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Service Manual - Genie Industries

1. N st o co WHT 23 P 2 gt g 5 BLK 22 Z a 5 99 2 BLK 26 M 9 gt i BLK RED 35 v 2 BLU RED 39 8 Zaz 2 cc cue 69x WHT 1 H P L cect BRN 2 H P L o ae eo BLU BLK 37 OLE BLU 36 GRN WHT 19 EUN 81 19 9 WHT BLK 31 mu Y WHT 30 O LC WHT RED 32 OCF WHT 21 O m o GEN OPTION 45 GRN WHT 1 m GRN WHT 45 Q B SPARE 44 GRN BLK 1 g RY 43 E m O SPARE GRN 1 m GRN 25 N SPARE 42 ORG RED 1 op BLK 33 41 tr 40 FUEL SELECT 39 BLU RED 1 2 den CHECK ENGINE 38 BLU WHT 1 E STEER RIGHT 37 BLU BLK 1 BLU WHT 12 STEER LEFT 36 BLU 1 SERE AA 35 BLK RED 1 Vr SPARE 34 BLK WHT 1 BLU WHT 38 e 8 START 33 BLK 1 BRAKE 32 WHT RED 1 RED 10 H P L E D C 31 WHT BLK 1 RED WHT 29 E D C 30 WHT 1 BLU BLK 11 O_O 2WD 4WD 29 RED WHT 1 1 i CON TILT ALARM 28
2. LFT DRV SELECT OPTION N o BRN 2 GROUND 2 m a i gt 5 A BLU RED 3 FE a 3 2 DRIVE ENABLE WHT 1 B 717 LIMIT SWITCH E g 85 y g _ e B EE DRIVE ENABLE E BLU WHT 3 gt 5 5 3 WHT BLK 1 FP jr DRIVE EDC a WHT RED 1 E g SON DRIVE BRAKE VALVE BLU 1 B STEER LEFT BLU BLI 1 627 0 STEER RIGHT 5 4 n AUXILIARY STEER g RELAY O BU RD 4 AUXILIARY STEER g 5 z VALVE tr RED WHT REDAWHT 1 B Ps m HIGH gt 8 MOTOR STROKE RE 21 Low 250n ed i sg BLK door ES 9 az aED WHT 8 BRN 8 SECONDARY BOOM UP T LIMIT SWITCH o 32 ORG 1 wars BRN 6 PRIMARY BOOM UP LIMIT SWITCH i E T 7 BRN 7 BOOM EXTEND lug a LIMIT SWITCH igo ud p c TZET 42 0050 i SEJA _
3. Part No 52856 Genie Z 60 34 ema CELIAE V V NOILOAS SSANUV Sti MTIS NHO JNIDN3 oL 6 S18 VL2 LHM 91 H3 8R1HM v dau n8 NOILdO VSETTIH LNOLND 13437 NWHOJLVId O FE 785 NOlLdO vZeg niag 1no1no 8 H33 NH9G 21919319 13437 GION3 1OS d NH8 d INHOd 1V 1d VIZ O3H 1 51 8LYO H3 385Ha8 1251 099 aang 1 HHWSIYTS z pi 9SrasH q1gvo5 922 19 6 INSI LHM grz a34 2251 28 ZHO LHM H33 Hfid LHM 8 18 GONnOHS NH8 SEZ LHM 1H NHH Z WSI LHM es HOLIMS 3119901 3NION3 MO3HO 318vo V9 G3H LHM o O 6 CH an ssvdAg aay O SL 4 Cee 9 VSEIHITIG
4. THROTTLE ACTUATOR FORD WIRING HARNESS WIRE COLOR CODE 1 POSITION SENSOR POWER FUEL PUMP STARTER CODE CODE CODE ORFE GRFC COLOR COLOR COLOR FUEL INJECTOR VALVES d BL BLUE GY GREY PURPLE 4 3 2 1 55 5 8 8 8 BK BLACK LB LIGHT BLUE R RED m d Eod m d SATEH NO I NR lis BR BROWN LG LIGHT GREEN T TAN 0 ol tie he bX bX bX bX SU s it Ba DB DARK BLUE N NATURAL w WHITE DARK GREEN ORANGE Y YELLOW LI 2 GREEN PK PINK a g M g 8 3 545 3 8g 5 gs 28 5 28 a8 599 g22o 568 9585 FORD ENGINE CONTROL MODULE ECM 23 vo 39 25 aS 553 25 ZOMO 9550 QUICK DISCONNECTS 2 zz sao Saas oa 25 Basa TO ECM 8 x S 55 s SHOWN 95TW18 IGNITION COIL 1 Y Fi NOT USED i r3 e o 361LR18 K1 VPWR 3 37BY18 F2 KEEP ALIVE PWR B NOTUSED c 5 uS NOTUSED 3 349DB18 G1 CRANKSHAFT SENSOR RETURN 1 9 350GY18 H2 CRANKSHAFT SENSOR RETURN EE D 282DB O18 di CAMSHAFT SENSOR FEED 1 a ta
5. NOTE CIRCUIT CONNECTION TO TB24 FOR UNITS WITHOUT GENERATOR OPTION Service Manual Electrical Schematic A Diesel Models Section 6 Schematics HIGH T RPM ENGINE SPEED L D B m BLK RED 1 io in OZ BLK REDHRA E H 8 a d RPM SOLENOID e FUNCTION ENABLE HIGH RPM y Y HIGH IDLE RELAY O d HIGH IDLE CUTOUT e RELAY 144 GENERATOR S ON 4 GRN WHT 1 GRN WHT 4 GENERATOR D OPTION 3 5 O osciLATE VALVE No 8 u lt 8 59 9 po 5 z z e w 8 OSCILLATE RELAY E RD 8 BK 8 BK 6 RD 6 N H J TNR 995 CE PLATFORM LEVEL um DISABLE OPTION a J gt 82 Ds gt WHT 5 BLK 5 PRIMARY BOOM LIFT zu a E 8 z s 6 z gt SECONDARY BOOM LIFT lt 8 xo T 9 N OSCILLATE LOCKOUT x PI BLK 1 lt 5 zoo x 8 ENGINE 2 5 amp E WNT RED 26 oz OIL TEMPERATURE 5 55652589996 NI gt SENDER ENGINE 8
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7. Part No 52856 SSANYVH b day rng H3 6eiorig HUGE HETHA gtt Y189 NY9 V V NOILO3S 01 6 S18 VI2 LHM aorma ge dasoria G9I Q3H OHO azz y18 E uus NOILdO GUO Nu8 v4z aau 4 TJ3A31 IAHOA1V 1d Gu FdSU 5UO 4noino v4 48 n8 5 13431 v9E TTIH 8O g INYOSLW 1d aLZ LHM H 3 LHf 018 8LHO WSILOnS 18v9 Y z 1go qad gse a3u rig8 WS 6RLHM WSI 9 034 inv oN3 Ob RUIT NO T3D3 NOI 6 er ssvdAg O 4 OH TFI AH3LIVG 9 31979 9 s GH sus mE No xv gt 31naow AndNI 1HVIS mE 1HVLS NDI 2 O SIPOg odo St Avia Lavis O1 gesigoria a 01 5 SZE C3H IHM p y M dae SZe rig mg g SFIHM eu VrE1HMOTTG C2 99 118 9 2 SSX IBIHM 318vo2 BLZ LHM g 8478 vera GNNOYD OF Li 88 LHW 18 vH go Moy 901 118 1 U OL 881 X18 NY9 a re gings zo T Sri 0HO A jg 51
8. AREE RET TABLE OF CONTENTS Section Five Troubleshooting Flow Charts continued 4 Engine Will Not Start On LPG But Will Start On Gasoline Gasoline EP G Models rere iter rre fern 5 14 5 Engine Will Not Start On Gasoline But Will Start On LPG Gasoline LP G 5 16 6 Engine High Idle Inoperative Gasoline LP G 5 17 7 Engine Low Idle Inoperative Gasoline LP G Models 5 18 8 Engine High Idle Inoperative Deutz Diesel Models 5 19 9 Engine Low Idle Inoperative Deutz Diesel Models 5 21 10 AllFunctions Inoperative Engine Starts and Runs 5 22 11 AllLiftand Steer Functions Inoperative Drive Functions Operational 5 23 12 Ground Controls Inoperative Platform Controls Operate Normally 5 24 13 Platform Controls Inoperative Ground Controls Operate Normally 5 25 14 Primary Boom Up Function Inoperative 5 26 15 Primary Boom Down Function Inoperative 5 30 16 Secondary Boom Up Function Inoperative 5 33 17 Secondary Boom Down Function
9. 6 10 Electrical Schematic Diesel 4 2 memes 6 12 Ground Control Box Wiring Diagram Diesel Models 6 14 Platform Control Box Wiring Diagram Diesel 6 15 Hydraulic Symbols 1 6 17 2W D Hydraulic S iet t eade b a bets em a dete 6 18 AWD Hydraulic Schematic eee e eben IH dte ede tn 6 19 Repair Procedures 7 1 Platform Controls l l Joystick Controllers 2 9 3o n Xe RR e eee m e 7 2 1 2 Horsepower Limiter memes 7 6 1 32 aee te Teide ea p et aTa 7 8 PartNo 52856 Genie Z 60 34 ix Service Manual Second Edition 2 M MMMR TABLE OF CONTENTS Section Seven Repair Procedures continued T A eade E Ee do 7 9 1 5 Toggle SwIIChes c ire ne ee ree 7 9 Platform Components 2 1 Platform iuto bete a a ana e ae 7 10 2 2 Platform Leveling Slave 00 7 10 2 3 Platform Rotators eee Er ed A eaten aera ens 7 11 Jib Boom Components 3 1 ID BOOM eie n ie ere d ho
10. 4 39 D 2 Change or Recondition the Engine Coolant Gasoline LP G Models 4 41 D 3 Change the Fuel Hoses 5 ee 4 42 D 4 Check the Engine Valve Clearance Gasoline LP G Models 4 43 D 5 Check the Engine Cylinder Compression Gasoline LPG Models 4 43 D 6 Cleanthe PCV Hoses and Fittings Gasoline LP G Models 4 44 D 7 Check the Fuel Injection Pumps and Injectors Deutz Diesel Models 4 44 D 8 Check the Toothed Belt Deutz Diesel 4 44 D 9 Replace the Timing Belt Gasoline LP G Models 4 44 D 10 Grease the Steer Axle Wheel Bearings 2WD Models 4 45 Troubleshooting Flow Charts INTO AUCTION ete 5 1 Reds 5 3 1 Engine Will Not Crank Over 5 6 2 Engine Cranks Over But Will Not Start Gasoline LP G Models 5 8 2A Engine Runs While Cranking Then Dies Gasoline LP G Models 5 10 3 Engine Cranks Over But Will Not Start Deutz Diesel Models 5 11 PartNo 52856 Genie Z 60 34 vii Service Manual Second Edition
