift to remove the pin Crushing hazard The primary boom will fall if not properly supported when the pivot pin is removed Crushing hazard The lift cylinder Will fall if not properly supported when the pivot pin is removed ACAUTION Crushing hazard The primary boom lift cylinder linkage arms may fall if not properly supported when the pivot pin is removed 9 Remove the primary boom lift cylinder barrel end pivot pin retaining fasteners A TEREX COMPANY Part No 88619 Z 80 60 pivot pin Remove the primary boom lift cylinder from the machine Crushing hazard The lift cylinder will become unbalanced and fall if not properly supported when the pin is removed Section 4 Repair Procedures September 2006 BOOM COMPONENTS 4 4 Primary Boom Extension Cylinder The primary boom extension cylinder extends and retracts the primary boom extension tube The primary boom extension cylinder is equipped with counterbalance valves to prevent movement in the event of a hydraulic line failure How to Remove the Primary Boom Extension Cylinder AWARNING Bodiy injury hazard This procedure requires specific repair skills lifting equipment and a suitable workshop Attempting this procedure without these skills and tools could result in death or serious injury and significant component damage Dealer service is strongly recommended
302. rotation lock pin SING unlocked locked Section Scheduled Maintenance Procedures September 2006 CHECKLIST D PROCEDURES 2 Remove the motor brake mounting bolts and 5 then remove the motor and brake from the drive hub and set them to the side Component damage hazard 6 CAUTION Hoses can be damaged if they are kinked or pinched 7 8 a motor b motor brake mounting bolts c brake d drive hub e drive hub mounting bolts 3 Remove the drive hub mounting bolts and use a lifting device to remove the drive hub from the machine 4 Remove the plug from the side of the drive hub Drain the oil from the hub into a container of adequate capacity Refer to Section 2 Specifications 3 56 Z 80 60 REV Install the drive hub Torque the drive hub mounting bolts to specification Refer to Section 2 Specifications Install the brake and motor onto the drive hub Torque the motor brake mounting bolts to specification Refer to Section 2 Specifications Fill the hub with oil from the side hole until the oil level is even with the bottom of the hole Apply pipe thread sealant to the plug Install the plug Adjust turntable rotation gear backlash Refer to Repair Procedure 9 1 How to Adjust the Turntable Rotation Gear Backlash Part No 88619 September 2006 Section Scheduled Maintenance Procedures REV D 6 Perform Engine Maintenance Diesel Models En
303. round control and pull out the red Emergency Stop buttons out to the on position at both the ground and platform controls 2 Press and hold the enter button until the engine symbol appears the display at the ground control box 3 Enter sensor calibration mode by pressing the buttons at the ground controls in the following sequence 41 41 4 Press the scroll button until PRIMARY BOOM ANGLE 70 is shown on the display 5 Press the plus button to select yes then press and hold the enter button a to accept 6 Press the scroll button until Exit is shown the display Press the plus button to select yes then press and hold the enter button to accept Result The alarm should sound Result The alarm does not sound Repeat this procedure beginning with step 1 Part No 88619 September 2006 Section 4 Repair Procedures REV 7 Loosen the Primary Boom Angle Sensor PBAS assembly bracket fasteners attached to the primary boom Loosen the wing nut and hex nut on the threaded rod to allow the threaded rod to move upward Tighten the fasteners 8 Seta digital level on top of the mast so it is viewable from the ground controls 9 Start the engine 10 Raise the boom until the digital level displays 70 11 Loosen the wing nut from threaded rod and move the threaded rod down until the engine turns off 12 Screw threaded rod into clevis yoke Tig
304. rt No 88619 September 2006 Section 3 Scheduled Maintenance Procedures REV Medium and high pressure filters The medium and high pressure filters are mounted to the engine side bulkhead 4 Inspect the filter condition indicators high pressure filters b filter condition indicators c medium pressure filter A 6 CHECKLIST A PROCEDURES Perform 30 Day Service The 30 day maintenance procedure is a one time A 8 B 7 B 9 B 24 Result The filter condition indicators should be operating with the plungers in the green area If 0 6 any of the indicators display the plunger in the red area this indicates that a hydraulic filter is being bypassed and the filter needs to be replaced See D 7 Replace the Hydraulic Filter Elements Part No 88619 sequence of procedures to be performed after the first 30 days or 40 hours of usage After this interval refer to the maintenance checklists for continued scheduled maintenance 1 Perform the following maintenance procedures Grease the Turntable Rotation Bearing and Rotate Gear Check the Tires Wheels and Lug Nut Torque Check the Drive Hub Oil Level and Fastener Torque Perform Engine Maintenance Perform Engine Maintenance Gasoline LPG Models Check the Turntable Rotation Bearing Bolts Perform Engine Maintenance Diesel Models Replace the Hydraulic Filter Elements TEREX COMPANY Section