11. 2 Counter balance sandwich valve manifold Biss 3 3 position 4 way 003 valve o 4 Check valve see Dres 5 3 position 4 way 003 valve Exams 6 3 position 4 way 003 valve 7 3 position 4 003 valve GO ise 8 3 position 4 way 003 valve Buses 9 Check valve 10 Flow regulator valve 11 Relief valve 1200 psi 83 bar Kee 12 Relief valve 1800 psi 124 bar 13 Relief valve 1600 psi 110 bar M 14 Proportional solenoid valve 15 Flow regulator valve o 16 Normally closed poppet valve 2 position 3 Pus This list continues Please turn the page Plug Torque Specifications control box Function J ib boom up down and platform rotate left right Platform level up down Platform level up down Differential sensing circuit turntable rotate left right and primary boom extend retract Turntable rotate left right Secondary boom up down Primary boom up down Primary boom extend retract Differential sensing circuit primary and secondary boom Primary and secondary boom prevents overflowing the proportional valve Primary boom extend Primary boom down
12. z WHT BLK 25 OIL PRESSURE START i SENDER oz Wah gt HOUR METER f N P leow 8 8 o2 jE WHT 21 E H PLUG BLK WHT 1 m FUEL SOLENOID N E leow 5 a PLUG E BLK WHT GLOW PLUG OPTION POWER RELAY go az GLOW PLUG OPTION F 5 pepe 3 BLK R1 E H 5 n Ew 5 C EJ STARTER MOTOR ES i AUXILIARY b E PUMP M EOM EE g ED 27 E x AUXILIARY N RED RED 27 E H 7 AUXILIARY POWER F TONNE RED 1 imd d 5 AUXILIARY PUMP Eo 2 N c RED RED BLK 1 RED BLK 28 E H RED WHT 23 E H gt e AM LEVEL SENSOR g S gt i m Ln Z 2 o o N a oO Xq T BLK RED E BLK RED 3 zs BLK RED 2 HORN i NI 2 N RELAY B 59 BLK 2 BLK R5 E H HORN a Q kz tr 88 es _ m x wo ORG BLK 1 ORG BLK 41 E H N T a c u PES Ea x m lt 1 5 bi i Ee e 9 all d imi ie 3 53 E 8 55 5 84 ac 6 w 3 N RED B RED 20 E H m Diesel Models A Section 6 Schematics Electrical Schematic Service Manual
13. 4 18 B 7 Inspect the Electrical 4 19 B 8 Inspect the Tires and Wheels including lug nut torque 4 19 B 9 Confirmthe Proper Brake Configuration 200 4 20 B 10 Check the Torque Hub Level and Fastener Torque REV B 4 21 B 11 Check and Adjust the Engine 0 0 04440 00 4 22 B 12 Test the Key Switch eene 4 23 B 13 Test the Emergency Stop 4 23 14 Testthe Ground Control Override 4002 1 4 24 B 15 Test the Platform Self leveling seseeeeeennnne 4 24 16 Test the eere eere pee teense 4 24 B 17 Testthe rotor op d E rper ree x a eene dees 4 24 B 18 Test the Engine Idle 1 4 25 B 19 Test the Fuel Select Operation Gasoline LPG Models 4 26 B 20 Test the Drive Enable 4 26 B 21 Test the Drive 4 1 4 27 B 22 Test the Drive Speed Stowed 4 27 B 23 Test the Alarm Package Optional 4 28 B 24 Perform H
14. WHT 21 E H ci 510 _ RED E H a PA E ORG BLK 1 E ORG BLK 41 E H 4 8 8 tr pP 1 Lo T x I ld 5 iB 18 1 rig ii E 5184 8129 x a RED F RED 20 EH N o Part No 52856 Genie Z 60 34 6 8 Section 6 Schematics Service Manual Electrical Schematic Gasoline LPG Models A B N mMm Ww Kej BRN 2 2 2 2 m E B 2 BLU RED 3 E gt 2 8 S 8 8 WHT 1 i gt 2 g 8 a zo g 2 E x E DRIVE ENABLE E BLU WHT 3 E E ut WHT BLK 1 X DRIVE EDG z i WHT RED 1 E G H g z 8 E BLU 1 B LO BLU BLK 1 o H g 6 BUIRD 4 78 i RED WHT 1 9
15. Floyd Bell Inc XB 09 630 Q 1 Alarm chime tone 45462 Floyd Bell Inc 09 525 1 19506 nes ENM Corporation T40A4508 1 KSI iuuenes Contact Keyswitch N O 45081 Telemecanique 2 2 101 2 LED Red 12V 323352359 Arctolectric Corp LE177C39007 1 S1 2 3 550 Contact Limit switch 19491 Telemecanique 2051 3 Level sensor Level sensor 4 5 44586 Power Comp of 1536 22 1 Pl P2 Contact N C seen 29732 Telemecanique ZB2 BE102 4 Contact 45081 Telemecanique 2 2 101 1 This list continues on the next page 6 2 Genie Z 60 34 Part No 52856 Service Manual Second Edition Section 6 Schematics Item Description Genie Part Part Number 1 Relay 12V DC continuous 27155 Stancor Ren Resistor 1000 25 watt Resistor 2500 25 watt R
16. Part No 52856 Genie Z 60 34 Section 5 Troubleshooting Flow Charts Service Manual Second Edition FAULT CODES Fault rotiem cause solton Intake Air Temperature IAT sensor high voltage Fuel pump high voltage Heated Oxygen HO 42 sensor high voltage Engine Coolant Temperature ECT sensor low voltage Intake Air Temperature IAT sensor low voltage Low oil pressure IAT sensor signal is greater than or equal to 4 93V DC for at least 3 seconds Fuel pump is receiving voltage when the ECM is not sending the signal to the fuel pump to turn ON A leaking or malfunctioning fuel injector misfiring cylinder faulty TP sensor or contamination from fuel OR use of improper thread sealant on sensor threads OR sensor wires shorted to ground or poor terminal connections OR HO sensor is bad ECM detects a excessively low signal voltage from the ECT sensor ECM detects a excessively low signal voltage from the IAT sensor Bad oil pressure switch wires shorted to ground or not enough engine oil Check for poor terminal connections or shorted wires from the IAT sensor to the ECM to ground OR replace IAT sensor Test the fuel pump relay see the Repair Section OR check for poor terminal connections from the fuel pump relay to fuel pump OR replace the ECM Test for a leaking or malfunctioning fuel injector misfiring cylinder or bad TP sensor Remove se
17. e 355GY W18 C1 THROTTLE POSITION SENSOR INPUT i 4 238ADG YI8 F3 FUEL PUMP MONITOR i NOTUSED i Y2 NOTUSED W3 NOT USED c D 555 18 53 FUEL INJECTOR 1 i 556W18 S2 FUEL INJECTOR 2 ct 557BR Y18 S1 FUEL INJECTOR 3 EE 558BR LB18 1 FUEL INJECTOR 4 i 2 11T Y20 351BR W18 2 VREF HETE H 1 16AR LG16 77DB Y18 R2 DRY FUEL MODULATOR SPEI 8 37BY18 B3 NOTUSED 4 16 2 39RW20 C2 NOT USED 1 4 t 37Y12 E 570BK W18 X2 POWER GROUND A qst qe 512 767PK BK16 570ABK W18 4 POWER GROUND 31 9 351DBR W20 4 p arog lt Wi POWER GROUND _1_2_ 7 34 570CBKWI2 4 e 570HBK W18 W2 POWER GROUND dB gue 22 a amp 37 18 209W P20 107P20 1 DATA LINK f 3 8 805 24 306T LB20 151LB BK20 1 DRIVE BY WIRE PSLI G20 SELF TEST INPUT x 2 674BR W20 306T LB20 12 GOVERNOR SELECT 1 M 11 914T 020 307BK Y20 K2 GOVERNOR SELECT 2 gt 2 EMEN D EFI o i ied PRESTR 5 674BR W20 1575 3591 GY Y20 4 914T O20 2 DATA LINK CONNECTOR EEE P 13 32R LB16 915PK LB20 N2 DATA LINK CONNECTOR 28 j 253DG W20 926ALB O16 FUEL PUMP RELAY CONTROL d i H M3 NOT USED 359FGY R20 B2 SINGLE RETURN i N3 NOTUSED 1 NOTUSED