305. s on the pumps AWARNING 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 88619 July 2006 Section 4 Repair Procedures REV B 4 Support the pumps with a suitable lifting device and remove the two drive pump mounting fasteners 5 Carefully pull the drive pump out until the pump coupler separates from the flex plate 6 Remove the drive pump assembly from the machine Component damage hazard CAUTION Be sure to open the two hydraulic tank valves and prime the pump after installing the pump Before installing the pump verify proper pump coupler spacing See 5 2 Flex Plate How to Prime the Pump 1 Connect a 0 to 600 psi 0 to 50 bar pressure gauge to the test port on the drive pump 2 Remove the safety pin if equipped from the engine tray latch The engine tray latch is located under the engine tray at the counterweight end of the machine 3 Remove the engine tray retaining fastener Swing the engine tray out away from the machine E qe ee un ae gt a engine tray anchor hole b engine tray retaining fastener A TEREX COMI Part No 88619 HYDRAULIC PUMPS 4 Locate the engine tray anchor hole at the pivot end of the engine tray 5 Install the bolt removed s
306. s switch and tag the machine to 20 Install the supply hose for the auxiliary power inform personnel of the condition unit and the return filter hose Models with hydraulic tank shut off valves 21 Open the two hydraulic tank valves at the hydraulic tank 0 22 Fill the tank with hydraulic oil until the level is M within the top 2 inches 5 cm of the sight gauge Do not overfill me open close 23 Clean up any oil that may have spilled Genie Part No 88619 Z 80 60 3 61 Section Scheduled Maintenance Procedures September 2006 CHECKLIST E PROCEDURES E 2 Grease the Steer Axle Wheel Bearings 2WD Models Maintaining the steer axle wheel bearings is essential for safe machine operation and service life Operating the machine with loose or worn wheel bearings may cause an unsafe operating condition and continued use may result in component damage Extremely wet or dirty conditions or regular steam cleaning and pressure washing of the machine may require that this procedure be performed more often 1 Loosen the wheel lug nuts Do not remove them 2 Block the non steer wheels then center a lifting jack with a minimum capacity of 25 000 Ibs 12000 kg under the drive chassis between the steer wheels 3 Raise the machine 6 inches 15 cm and place blocks under the drive chassis for support 4 Select a wheel Remove the lug nuts and remove the tire and wheel assembly 5 Check for wheel bearing wear by attemp
307. s and additional engine information are available in the Deutz 913 Operation Manual Deutz part number 0297 7341 OR the Deutz BF4L2011 Operation Manual Deutz part number 0297 9929 Deutz 913 Operation Manual CHECKLIST E PROCEDURES Perkins Models Required maintenance procedures and additional engine information are available in the Perkins 704 30 User s Handbook Perkins part number TPD 1336E OR the Perkins 804C 33 Operation and Maintenance Manual Perkins part number SEBU7853 00 Perkins 704 30 User s Handbook Genie part number 101840 Perkins 804C 33 Operation and Maintenance Manual Genie part number 111332 To access the engine 1 Remove the engine tray retaining fastener located under the engine tray Swing the engine tray out and away from the machine 2 Install the fastener that was just removed through the engine tray and into the engine tray anchor hole in the turntable AWARNING Crushing hazard Failure to install the fastener into the engine tray anchor hole to secure the engine Genie part number 62446 tray from moving could result in death or serious injury Deutz BF4L2011 Operation Manual Genie part number 84794 Genie Part No 88619 Z 80 60 3 65 Section Scheduled Maintenance Procedures September 2006 CHECKLIST E PROCEDURES E 6 Perform Engine Maintenance Deutz Models Engine specifications require that this procedure be performed every 5000 hours
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309. sec 12 2 m 66 sec Gradeability Refer to Operator s Manual Braking distance maximum High range on paved surface 90 Continuous improvement of our products is Genie policy Product specifications are subject to change without notice A TEREX COMPANY 2 2 Z 80 60 Part No 88619 September 2006 Section 2 Specifications REV Function Speeds Specifications Function speeds factory settings Primary boom up stowed retracted 35 to 65 57 to 63 seconds Primary boom down stowed retracted 35 to 65 50 to 56 seconds Secondary boom up stowed 60 to 70 seconds Secondary boom down stowed 60 to 70 seconds Primary boom up unstowed 35 to 65 80 to 96 seconds Primary boom down unstowed 35 to 65 80 to 96 seconds Boom extend stowed 48 to 52 seconds Boom retract stowed 38 to 42 seconds Turntable rotate 360 boom fully stowed 114 to 126 seconds Turntable rotate 360 boom unstowed 200 to 240 seconds Part No 88619 A TEREX Boom function speeds maximum from platform controls SPECIFICATIONS Jib boom up 40 to 55 seconds Jib boom down 40 to 55 seconds Primary boom up 75 to 120 seconds Primary boom down 75 to 120 seconds Secondary boom up 120 to 180 seconds Secondary boom down 120 to 180 seconds Secondary boom ex
310. service center Contact the Genie Industries Service Department to locate your local authorized service center How to Remove the Drive Pump CAUTION Component damage hazard The work area and surfaces where this procedure will be performed must be clean and free of debris that could get into the hydraulic system and cause severe component damage Dealer service is recommended 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 2 Hydraulic Hose and Fitting Torque Specifications 1 Disconnect the wire harness at the electronic displacement controller EDC located on the drive pump A TEREX REV B 2 Models without hydraulic tank shutoff valves Remove the drain plug from the hydraulic tank and completely drain the tank into a suitable container Refer to Section 2 Specifications Models with hydraulic tank shutoff valves Close the two hydraulic tank valves located at the hydraulic tank Component damage hazard The CAUTION engine must not be started with the hydraulic tank shutoff valves in the closed position or component damage will occur If the tank valves are closed remove the key from the key switch and tag the machine to inform personnel of the condition closed 3 Tag disconnect and plug the hydraulic hoses at the drive and function pumps Cap the fitting