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20. Cold cranking ampere 1000A Intake 0 012 in 0 3 mm Reserve capacity 25A rate 200 minutes Exhaust 0 020 in Fan belt deflection 3 3 to 4 2 inch 0 5 9 to 12 mm Lubrication system Oil pressure 26 to 87 psi 1 8to 6 0 bar Oil capacity 11 quarts including filter 10 5 liters Cil viscosity requirements Temperature below 60 F 15 5 C synthetic 5W 30 10 F to 90 F 23 to 32 C 10W 40 Temperature above 4 F 34 C 15W 40 Engine oil should have properties of API classification CC SE CD SE CC SF or CD SF grades Injection system Injection pump make OMAP PartNo 52856 Genie Z 60 34 2 5 Section 2 Specifications Service Manual Second Edition pu J o o SPECIFICATIONS Hydraulic Hose and Fitting Torque Specifications Your machine is equipped with Parker S eal Loke O ring face seal fittings and hose ends Machines that utilize Parker Seal Loke O ring face seal fittings and hose ends require that the fittings and hose ends be torqued to specification when they are removed and installed or when new hoses or fittings are installed Hydraulic Hose and Fitting Torque Specifications SAE O ring Boss Port tube iting SAE Dash Installing SAE Dash 24 4 j eds 36 27 gt 399 6 mnm 23 e 39 a mnm 49 44 60 0 Aummm 69 95 pe Steel jgtea 39 Amn
21. Gasoline LP G Models D 5 Check the Engine Cylinder Compression Gasoline LP G Models D 6 Clean the PCV Hose and Fittings Gasoline LP G Models D 7 Check the Fuel Injection Pump and Injectors n Deutz Diesel Models D 8 Check the Toothed Belt Deutz Diesel Models D 9 Replace the Timing Belt Gasoline LP G Models D 10 Grease the Steer Axle Wheel Bearings 2WD Models 3 6 Genie Z 60 34 Part No 52856 Service Manual Second Edition Section 3 Scheduled Maintenance Inspections 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 page to use for each inspection Select the appropriate checklist s for the type of inspection to be performed Daily Inspection A Quarterly Inspection Annual Inspection 2 Year Inspection A B C D Place a check in the appropriate box after each inspection procedure is completed the maintenance tables in this section and the step by step procedures in section 4 to learn how to perform these inspections If any inspection receives an 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 N no remove from service R repaired Comments Checklist A Refer to Table A B 20 Drive enable
22. pls 743GY20 D1 INTAKE AIR TEMP SENSOR 358LG BK20 B1 MAP SENSOR INPUT 354LG R18 D2 ECTSENSOR 1 dtl i T2 N USAGE x 342LG P16 L3 STARTER LOCKOUT dis H Et NOT USED i Y 6 264W LB18 R1 IDLE AIR CONTROL i 225BK Y20 D3 DRY FUEL SENSOR U 253BDG W20 13 OIL PRESSURE 57BK18 2420018 P2 DRYFUEL LOCKOFF MATING FACE 961 018 IGNITION COIL 2 SHOWN 74GY LB18 E2 25 SENSOR SIDE D 1 1 a 1 a N wo ono NO wn wr on POSG 85 283 S2 892 S2 85 98 95 Saag a 55805 2g 329 59 58 2 52 58 99 552552 7 Pb B ss 380 5293 58 8 59 38 S880 85 14 peg a S 8 885 89 2 8 6 wy 1 WIRES ARE LABELLED WITH FORD CIRCUIT NUMBER COLOR AND WIRE GUAGE L one EXAMPLE 74GY LB18 MEANS CIRCUIT 74 GREY WIRE WITH LIGHT BLUE STRIPE 18 GUAGE WIRE i z A msie THE DIAGNOSTIC 2 INTERNAL SPLICES ARE NOT SHOWN 2 ret GROUND CONTROL BOX CONNECTOR 9 OIL PRESSURE Bis eg SWITCH NC ENGINE wo HEATED Sah COOLANT A m AW G INTAKE AIR 8 OXYGEN eno 4 TEMPERATURE U 5 TEMPERATURE SENSOR Eo SENSOR MANIFOLD SENSOR 25 Bere 5 ABSOLUTE 020 IAT moo PRESSURE mos 5zo di SENSOR 8032 mo 5939 925 29 Soz 29 i LPG LOCKOUT RELA
23. 2 Remove the upper and lower retaining clips from the gas strut 3 Gently pry the strut pivot sockets off of the ball studs and remove the strut P rotect the strut cylinder rod from damage Mark the location of the hinge support bracket on the bulkhead to ensure proper cover alignment during installation 4 Remove the cover hinge bolts that fasten the hinge support bracket to the bulkhead Turntable Covers 5 Carefully lift and remove the cover from the machine AWARNING AWARNING Bodily injury hazard Safety decals are essential to safe machine operation Failure to replace all safety and instructional decals could result in death or serious injury If a turntable cover must be replaced be sure that all appropriate safety and instructional decals are applied to the new cover Crushing hazard The turntable cover may become unbalanced and fall if itis not properly supported and secured to an appropriate lifting device Alignment adjustments may be necessary when a new cover is installed PartNo 52856 Genie Z 60 34 Section 7 Repair Procedures Service Manual Second Edition Deutz Engine FAL 1011F 7 1 RPM Adjustment Refer to Maintenance Procedures B 12 Check and Adjust the Engine RPM 7 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 OO pump
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25. 7 Remove the pin retaining fasteners from the slave cylinder rod end pivot pin and the slave cylinder barrel end pivot pin Do not remove the pins 8 Use a soft metal drift to remove the barrel end pivot pin 9 Tag disconnect and plug the hydraulic hoses from the slave cylinder Cap the fittings on the cylinder Bodily injury hazard S praying AWARNING 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 10 Pull the hoses up through the platform rotator CAUTION Component damage hazard Hoses can be damaged if they are kinked or pinched 11 Remove the pin retainer from the slave cylinder rod end pivot pin and the rotator pivot pin 12 Use a soft metal drift to drive both pins out then remove the platform rotator from the machine Genie Z 60 34 Part No 52856 Service Manual Second Edition Section 7 Repair Procedures How to Bleed the Platform Rotator Do notstart the engine Use auxiliary power for all machine functions in this procedure 1 Connecta clear hose to the top bleed valve Place the other end ofthe hose in a container to collect any discharge a top bleed valve b X bottom bleed valve C container d clearhose 2 Open the top bleed valve but do not remove it 3 Startthe engine from the ground controls 4 Hold the platform rotate switch to the right for
26. Lower the primary boom to the stowed position Does the oscillate cylinder fully retract yes Start the engine from the ground controls and raise the secondary boom approximately 2 feet 0 6 m Does the oscillate cylinder fully extend yes Continued on the next page Section 5 Troubleshooting Flow Charts Turn the engine off and less place a block between than the rod end wedge and 250 psi the cylinder barrel to prevent the cylinder from retracting Install a 0 to 1500 psi 103 bar pressure gauge at the quick disconnect coupling on the function manifold Start the engine then raise the primary boom 2 feet 0 6 m and check the pressure 250 psi Check voltage at 43 0V 12V Check voltage at TB42 oV Check voltage at the blk 9 wire on the oscillate 12V solenoid valve item HH Lower the boom to the less than stowed position and turn 2 400 the engine off Install a 0 a to 3000 psi 207 bar gauge to the test port on the function manifold then place a block between the rod end wedge on the oscillate cylinder and the wedge stop on the axle to prevent the cylinder from extending Start the engine and raise the secondary boom 2 feet 0 6 m Check the pressure on the gauge 2400 psi CHART 33 Adjust the oscillate relief valve item GG to 250 psi 17 bar OR check to make sure LS1 is not being activated OR replace LS1 contact
27. PRIMARY BOOM COMPONENTS How to Disassemble the Primary Boom Complete disassembly of the primary boom is only necessary if the outer or inner primary boom tubes must be replaced The extension cylinder can be removed without completely disassembling the primary boom See 4 4 How to Remove the Extension Cylinder 1 Remove the primary boom See 4 2 How to Remove the Primary Boom 2 Place blocks under the extension cylinder for support 3 Remove the cotter pin from the extension cylinder barrel end pivot pin Use a soft metal drift to remove the pin 4 Remove and label the wear pads from the platform end of the primary boom Pay careful attention to the location and amount of shims used with each wear pad 5 Supportand slide the extension boom and extension cylinder out of the platform end of the primary boom Crushing hazard The extension AWARNING boom may become unbalanced and fall when itis removed from the primary boom if is not properly supported 6 Remove the external snap rings from the extension cylinder rod end pivot pins Use a soft metal drift to remove the pins 7 Supportand slide the extension cylinder out of the platform end of the extension boom 8 Remove and label the wear pads from the extension boom Pay careful attention to the location and amount of shims used with each wear pad PartNo 52856 Genie Z 60 34 7 21 Section 7 Repair Procedures Service Manual Second Editi
28. Remove the block and check for mechanical restrictions keeping oscillate cylinder from retracting OR replace oscillate cylinder Repair open in wht wire with diode from TB21 to TB43 Adjust LS4 so that it is activated when the secondary boom is raised 2 feet 0 6 m OR repair LS4 or replace LS4 contact Replace CR9 Adjust system relief valve item W to 2400 psi 165 bar Remove the block and check for mechanical restrictions keeping oscillate cylinder from extending OR replace oscillate cylinder Part No 52856 Genie Z 60 34 5 77 Section 5 Troubleshooting Flow Charts N CHART 33 Continued from the previous page Lower the secondary boom to the stowed position Does the oscillate cylinder fully retract yes Start the engine from the ground controls and rotate the turntable until the boom is past one of the non steer tires Does the oscillate cylinder fully extend yes Continued on the next page Service Manual Second Edition Turn the engine off and less place a block between than the rod end wedge and 250 psi the cylinder barrel to prevent the cylinder from retracting Install a 0 to 1500 psi 103 bar pressure gauge at the quick disconnect coupling on the function manifold Start the engine then raise the secondary boom 2 feet 0 6 m and check the pressure 250 psi Check for continuity to ground on the yellow co
29. A Apply pipe thread sealant to the plug and then install it in the torque hub Check the torque hub mounting fasteners Torque the fasteners to 160 ft Ibs 217 Nm Repeat this procedure for each drive torque hub Drive Torque Hub Oil eletrical rotary coupler torque hub plug brake Capacity 40 fluid ounces 1 2 liters ao oo Type SAE 90 multipurpose hypoid gear oil API service classification GL5 Part No 52856 Genie Z 60 34 4 21 Section 4 Scheduled Maintenance Procedures Service Manual Second Edition May 2007 TABLE B PROCEDURES 4 f necessary add oil until the oil level is even with the bottom of the side plug hole then re install the plug into the hub Turntable Rotate Torque Hub Oil 8 fluid ounces 0 24 liters Capacity TypeSAE 90 multipurpose hypoid gear oil API service classification GL5 5 Check the turntable torque hub fasteners Torque the fasteners to 160 ft Ibs 217 Nm B 11 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 Gasoline LPG 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 Servi
30. BLU 36 amp Ogor a T gu WHT BLK 31 C WHT 30 GRN WHT 19 WHT RED 32 Ju WHT 21 rop Q 5 oY C GENER OPT 45 GRN WHT 1 E WP SPARE 44 GRN BLK 1 2 a 43 E N E IN SPARE GRN 1 8 D 0 SPARE 42 ORG RED 1 a 33 41 40 a SPARE 39 BLU RED 1 5 t SPARE 38 BLU WHT 1 STEER RIGHT 37 BLU BLK 1 BLU WHT 12 STEER LEFT 36 BLU 1 O BLU RED 13 RPM 35 BLK RED 1 G GL PLG OPT 34 BLK WHT 1 BLK WHT 34 9 8118 START 33 BLK 1 BRAKE 32 WHT RED 1 RED 10 H P L E D C 31 WHT BLK 1 RED WHT 29 E D C 30 WHT 1 BLU BLK 11 2WD AWD 29 RED WHT 1 2 TILT ALARM 28 RED BLK 1 AUX PWR 27 RED 1 8 xiz Y 20 PWR F S 26 BLK FS ue BLU 10 PWR START 25 RED FS uA m 24 PWR CONT WHT F S BEBANHTS PWR FRMPLAT 23 wHT 2 RED 27 PWR TO PLAT 22 BLK 2 GRN 17 Olz 21 OPTION WIRE 2 WHT GHNAVHTAS JIB VALVE 19 GRN WHT 3 GRNBLK 18 PLAT ROT R 18 GRN BLK 3 Pu amp PLAT ROT L 17 GRN 3 2 M d PLAT LVL F C 16 ORG RED 3 20 C PLAT LVL DN 15 ORG BLK 3 9 Y PLAT LVL UP 14 ORG 3 V DRV ENA LT 13 BLU RED 3 f DRV ENA 12 BLUWHT 3 AT y BLK WHT 8 SEC BOOM DN 11 BLU BLK 3 BLK 7 SEC BOOM UP 10 BLU 3 RED 1 HORN 9 BLK RED 3 8 BLKWHT 3 gt 0 Gc EXTEND 7 BLK 3 ee