311. ssure 2300 rpm 320 psi Neutral position 22 bar Secondary boom down relief pressure 2500 psi measured at PTEST port 172 bar Function pumps Secondary boom up relief pressure 2500 psi Type two section tandem gear pump measured at Presr port 172 bar Displacement Pump 1 inner 1 94 Primary boom extend relief pressure 1300 psi 31 8 measured at Presr port 89 6 bar Flow rate 2300 rpm 17gP Secondary boom extend relief pressure 2600 psi 64 4 L min measured at port 179 bar Displacement Pump 2 outer 0 58cuin platform manifold relief pressure 3000 psi 9 5 cc 207 bar Flow rate 2300 rpm 5 gpm Platform manifold flow regulator 3 gpm 19 L min 11 4 L min Continuous improvement of our products is a Genie policy Product specifications are subject to change without notice Genie Part No 88619 Z 80 60 2 5 Section 2 Specifications SPECIFICATIONS Oscillate manifold Oscillate relief pressure item GG 800 psi 55 1 bar Platform manifold Platform level flow regulator item CH 1 gpm 0 38 L min Drive manifold Hot oil relief pressure 280 psi 19 3 bar Brakes Brake release pressure 215 psi 14 8 bar Drive motors Displacement per revolution variable 0 9 to 2 7 cu in 2 speed motor 14 7 to 45 cc Hydraulic tank return filter High pressure filter Beta 3 gt 200 High pressure filter 102 psi bypass pressure 7 bar Medium pressure filter Beta 3 gt 200 Medium press
312. sts Return to Perform service problem repair solved A TEREX COMPANY Part No 88619 Z 80 60 6 1 Section 6 Schematics July 2006 Wire Circuit Legend Circuit numbering 1 Circuit numbers consist of three parts the circuit prefix circuit number and circuit suffix The circuit prefix indicates the type of circuit The circuit number describes the function of the circuit The circuit suffix provides an abbreviation for the number or may be used to further define the function of this portion of the REV B Circuit suffix Definition Suffix AC Generator GEN Alternator Field AF Angle ANG Auxiliary Boom Valve ABV Auxiliary Forward Valve AFV Auxiliary Hydraulic Pump AH circuit It also may be used to indicate the final Auxiliary Platform Valve APV end of the circuit i e LS or limit sw Auxiliary Reverse Valve ARV 2 22 number may be used more than once A 2 Valve AE Axle Axle Retract Valve AXR For Example Axle Front Position FAP 74 PL This is the circuit for the lockout Axle Rear Position RAP valve 1 C stands for control 74 is the number of the circuit Battery BAT for the primary 1 lock out valve Boom Extended BEX PL stands for Primary Lockout Boom Stowed BST S 62 BST This is the circuit that communicates to the onboard Brake BRK computers of the machine that the boom is fully stowed S Bypass Valves BV stands for safety 62 is the number of the circuit for boo
313. support and slide the extension cylinder out of the boom extension AWARNING Crushing hazard The extension cylinder could fall when removed from the extension boom if not properly supported Component damage hazard Be careful not to damage the primary boom angle sensor PBAS when removing the cylinder from the primary boom CAUTION Component damage hazard Hoses and cables can be damaged if they are kinked or pinched CAUTION Note the length of the cylinder after removal For ease of installation the cylinder must be at the same length for reinstallation A TEREX COMI Part No 88619 BOOM COMPONENTS 4 5 Primary Boom Angle Sensor A properly functioning primary boom angle sensor PBAS is essential to safe machine operation The primary boom angle sensor is used to limit the angle of the primary boom relative to the angle of the secondary boom and gravity The ECM at the ground controls TCON monitors the position and angle of the primary boom using the signal from PBAS The PBAS signal is used to control the ramping of the primary boom as well as velocity control limiting the speed of the primary boom to 1 3 feet 0 4 meters per second How to Replace the Primary Boom Angle Sensor Perform this procedure on a firm level surface with the boom in the stowed position 1 Remove the retaining fasteners from the boom end cover at the pivot end of the primary boom Remove the cover from the machine
314. t in death or serious injury 4 Be sure that all nuts and bolts are tight 5 Inspect all welds for cracks 6 Inspect for exhaust leaks i e carbon buildup around seams and joints 7 Remove the engine tray retaining fastener from the engine tray anchor hole at the pivot end of the engine tray 8 Swing the engine tray in towards the machine Install the bolt that was just removed into the original hole to secure the engine tray Crushing hazard Failure to install the bolt into the engine tray to secure it from moving could result in death or serious injury A TEREX COM REV C B 5 Inspect the Engine Air Filter Genie requires that this procedure be performed every 250 hours or quarterly whichever comes first Perform this procedure more often if dusty conditions exist Maintaining the engine air filter in good condition is essential to good engine performance and service life Failure to perform this procedure can lead to poor engine performance and component damage Perform this procedure with the engine off 1 Open the engine side cover Empty the dust discharge valve by pressing together the sides of the discharge slot Clean the discharge slot as needed retaining clamp canister end cap c dust discharge valve om Part No 88619 September 2006 Section 3 Scheduled Maintenance Procedures REV 2 Disconnect the retaining clamp from the air cleaner canister Rem