31. M Unless otherwise specified perform each maintenance procedure with the machine in the following configuration Machine parked on a flat level surface Boom in stowed position Turntable rotated with the boom between the non steering wheels Turntable secured with the turntable rotation lock Key switch in the orr position with the key removed Wheels chocked About This Section This section contains detailed procedures for each scheduled maintenance inspection Each procedure includes a description safety information and step by step instructions Symbols Legend Safety alert symbol used to alert personnel to potential personal injury hazards Obey all safety messages that follow this symbol to avoid possible injury or death Red used to indicate the presence of an imminently hazardous situation which if not avoided will result in death or serious injury Orange used to indicate the AWARNING presence of a potentially hazardous situation which if not avoided could result in death or serious injury Yellow with safety alert symbol A CAUTION m used to indicate the presence of a potentially hazardous situation which if not avoided may cause minor or moderate injury Yellow without safety alert symbol used to indicate the presence of a potentially hazardous situation which if not avoided may result in property damage CAUTION Green used to indicate operation or mainte
32. Primary Boom Components 4 1 Cable Track 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 Two Hydraulic Hose and Fitting Torque Specifications 1 Raise the jib boom slightly and place blocks under the platform mounting weldment Then lower the jib boom until the platform is resting on the blocks just enough to support the platform n el 1l Do not rest the entire weight of the boom on the blocks 2 Separate the foot switch quick disconnect plug from the platform toe board 3 Open the platform control box 4 Remove the platform control box mounting fasteners Then lower the control box and set it aside If your machine is equipped with an airline to platform option the airline must be disconnected from the platform before removal 5 Remove the platform control box mounting fasteners 6 Tag disconnect and plug the hydraulic hoses from the platform leveling slave cylinder Cap the fittings on slave cylinder Bodily injury hazard S praying AWARNING 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 Pullthe slave cylinder hydraulic hoses out of the protective sheath 8 Tagand disconnectthe wiring from the ji
33. Repair open in brown ground wire circuit to primary boom up directional valve coil OR begin troubleshooting from beginning of chart Part No 52856 Genie Z 60 34 5 29 Section 5 Troubleshooting Flow Charts Chart 15 Primary Boom Down Function Inoperative Be sure all other functions operate normally With the key switch turned to ground controls and both Emergency Stop buttons pulled out to the ON position move the function enable switch to either side and hold the primary boom up toggle switch TS19 at the ground controls in the down direction and check voltage on red wht wire on primary boom up down proportional valve coil item N 12V or more Continued on the next page Service Manual Second Edition Move the function enable switch to either 1110 side and hold the 12V primary boom up toggle switch TS19 at the ground controls in the down direction and check voltage at TB3 11 to With the keyswitch 12V turned to platform controls and both Emergency Stop buttons pulled out to theon osition activate footswitch and primary boom function controller BP 1 on platform control panel in down direction and check voltage at TP3 oV Activate footswitch and check voltage at terminal on BP1 12V or more Re adjust controller see Repair Section OR replace controller BP1 OR consult Genie Industries Service Department Repair open in
34. a 5 e TL I NN Val gt a tierod b steering cylinder C pivot pin d retaining bolt e hub f yoke g yoke pivot pin h axle 2 Loosen the wheel lug nuts Do not remove them 3 Blockthe non steering wheels and then center a lifting jack of ample capacity under the steering axle 4 Raisethe machine approximately 10 inches 25 4 cm and place blocks under the chassis for support 5 Remove the lug nuts then the tire and wheel assembly 6 Remove the pin retaining fasteners from the yoke pivot pin 7 Oscillating axle equipped models Place a block between the oscillate cylinder lock out wedge and the chassis on the same side as the yoke hub being serviced a chassis b block c oscillating axle d yoke e hub 8 Supportand secure the yoke hub assembly to a lifting jack 9 Use a soft metal driftto drive the yoke pivot pin down and out 10 Remove the yoke hub assembly from the machine Crushing hazard The yoke hub ACAUTION assembly may become unbalanced and fall when the yoke pivot pin is removed if itis not properly supported and secured to the lifting jack Torque specifications 125 ft lbs 169 5 Nm Lug nut PartNo 52856 Genie Z 60 34 7 67 Section 7 Repair Procedures Service Manual Second Edition 2WD STEERING AXLE COMPONENTS How to Remove the Hub and Bearings 1 Loosen the wheel lug nuts Do not remove them 2 Blockthe non steering wheels an
35. 0 lt DE O gas d 9 BLK c 100 NHP S2 e WHT 8 BRN 8 RED T 5o Ei 42 ORG 1 WHT 6 BRN 6 E g WHT 7 T BRN 7 42 t BLK 3 EXTEND RETRACT BLK WHT 3 EXTEND poom BLKWHT B p RETMeT o BLK WHT 4 2 d bs EE EO 1 BLK RED 4 9 e x WHT RED 3 o E E WHT BLK 3 2 a WHT 3 pie WHT E wiri RIGHT TURNTABLEROTATE WHT BLK Ex ET WHT BLK 4 rn 8 x 9 5 14 12 1 WHT RED 4 hd 5 4 RED z Boo crit RED 4 primary 800m RED BLK ET nl RED BLK 4 pi D a 10 N 2 B REDWHT 4 E 4 RED 3 pie RED BLK 3 RED WHT 3 e a E BLU BLK 3 BLU 3 e BLK 2 BLU BLU BLU 4 E ue BOOM SECONDARY 2 BLK 1 DOWN BLU BLK BLU BLK 4 2 Ye RED WHT a ORG 3 e ur PLATFORM LEVEL DOWN ORG BLK 3 ORG B 2 ORG 4 E UP PLATFORM LEVEL x ORG BLK m d ORG BLK 4 E ORG RED 4 obs n H a ORG RED 3 IE DS d CE PLATFORM LEVEL DISABLE OPTION 2 GRN 3 zo e oz UP JIB BOOM DOWN GRN BLK 3 GRN 8 p o GRN 4 a a BOOM GRN BLK 9 E o GRN BLK 4 2 B 2 RIGHT pL ATFORM ROTATE E RIGHT PLATFORM ROTATE p LEFT 2 M i M J 2 E BRN GRN WHT GRN WHT 3
36. 12 With keyswitch turned to 0V platform control and both Emergency Stop buttons pulled out to the ON position activate footswitch and platform rotate toggle switch TS5 in the left direction and check voltage at the grn wht wire at the jib delay capacitor 12V Continued on the next page Repair open in grn wht wire from TS15 to TB19 to TP19 OR test toggle switch See Repair Section Repair open in red power wire circuit through controllers and Check voltage on center 0V terminal of TS5 function toggle switches to TS5 12V With keyswitch turned to joy platform control and both Emergency Stop buttons pulled out to the ON position activate footswitch and platform rotate toggle switch TS5 in the right direction and check voltage at TP 19 Repair open in grn wht wire from TP19 to jib delay capacitor Activate footswitch and 12V platform rotate toggle switch TS5 in the right direction and check voltage at the grn wht wire on TS5 Repair open in grn wht wire from TS5 to TP19 oV Test toggle switch See Repair Section OR replace platform rotate toggle switch TS5 Genie Z 60 34 Part No 52856 Service Manual Second Edition Section 5 Troubleshooting Flow Charts S CHART 26 With keyswitch turned to Replace the jib delay Continued from the platform control and capacitor OR repair previous page both Emerg