315. t 75 of the highest cylinder Low idle no load 1300 rpm Frequency 385 7 Hz High idle no load 2300 rpm Frequency 570 4 Hz Valve clearance cold Intake 0 006 in 0 15 mm Exhaust 0 006 in 0 15 mm Lubrication system Oil pressure 40 to 60 psi 2 75 to 4 14 bar Oil capacity 14 3 quarts including filter 13 5 liters Oil viscosity requirements Units ship with 15W 40 Extreme operating temperatures my require the use of alternative engine oils For oil requirements refer to the Engine Operator Handbook on your machine Continuous improvement of our products is a Genie policy Product specifications are subject to change without notice A TEREX REV Injection system Injection pump make IMSA Injection pump pressure 8702 psi 600 bar Injector opening pressure 3626 psi 250 bar Fuel Requirement For fuel requirements refer to the engine Operator s Manual on your machine Batteries Type 12V DC Group 31 Quantity 2 Cold cranking ampere 1000A Reserve capacity 25A rate 200 minutes Alternator output 55A 12V DC 3 8 to 1 2 inch 9to 12 mm Fan belt deflection Part No 88619 September 2006 Section 2 Specifications REV Deutz BF4L 2011 Engine Displacement 189 6 cu in 3 1 liters Number of cylinders 4 3 7 x 4 409 inches 94 x 112 mm Bore and stroke Horsepower 69 1 2500 rpm 51 5 kW 2500 rpm Continuous 72 8 2500 rpm
316. t the wire connectors from 8 the platform control box 2 Tag disconnect and plug the hydraulic hoses from the counterbalance valve manifold located 9 on the platform rotator Cap the fittings on the manifold AWARNING 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 TEREX COMPANY Part No 88619 Z 80 60 BOOM COMPONENTS Remove the mounting fasteners from the outlet box Remove the outlet box and lay to the side Remove the hose clamp from the platform support Tag and disconnect the electrical connector from the platform angle sensor The platform angle sensor is mounted to the platform rotator Tag and disconnect the electrical connectors for the foot switch and jib boom limit switch Remove the platform manifold mounting fasteners Remove the manifold and lay to the side CAUTION Component damage hazard Cables and hoses can be damaged if they are kinked or pinched Remove the hose and cable cover retaining fasteners from the jib boom Remove the hose and cable cover from the machine Remove the hose and cable clamp from the jib boom pivot pin ACAUTION Crushing hazard The jib boom may fall if not supported when the jib boom pivot pin is removed Section 4 Repair Procedures September 2006 BOOM COMPONENTS 10 Tag disconnect and plug
317. t with electrically charged circuits could result in death or serious injury Remove all rings watches and other jewelry Component damage hazard CAUTION Electrostatic discharge ESD can damage printed circuit board components Maintain firm contact with a metal part of the machine that is grounded at all times when handling printed circuit boards OR use a grounded wrist strap A TEREX COMPANY REV A Carefully remove the membrane decal from the control box lid while guiding the ribbon cables out of the control box lid Remove any decal adhesive from the control box lid with a mild solvent Component damage hazard CAUTION Certain solvents can damage LCD display Do not allow any solvent to come in contact with the LCD display screen Install the new membrane decal onto the control box lid while guiding the ribbon cables through the control box lid Connect the ribbon cables to the ECM circuit board Close the control box lid and install the retaining fasteners Part No 88619 July 2006 Section 4 Repair Procedures 2 Hydraulic Pumps 7 1 2 Tag disconnect and plug the hydraulic hoses at Function Pump the function pump Cap the fittings on the How to Remove the Function AWARNING Podily injury hazard Spraying hydraulic oil can penetrate and Pump burn skin Loosen hydraulic When removing a hose assembly or fitting the O ring on the fitting and or hose end must be replaced and then torqued to s
318. tend 25 to 40 seconds Secondary boom retract 25 to 40 seconds Primary boom extend 32 to 45 seconds Primary boom retract 32 to 45 seconds Turntable rotate 360 boom fully stowed 78 to 86 seconds Turntable rotate 360 boom raised or extended 165 to 185 seconds Platform rotate 160 10 to 16 seconds Continuous improvement of our products is a Genie policy Product specifications are subject to change without notice Section 2 Specifications September 2006 SPECIFICATIONS Hydraulic Specifications Hydraulic Oil Specifications Hydraulic oil type Chevron Rykon MV equivalent viscosity grade Multi viscosity Viscosity index rating 200 Cleanliness level minimum 15 13 Water content maximum 200 ppm Chevron Rykon MV oil is fully compatible and mixable with Shell Donax TG Dexron oils Genie specifications require hydraulic oils which are designed to give maximum protection to hydraulic systems have the ability to perform over a wide temperature range and have a minimum viscosity index rating greater than 140 They should provide excellent antiwear oxidation corrosion inhibition seal conditioning and foam and aeration suppression properties Continuous improvement of our products is a Genie policy Product specifications are subject to change without notice Genie Optional fluids REV Biodegradable Petro Canada Environ M