37. Activate footswitch and check voltage at terminal on BP1 12V or more Re adjust controller see Repair Section OR replace controller BP1 OR consult Genie Industries Service Department 12V or more 12V or more 12V or more CHART 15 Repair open in red blk 2 wire circuit from TB2 to primary boom down function directional valve coil item G OR repair open in brown ground wire circuit to valve coil Troubleshoot the primary boom down function toggle switch TS19 on ground control panel OR repair open in red blk 2 wire circuit from TS19 to TB2 OR consult Genie Industries Service Department Repair open in red wire from TP2 to TB2 Repair open in power supply circuit from TP24 to BP1 OR repair open in brown ground wire circuit from ground to 1 Part No 52856 Genie Z 60 34 5 31 Section 5 Troubleshooting Flow Charts Service Manual Second Edition N CHART 15 Disconnect wires to 0 or primary boom down infinite directional valve coil ohms item G and test the resistance of the valve coil See Repair Section Continued from the previous page Replace primary boom down directional valve coil item G 510 7 ohms Install a 0 to 5000 PSI Check for mechanical 345 bar pressure restrictions keeping gauge at the quick primary boom from disconnect coupling on moving OR repair the function manifold cylinder or cylinder item V a
38. Emergency Stop button normally closed E Relay contact normally open e amp A ANYI Ground supression circuit NC 183 Limit switch 151 NO Limit switch normally open held closed PLAT _ GRND Key switch HORN D P4 Horn button normally open e i Relay panel contactor 53 c U Toggle switch SPDT Toggle switch DPDT Part No 52856 Genie Z 60 34 Service Manual Second Edition Section 6 Schematics IEEE C I U JH M N QN Abbreviation Legend LABEL DESCRIPTION BAT aeui Battery BP ossia Proportional controller woe Circuit breaker CR nos haven Control relay DP used Drive proportional controller EB uui Flashing beacon Foot switch PP Horn or Alarm HM Hour meter Keyswitch Le doa LED Limit switch Pocos Power switch PES Power relay B uet Resistor TB attese Terminal base location Terminal platform location Toggle switch Part No 52856 Genie Z 60 34 6 5 Section 6 Schematics Service Manual Second Edition mmEm E 6 6 Genie Z 60 34 Part No 52856 FORD 42 PIN QUICK DISCONNECT ENGINE HARNESS 2 SEE PAGE 1 TACH LEAD RED 10awg KEEP ALIVE PWR YELLOW 10awg KEEP A
39. How to Remove the Fuel Tank PartNo 52856 Genie Z 60 34 7 61 Section 7 Repair Procedures Service Manual Second Edition FUEL AND HYDRAULIC TANKS 2 Close the two hydraulic shutoff valves located atthe hydraulic tank open closed Component damage hazard The CAUTION engine must not be started with the hydraulic tank shutoff valves in the cLosep 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 3 Remove the drain plug from the hydraulic tank 4 Completely drain the tank into a suitable container See capacity specifications 5 Tag disconnect and plug the two suction hoses that are attached to the hydraulic tank shutoff valves 6 Disconnect and plug the T fitting located at the return filter with the 2 hoses connected to it Cap the fitting on the return filter housing 7 Disconnectand plug the supply hose for the auxiliary power unit Cap the fitting on the hydraulic tank 8 Remove the retaining fasteners from the hydraulic tank hold down straps Remove the straps from the hydraulic tank 9 Support the hydraulic tank with 2 lifting straps Place one lifting strap at each end of the tank and attach the lifting straps to an overhead crane 10 Remove the hydraulic tank from the machine Crushing hazard The hydraulic AWARNING tank may become unbalanced and fall if it
40. MAINTENANCE TABLES Tools are New parts engine engine service required required required required suggested C 1 Check the Primary Boom Wear P ads C 2 Check the Turntable Rotation Bearing Bolts C 3 Check the Free wheel Configuration Ea Pa Pa C 4 Grease the Turntable Rotation Bearing and Rotate Gear 5 Replace the Torque Hub Oil 5 C 6 Replace the Hydraulic Tank Return Filter 7 Replace the Drive Loop Hydraulic Filter o C 8 Replace the Diesel Fuel Filter Water Separator Deutz Diesel Models C 9 Replace the Gasoline Fuel Filters Gasoline LP G Models E C 10 Replace the PCV Valve Gasoline LP G Models C 11 Replace the Spark Plugs Gasoline LP G Models C 12 Check and Adjust Air LP G Mixture Gasoline LP G Models EEEERHEEHEEH C 13 Check the Engine Valve Clearances Deutz Diesel Models Ea A Pa Va Ea PA VA gt Eg Part No 52856 Genie Z 60 34 3 5 Section 3 Scheduled Maintenance Inspections Service Manual Second Edition MAINTENANCE TABLES Warm Cold Dealer Table D Tools are New parts engine engine service required required required required suggested D 1 Test or Replace the Hydraulic Oil D 2 Change or Recondition the Engine Coolant Gasoline LP G Models D 3 Change the Fuel Hoses Ea NE D 4 Check the Engine Valve Clearance
41. PartNo 52856 Genie Z 60 34 7 47 Section 7 Repair Procedures Service Manual Second Edition MANIFOLDS How to Override a Valve How to Check the Resistance A hydraulic valve may need to be manually of a Valve Coil 3 1 1 the key switch to the orr position and proportional boom functions primary boom disconnectthe wires from the valve coil to be secondary boom extend retract and turntable tested rotate use a variable position proportional valve and a three position directional valve 2 Connectthe leads from an ohmmeter to the Example one position for boom up one valve coil terminals position for neutral and one position for boom down The platform rotate jib boom and platform level functions use only three position valves The three position valves and the proportional valves can be manually overridden To identify the manifold valves see 11 1 Function Manifolds in this section 1 Push the button on the end of the valve in 14 inch 6mm Valve coil specifications Proportional solenoid valve 12V 4 to 50 schematic items N and Q 3 position 4 way directional valve 10V 2 5 to 3 20 2 Move the ground control function switch for the schematic items A C E F G and H function being overridden to operate function 2 position 3 way solenoid valve 10V 7 to 90 AWARNING Collision hazard Impact with schematic item P moving boom components