319. tep 2 Extend the boom until the wear pads are accessible Loosen the wear pad mounting fasteners Install the new shims under the wear pad to obtain zero clearance and zero drag Tighten the mounting fasteners Extend and retract the boom through an entire cycle Check for tight spots that could cause binding or scraping Always maintain squareness between the outer and inner boom tubes Part No 88619 September 2006 Section 4 Repair Procedures REV Wear Pad Specifications Primary boom wear pad specifications Top bottom and side wear pads platform end of boom Side and bottom wear pads pivot end of boom Top wear pads pivot end of boom Secondary boom wear pad specifications Top and side wear pads extension end of boom Bottom wear pads extension end of boom Top wear pads pivot end of boom Bottom and side wear pads pivot end of boom BOOM COMPONENTS How to Remove the Primary Boom Minimum AWARNING Bodily injury hazard This procedure requires specific repair skills lifting equipment and a 5 8 inch suitable workshop Attempting this 15 9 mm procedure without these skills and tools could result in death or 1 2 inch serious injury and significant 12 7 component damage Dealer service is strongly recommended 5 8 inch 15 9 mm Perform this procedure with the boom in the stowed position Minimum When removing a hose assembly or fitting the O ring on the fi
320. tep 4 into the anchor hole to secure the engine tray from moving AWARNING Crushing hazard Failure to install the bolt into the engine tray to secure it from moving could result in death or serious injury 6 Deutz and Perkins models Tag and disconnect the engine wiring harness from the fuel shutoff solenoid at the injector pump GM and Ford models Close the valve on the LPG tank Disconnect the hose from the tank Move the fuel select switch to the LPG position 7 Have another person crank the engine with the starter motor for 15 seconds wait 15 seconds then crank the engine an additional 15 seconds or until the pressure reaches 320 psi 22 bar 8 Deutz and Perkins models Connect the engine wiring harness to the fuel solenoid GM and Ford models Connect the LPG hose to the LPG tank and open the valve on the tank 9 Start the engine from the ground controls and check for hydraulic leaks Section 4 Repair Procedures July 2006 Manifolds 8 1 Function Manifold View 1 The function manifold is located next to the ground control box Index Schematic No Description Item Function 1 Differential sensing valve Secondary boom up extend and down retract 2 Relief valve 2500 psi 172 bar B Secondary boom 3 Solenoid valve 2 position 2 way C Secondary boom up circuit 4 Relief valve 2500
321. the Perkins 704 30 User s Handbook Perkins part number TPD 1336E OR the Perkins 804C 33 Operation and Maintenance Manual Perkins part number SEBU7853 00 Perkins 704 30 User s Handbook Genie part number 101840 Perkins 804C 33 Operation and Maintenance Manual Genie part number 111332 To access the engine 1 Remove the engine tray retaining fastener located under the engine tray Swing the engine tray out and away from the machine Genie part number 62446 2 Install the fastener that was just removed through the engine tray and into the engine tray Deutz BF4L2011 Operation Manual anchor hole in the turntable Genie part number 84794 AWARNING Crushing hazard Failure to install the fastener into the engine tray anchor hole to secure the engine tray from moving could result in death or serious injury C 2 Genie Part No 88619 Z 80 60 3 43 Section 3 Scheduled Maintenance Procedures September 2006 CHECKLIST C PROCEDURES Grease the Platform Overload Mechanism if equipped Genie specifications require that this procedure be performed every 500 hours or 6 months whichever comes first Perform this procedure more often if dusty conditions exist Application of lubrication to the platform overload mechanism is essential to safe machine operation Continued use of an improperly greased platform overload mechanism could result in the system not sensing an overloaded platform condition and will res
322. the opposite leveling arm Do not remove the pin 11 Use a soft metal drift to remove the platform level cylinder rod end pivot pin 12 Carefully pull the platform leveling cylinder out of the boom Crushing hazard The jib boom ACAUTION cylinder will fall if not properly supported when the platform level cylinder rod end pivot pin is removed How to Bleed the Platform Leveling Cylinder Do not start the engine Use auxiliary power for all machine functions in this procedure 1 Raise the jib boom to a horizontal position 2 Push the platform level up and down buttons through two complete platform leveling cycles to remove any air that might be in the system Section 4 Repair Procedures July 2006 PLATFORM COMPONENTS 2 3 Platform Rotator The platform rotator is a hydraulically activated helical gear assembly used to rotate the platform 160 degrees How to Remove the Platform Rotator Component damage hazard Mark CAUTION the platform mounting weldment and the rotator flange before removing the platform mounting weldment The platform mounting weldment must be replaced in the exact same position on the rotator flange as it was before removal If a new rotator is installed or the rotator is disassembled proper alignment can be achieved by rotating the rotator all the way to the left and then installing the platform mounting weldment all the way in the left position When removing a hose assembly or f