42. RED BLK 1 ORG X ou AUX PWR 27 RED 1 Hu vi 5 PWR TOES 26 BLK FS BLU 10 m PWR START 25 RED FS Y 24 PWR CONT WHT F S SEDANS PWR FRM PLAT 23 WHT 2 RED 27 M PWR TO PLAT 22 BLK 2 GRN 17 OOO 5 21 E OPTION WIRE 2 WHT JIB VALVE 19 GRN WHT 3 a 5 8 PLAT ROT R 18 GRN BLK 3 PLAT ROT L 17 GRN 8 pm PLAT 16 ORG RED 3 5 p PLAT LVL DN 15 ORG BLK 3 lt Y Q Qoo PLAT LVL UP 14 oRG 3 LIC DRV ENA LT 13 BLU RED 3 o e DRV ENA 12 BLU WHT 3 R BLK WHT 8 SEC BOOMDN 11 BLU BLK 3 BLK 7 SEC BOOM UP 10 BLU 3 RED 1 HORN 9 BLK RED 3 ps RETRACT 8 BLK WHT 3 gt be Bed EXTEND 7 BLK 3 o mr O SWING 6 WHT RED 3 Dx 9 2 SWING RIGHT 5 WHT BLK 3 iy x R SWING LEFT 4 WHT 3 RED BLK 2 1 PRIMARY 3 RED WHT 3 PRIMARY DN 2 RED BLK 3 PRIMARY UP 1 RED 3 WHT BLK 5 i amp a a ms 9 Ly a WHT 4 N gt b gt z 2 x v tc en 2 3 4 5 6 7 8 9 1b fu e a O ae 2 WHT RED 6 v 9o gt 3 Tz 5 ORG 14 5 50 Q RED BLK 28 I m ra T ORG BLK 15 i g s e O HE ORG RED 16 a 5 lt BLK RED 9 6 11 Genie Z 60 34 Part No 52856
43. 1 Connecta 0 to 600 psi 0 to 41 bar pressure gauge to the test port item 11 located on the drive manifold 2 Startthe engine from the platform controls 3 Drive the machine slowly in either direction and observe the pressure reading on the pressure gauge 4 Turnthe engine off Hold the charge pressure relief valve and remove the cap index 3 5 Adjustthe internal hex socket Turn it clockwise to increase the pressure or counterclockwise to decrease the pressure Then install the valve cap 6 Restartthe engine Drive the machine in either direction and recheck the valve pressure 7 Turn the engine off then remove the pressure gauge Charge Pressure Relief valve specifications Pressure 250 psi 17 2 bar 7 60 Genie Z 60 34 Part 52856 Service Manual Second Edition Section 7 Repair Procedures Fuel and Hydraulic Tanks 12 1 Fuel Tank How to Remove the Fuel Tank Explosion and fire hazard Engine fuels are combustible Remove the fuel tank 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 1 Turn the manual fuel shutoff valve to the CLOSED position 2 Remove the tank side turntable cover See 6 1 How to Remove a Turntable Cover 3 Disconnect drain and plug the s
44. A 5 Check the Engine Coolant Level Gasoline LP G Models 4 3 A 6 Check for Fuel Eeaks i di a eia nut 4 3 A 7 Check the Hydraulic 4 4 A 8 Check for Hydraulic Leaks oo eee teeter eee mmm 4 5 A 9 Check the Tire Pressure nece e e et E ERE Era 4 5 10 Test the Oscillate Axle Lockout oscillating axle equipped models 4 6 PartNo 52856 Genie Z 60 34 Service Manual Second Edition May 2007 TABLE OF CONTENTS Section Four Scheduled Maintenance Procedures continued A 11 Test the Platform and Ground 4 6 A 12 Testthe Auxiliary Power Operation 4 7 A 13 Test the Tilt Sensor nennen entere 4 8 A 14 Test the Limit 4 9 A 15 Replace the Engine Oil and Filter Gasoline LPG Models 4 12 A 16 Replace the Engine Air 4 13 B 1 Check the Engine Belt sse 4 15 B 2 Check the Radiator Gasoline LPG 4 16 B 3 Check the Oil Cooler and Cooling Fins Deutz Diesel Models 4 16 B 4 Check the Exhaust System sss 4 17 B 5 Check the Battery cine Rede a eet 4 18 6 Chech the Hydraulic Return Filter Condition Indicator
45. C 4 Grease the Turntable Rotation Bearing and Rotate Gear Yearly 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 on the platform end of the engine side bulkhead 2 Pump grease into the turntable rotation bearing Rotate the turntable in increments of 4 to 5 inches 10 to 13 cm ata 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 Oil type Multipurpose grease C 5 Replace the Torque Hub Oil Replacing the torque hub oil is essential for good machine performance and Service life Failure to replace the torque hub oil at yearly intervals may cause the machine to perform poorly and continued use may cause component damage Non steer torque hubs 1 Select the non steer torque hub to be serviced Then drive the machine until one of the two plugs is at the lowest point 2 Remove both plugs and drain the oil Genie Z 60 34 Part No 52856 Service Manual Second Edition Section 4 Scheduled Maintenance Procedures TABLE C PROCEDURES 3 Drive the machine until one plug is atthe top 3 Attach the lifting strap from an overhead crane and the other is at 90 degrees to the platform end of the lower secondary boom arm for support Do
46. Contact with AWARNING 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 2 engine pivot plate retaining bolts and swing the engine out away from the machine to access the wiring a engine pivot plate b pivot plate retaining bolts 3 Inspect the following areas for burnt chafed corroded and loose wires Engine wiring harness Turntable wiring 4 Openthe ground controls side turntable cover 5 Inspect the following areas for burnt chafed corroded and loose wires Inside of the ground control box Function manifold wiring TABLE B PROCEDURES 6 Startthe engine from the ground controls and raise the secondary boom above the turntable covers 7 Inspect the turntable area for burnt chafed and pinched cables 8 Lowerthe boom into the stowed position and turn the engine off 9 Inspectthe following areas for burnt chafed corroded pinched and loose wires Cable track on the primary boom Cables on the primary secondary and jib booms Inside of the platform control box B 8 Inspect the Tires and Wheels including lug nut torque Maintaining the tires and wheels in good condition is 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 fashi
47. Cycle time 8 5V DC 30 to 40 seconds Secondary boom down lo range Cycle time Ramp rate 2 to 3 seconds Turntable Rotation Controller Adjustments Do not adjust the joystick controllers unless the static battery voltage is above 12V DC and the alternator is operating properly with 13 6 to 14 5V DC output Electrocution hazard Contact AWARNING with electrically charged circuits could result in death or serious injury Remove all rings watches and other jewelry 1 Check the battery condition with a volt meter The reading should be 12V DC or more to accurately adjust the controller 2 Turn the key switch to platform control and pull outthe Emergency Stop button to the on position at both the ground and platform controls Do not start the engine PLATFORM CONTROLS 3 Openthe platform control box lid and locate the turntable rotation controller R efer to the platform control box illustration page 7 2 ramp rate adjustable trimpot lo range adjustable trimpot terminal R not used not used terminal X not used terminal ground terminal positive terminal A proportional output threshold adjustable trimpot hi range adjustable trimpot 57 0000o0ox u 4 Setthe preliminary ramp rate Turn the trimpot adjustment screw counterclockwise 15 turns or until you hear a repeated click 5 Connectthe red lead from a volt meter to the A terminal on the controller printed cir