323. this procedure Indicates that dealer service is required to perform this procedure Bis Ei A TEREX REV B Pre delivery Preparation Report The pre delivery preparation report contains checklists for each type of scheduled inspection Make copies of the Pre delivery Preparation report to use for each inspection Store completed forms as required Maintenance Schedule There are five types of maintenance inspections that must be performed according to a schedule daily quarterly six months annual and two years The Scheduled Maintenance Procedures Section and the Maintenance Inspection Report have been divided into five subsections A B C D and E Use the following chart to determine which group s of procedures are required to perform a scheduled inspection Inspection Checklist Daily or every 8 hours A Quarterly or every 250 hours A B Six months or every 500 hours A B C Annual or every 1000 hours A B C D Two years or every 2000 hours A B C D E 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 Part No 88619 Pre Delivery Preparation Fundamentals It is the responsibility of the dealer to perform the Pre delivery Preparation The Pre delivery Preparation is performed prior to each d
324. ting to move the wheel hub side to side then up and down Result There should be no side to side or up and down movement A TEREX REV Skip to step 10 if there is no movement 6 Remove the dust cap from the hub then remove the cotter pin from the castle nut 7 Tighten the castle nut to 35 ft lbs 47 Nm to seat the bearings 8 Fully loosen the castle nut then re tighten to 8 ft lbs 11 Nm 9 Check for wheel bearing wear by attempting to move the wheel hub side to side then up and down O Result If there is side to side or up and down movement continue to step 11 and replace the wheel bearings with new ones When replacing a wheel bearing both the inner and outer bearings including the pressed in races must be replaced O Result If there is no side to side or up and down movement continue with step 11 and grease the wheel bearings 10 Remove the dust cap from the hub then remove the cotter pin from the castle nut 11 Remove the castle nut 12 Pull the hub off of the spindle The washer and outer bearing should fall loose from the hub 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 88619 September 2006 Section 3 Scheduled Maintenance Procedures REV 15 Place the large inner bearing into the rear of the hub 16 Install a new bearing grease s
325. tion coil 2 shorted OR ignition coil 2 is faulty Repair wiring and or connections to ignition coil 2 OR replace ignition coil 2 If this fault appears on your machine contact 51 1 PPPT High Voltage Norusod Genie Industries Service Department If this fault appears on your machine contact 51 2 EowVoltage Not used Genie Industries Service Department If this fault appears on your machine contact 51 3 ER Genie Industries Service Department 514 FPP1 Lower than IVS Limit Not used If this fault appears on your machine contact Genie Industries Service Department If this fault appears on your machine contact 521 High Voltage Not usad Genie Industries Service Department 522 FPP2 Low Voltage Not used If this fault appears on your machine contact Genie Industries Service Department 531 TPS1 Signal Voltage High The 1 throttle position sensor wiring and or connections open or shorted OR there is a poor system ground connection OR throttle position sensor 1 is faulty Be sure system ground connections are in place and secure OR repair wiring and or connections to sensor OR replace throttle position sensor 1 532 TPS1 Signal Voltage Low The 1 throttle position sensor wiring and or connections open or shorted OR there is a poor system ground connection OR throttle position sensor 1 is faulty Be sure system ground connections are in place and secu
326. tting 5 8 inch and or hose end must be replaced 15 9 mm and then torqued to specification during installation 1 2 inch Refer to Section 2 Hydraulic Hose 12 7 mm and Fitting Torque Specifications 1 2 inch 1 Remove the jib boom 12 7 mm See 3 1 How to Remove the Jib Boom inch 2 Remove the fasteners securing the limit switch 22 2 mm to the primary boom at the pivot end of the boom Do not disconnect the wiring Move the limit switch to a safe location 3 Tag and disconnect the wire harness from the primary boom angle sensor PBAS The primary boom angle sensor is located inside the primary boom at the pivot end Genie Part No 88619 A TEREX COMPANY Section 4 Repair Procedures September 2006 BOOM COMPONENTS 4 Tag disconnect and plug the primary boom extension cylinder hydraulic hoses Cap the fittings on the cylinder AWARNING 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 5 Attach a lifting strap from an overhead crane to the barrel end of the primary boom lift cylinder 6 Remove the pin retaining fasteners from the primary boom lift cylinder barrel end pivot pin 7 Place blocks under both ends of the primary boom lift cylinder for support 8 Use a soft metal drift to remove the barrel end pivot pin Rest the barrel end of the primary boom cylin
327. ult in component damage 1 Locate the grease fittings on each pivot pin of the platform overload assembly 2 Thoroughly pump grease into each grease fitting using a multi purpose grease Grease Specification Chevron Ultra duty grease EP NLGI 2 lithium based or equivalent 4 Using a suitable lifting device place appropriate test weight equal to that of the maximum platform capacity in one of the locations shown A TEREX COM REV C C 3 Test the Platform Overload System if equipped Genie specifications require that this procedure be performed every 500 hours or 6 months whichever comes first Testing the platform overload system regularly is essential to safe machine operation Continued use of an improperly operating platform overload system could result in the system not sensing an overloaded platform condition Machine stability could be compromised resulting in the machine tipping over Perform this procedure with the machine on a firm level surface 1 Turn the key switch to platform control Start the engine and level the platform 2 Determine the maximum platform capacity Refer to the machine serial plate 3 Remove all weight tools and accessories from the platform Failure to remove all weight tools and accessories from the platform will result in an inaccurate test Part No 88619 September 2006 Section Scheduled Maintenance Procedures REV 4 Using a suita
328. ure filter 51 psi bypass pressure 3 5 bar Hydraulic tank return filter 10 micron with 25 psi 1 7 bar bypass Continuous improvement of our products is a Genie policy Product specifications are subject to change without notice A TEREX COMI September 2006 lt REV C Manifold Component Specifications Plug torque SAE No 2 50 in Ibs 6 Nm SAE No 4 14 ft lbs 18 9 Nm SAE No 6 23 ft lbs 31 2 Nm SAE No 8 36 ft lbs 48 8 Nm SAE No 10 62 ft lbs 84 1 Nm SAE No 12 84 ft lbs 113 9 Nm Valve coil resistance specifications Proportional solenoid valve 12V DC 4 to 60 schematic items G R and BB 3 position 4 way solenoid valve 12V DC 4 5 to 6 50 schematic items GB GP and GQ 3 position 4 way solenoid valve 10V DC 5 to 70 schematic items O S BA BB CA CB CP and CQ 2 position 2 way solenoid valve 10V DC 5 5 to 7 50 schematic items C and P 2 position 3 way solenoid valve 10V DC 4 5 to 6 50 schematic items H J V X Z AA BC BD CE CF EE EF FB and FC Part No 88619 September 2006 Section 2 Specifications REV GM 3 0L EFI Engine Displacement 181 cuin 3 liters Number of cylinders 4 Bore amp stroke 4 x 3 6 inches 101 6 x 91 44 mm Horsepower Intermittent 67 2300 rpm 49 kW 2300 rpm Continuous 60 2300 rpm 45 kW 2300 rpm Firing order 1 3 4 2 Low idle 1650 rpm Frequency 386 1 Hz High idle 23
329. ured with the turntable rotation lock pin Key switch in the off position with the key removed Wheels chocked All external AC power supply disconnected from the machine A TEREX COM Part No 88619 Repair Procedures About This Section Most of the procedures in this section should only be performed by a trained service professional in a suitably equipped workshop Select the appropriate repair procedure after troubleshooting the problem Perform disassembly procedures to the point where repairs can be completed To re assemble perform the disassembly steps in reverse order Symbols Legend A 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 Used to indicate the presence of an imminently hazardous situation which if not avoided will result in death or serious injury AWARNING Used to indicate the presence of a potentially hazardous situation which if not avoided could result in death or serious injury With safety alert symbol used to ACAUTION indicate the presence of a potentially hazardous situation which if not avoided may cause minor or moderate injury Without safety alert symbol used to indicate the presence of a potentially hazardous situation which if not avoided may result in property damage CAUTION Used to indicate operation or maintenance informatio
330. ve hubs could result in death or serious injury and property damage All models 13 Be sure the free wheel valve on the drive pump is closed clockwise The free wheel valve is located on the drive pump and should always remain closed drive pump b screwdriver lift pump d free wheel valve Section 3 Scheduled Maintenance Procedures September 2006 CHECKLIST D PROCEDURES D 3 Check the Turntable Rotation Bearing Bolts Maintaining proper torque on the turntable bearing bolts is essential to safe machine operation Improper bolt torque could result in an unsafe operating condition and component damage 1 Raise the secondary boom approximately 8 feet 2 4 m 2 Remove the engine tray retaining fastener Swing the engine tray out away from the machine FFL er aa a engine tray anchor hole b engine tray retaining fastener 3 Locate the engine tray anchor hole at the pivot end of the engine tray A TEREX COMPS REV 4 Install the bolt that was just removed into the anchor hole to secure the engine tray from moving AWARNING Crushing hazard Failure to install the bolt into the engine tray to secure it from moving could result in death or serious injury 5 Confirm that each turntable mounting bolt is torqued in sequence to specification Refer to Section 2 Specifications 28 1 24 5 20 O 9 6 09 Og 12 0 17 O 21 o 25
331. ve the cover A TEREX COMI REV C 7 Locate secondary boom 1 retract operational limit switch LSS1RO at the end of the secondary boom 8 Carefully disconnect the wire harness from LSS1RO and install a wire jumper between pin 1 and pin 2 of the deutsch connector on the wire harness 9 Install a second wire jumper between pin 3 and pin 4 of the deutsch connector on the wire harness Result The display should show ort 10 Press and hold the low speed function enable button and lower the secondary boom Result The secondary boom should lower to 60 and the engine should stop W Result If the engine does not stop at 60 and the secondary boom continues to lower the secondary boom 2 angle safety limit switch LSS2AS is out of adjustment or the wiring circuit is faulty and will need to be replaced or repaired AWARNING Bodiy injury hazard If the secondary boom lowers to less than 60 without stopping the engine stop immediately and raise the secondary boom above 60 Failure to raise the secondary boom could result in death or serious injury 11 Remove the wire jumpers installed in steps 8 and 9 and connect the wire harness to LSS1RO Part No 88619 September 2006 Section 3 Scheduled Maintenance Procedures REV Secondary Boom 1 Retracted Safety Limit Switch LSS1RS 12 Simultaneously push the LCD screen buttons shown to activate status
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333. wed position 1 Create start and finish lines by marking two lines on the ground 40 feet 12 2 m apart 2 Start the engine from the platform controls 3 Press the engine rpm select button until the foot switch activated high idle rabbit and foot switch symbol is selected 4 Choose a point on the machine i e contact patch of a tire as a visual reference for use when crossing the start and finish lines 5 Bring the machine to top drive speed before reaching the start line Begin timing when your reference point on the machine crosses the start line 6 Continue at full speed and note the time when the machine reference point crosses the finish line Refer to Section 2 Specifications Part No 88619 September 2006 Section 3 Scheduled Maintenance Procedures REV B 16 Test the Drive Speed Raised or Extended Position Proper drive function movement is essential to safe machine operation The drive function should respond quickly and smoothly to operator control Drive performance should also be free of hesitation jerking and unusual noise over the entire proportionally controlled speed range Select a test area that is firm level and free of obstructions 1 Create start and finish lines by marking two lines on the ground 40 feet 12 2 m apart 2 Start the engine from the platform controls 3 Press the engine rpm select button until the foot switch activated high idle rabbit and foot switch sym
334. 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 M 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 TEREX COMPANY Part No 88619 Z 80 60 V Section 1 Safety Rules September 2006 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 A 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 Used to indicate the presence of an imminently hazardous situation which if not avoided will result in death or serious injury Used to indicate the presence of a AWARNING potentially hazardous situation which if not avoided could result in death or serious injury With safety alert symbol used
335. y inspect the cable track and determine which 4 link section needs to be replaced 2 Carefully remove the snap rings from each end of the damaged section of cable track 3 Remove the retaining fasteners from the upper black rollers from the 4 link section of cable track to be replaced Remove the rollers 4 Lift up the hoses and cables and carefully remove the damaged 4 link section of cable track CAUTION Component damage hazard Hoses and cables can be damaged if they are kinked or pinched 5 Remove the upper rollers from the replacement section of cable track 6 Lift up the hoses and cables and carefully insert the new 4 link section of cable track CAUTION Component damage hazard Hoses and cables can be damaged if they are kinked or pinched TEREX COMPANY Section 4 Repair Procedures September 2006 BOOM COMPONENTS 7 Connect the ends of the replacement cable track section to the existing cable track using the snap rings 8 Install the rollers onto the new section of cable track 9 Operate the boom extend retract function through a full cycle to ensure smooth operation of the cable track A TEREX REV 4 2 Primary Boom How to Shim the Boom 1 Measure each wear pad Result Each wear pad meets minimum specification Proceed to step 2 Result Each wear pad does not meet minimum specification Replace any wear pad that does not meet minimum specification Proceed to s
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337. ylinder Perform this procedure on a firm level surface with the boom in the stowed position 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 2 Hydraulic Hose and Fitting Torque Specifications 1 Rotate the boom until the turntable counterweight is between the circle end and square end tires A TEREX Part No 88619 AXLE COMPONENTS 2 Tag disconnect and plug the oscillating axle cylinder hydraulic hoses Cap the fittings on the oscillate cylinder AWARNING 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 3 Remove the pin retaining fasteners from the oscillate cylinder rod end pivot pin Use a soft metal drift to remove the pin 4 Attach a lifting strap from an overhead crane to the barrel end of the oscillating cylinder 5 Remove the pin retaining fasteners from the oscillate cylinder barrel end pivot pin Use a soft metal drift to remove the pin Crushing hazard The oscillate ACAUTION cylinder may become unbalanced and fall if not properly supported when removed from the machine 6 Remove the oscillate cylinder from the machine Section 4 Repair Procedures September 2006 aos This page intentionally le
338. z z HWd9 S19d601d HNWH9 S18d60Ld P PIND AVS 5 PE 10 gt E if 58 als SIXV A 93A 56 0102 E Sua 1 HSNS LLL 55 1 1 GNDDCN BR P21DCN WH P53LS WH BK S56PRV RD 8d9 qQN9 HSNS S56PRV RD GNDDCN BR P21DCN WH P53LS WH BK Continued on View 9 6 27 enie Z 80 60 A TEREX COMPANY G Part No 88619 July 2006 Section 6 Schematics Electrical Schematic View 10 Limit Switches July 2006 Section 6 Schematics Electrical Schematic View 11 Deutz F4L 913 Engine before serial number 339 Section 6 Schematics July 2006 Electrical Schematic View 11 REV B Deutz F4L 913 Engine before serial number 339 A B C D E F O I c 2

88619 Z-80/60 Service Manual

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