48. GRN BLK 3 5 GRN lt E p GRN 4 P GRN BLK JIB BOOM DOWN 1 GRN BLK 4 jj 2 E E e RIGHT P RIGHT PLATFORM A PLATFORM ROTATE Lepr ROTATE 1 LEFT E o a ly BRN GRN WHT GRN WHT 3 i 2 m B 2 9p RED A X A tr 7 TuIB VALVES 6 13 Genie Z 60 34 Part No 52856 Service Manual Ground Control Box Wiring Diagram Diesel Models Section 6 Schematics
49. Ground Controls 9 1 co 87 Control Relays Relays used for single function switching are single 86 87a 85 pole double throw SPDT relays How to Test Single Pole Double Throw Relay terminal no 87a N C terminal no 85 ground terminal no 30 common AWARNING Electrocution hazard terminal no 86 coil Contact with electrically charged terminal no 87 N O circuits could cause death or serious injury Remove all rings watches and other jewelry Control Relay Schematic without resistor 1 Labeland then disconnect all the wiring from the relay to be tested C 2 Connectthe leads from an ohmmeter or continuity tester to each terminal combination and check for continuity Terminals 85 and 86 85 87 87a representthe coil and should not be tested in r o any other combination m Test Desired result terminal 85 to 86 without resistor 85 to 950 O 86 30 terminal 85 to 86 with resistor 75 to 850 terminal 87 to 87a amp 30 no continuity infinite Q Control Relay Schematic with resistor terminal 87a to 30 continuity zero O 3 Connect12V DC to terminal 85 and a ground wire to terminal 86 then test the following 85 87 87a terminal combinations L Test Desiredresult N12 terminal 87 to 87a amp 30 no continuity infinite Q 86 30 terminal 87 to 30 continuity zero Q 7 36 Genie 7
50. HOUR METER uw P BLU RED 1 o E I RED WHT 23 E H vex gt FLASHING BEACONS 522 ATA x ores F hy D CHECK ENGINE LED 9 Si N 8 m BB 29 3 sz g olg a EXE EE E ES EAES 2 iu 7 z a BLK 1 E ENGINE a 2 START E F ENGINE a START BLK e N To o WT PUR FEH 209 PIN18 4 RED LGRN 16 g BRN WHT FEH 674 PIN7 TAN LBLU FEH 306 PIN24 FORD YEL FEH 37B PIN8 42 PIN PLUG iva YEL 37 PIN9 x 787 PINS m BLK WHT 570 PIN34 BLK WHT 570 42 FUEL PUMP 2 bw o RED FEH 361N w n DGRN FEH 242 952 602 lt 1 cor e 1 5 gt LPG LOCKOUT SOLENOID S BLK R1 E H nis a STARTER MOTOR lom xg d FY bs e x FR S iN ou AUXILIARY POWER RED 1 d RELAY N 1 e AUXILIARY PUMP gg 6 1 x RED E RED BLK 1 E RED BLK 28 E H x 2 23 WHT 2 RED WHT 23 E H LEVEL SENSOR a e I 1 9 9 E n m VIE a a z 5 g e ar BLKRED BLK RED 3 R BLK RED o n SERVICE HORN ur RELAY 2 BLK R4EH BLK 2 E H SERVICE HORN e m 2 tr aa 5 Q
51. coil See Repair Section Install a 0 to 5000 PSI 345 bar pressure gauge at the quick disconnect coupling on the boom function manifold and start the engine Move the function enable switch in the high rpm position and hold the turntable rotate left toggle switch at the ground controls in the left direction and check the pressure Continued on the next page 2 5 to 3 5 ohms less than 2400 PSI Replace turntable rotate left directional valve coil item E Exchange flow regulator function valve item O with a like operates valve item J Check turntable rotate left function Replace defective flow regulator valve function inoperative Repair or replace the turntable rotation motor OR function manifold could have an internal defect Consult Genie Industries Service Department 5 46 Genie 2 60 34 Part No 52856 Service Manual Second Edition Section 5 Troubleshooting Flow Charts Continued from the previous page Plumb a 0 to 5000 psi Turntable rotation 0 to 345 bar pressure lesstfian manifold could have an gauge into the hose 250 psi internal defect OR the from the turntable 0 030 orifice may be rotation manifold to the plugged OR consult turntable rotation brake Genie Industries Service Move the function Department enable switch to either side and activate the turntable rotate left function 250 psi or more Exchange turntable rota
52. e Steel 260 24 Aluminum 208 355 Torque Procedure 1 Replace the O ring The O ring must be 3 Be sure that the face seal O ring is seated and replaced anytime the seal has been broken retained properly The O ring cannot be re used if the fitting or hose end has been tightened beyond finger tight 4 Position the tube and nut squarely on the face seal end of the fitting and tighten the nut finger tight The O rings used in the Parker Seal Lok fittings and hose ends are a custom size O ring They 5 Tighten the nut or fitting to the appropriate torque per given size as shown in the table are nota standard SAE size above O ring They are available in 6 Operate all machine functions and inspect the the O ring field service kit hoses and fittings and related components to Genie part no 49612 be sure thatthere are no leaks 2 Lubricate the O ring before installation 2 6 Genie Z 60 34 Part No 52856 Service Manual Second Edition Section 3 Scheduled Maintenance Inspections Scheduled Maintenance Inspections Observe and Obey M Maintenance inspections shall be completed by a person trained and qualified on the maintenance of this machine M Scheduled maintenance inspections shall be completed daily quarterly annually and every 2 years as specified on the Maintenance Inspection Report Failure to properly complete each AWARNING inspection when required may cause deat
53. e B bsr RED zm x n JIB VALVES GROUND DRIVE ENABLE LIMIT SWITCH DRIVE BRAKE VALVE STEER LEFT STEER RIGHT AUXILIARY STEER RELAY AUXILIARY STEER VALVE MOTOR STROKE SECONDARY BOOM UP LIMIT SWITCH PRIMARY BOOM UP LIMIT SWITCH BOOM EXTEND LIMIT SWITCH BOOM EXTEND BOOM RETRACT TURNTABLE ROTATE RIGHT TURNTABLE ROTATE LEFT TURNTABLE ROTATE amp EXTEND RETRACT FLOW CONTROL PRIMARY BOOM UP PRIMARY BOOM DOWN PRIMARY BOOM FLOW CONTROL SECONDARY BOOM UP SECONDARY BOOM DOWN PLATFORM LEVEL UP PLATFORM LEVEL DOWN PLATFORM LEVEL FLOW CONTROL PLATFORM ROTATE LEFT PLATFORM ROTATE RIGHT 6 9 Genie Z 60 34 Part No 52856 Service Manual Ground Control Box Wiring Diagram B Gasoline LPG Models Section 6 Schematics
54. item Q OR repair open in brown ground wire circuit to valve coil Repair open in blk red wire from TP6 to TB6 Repair open in power supply circuit from TP24 to TS8 Replace extend retract toggle switch TS8 5 42 Genie Z 60 34 Part No 52856 Service Manual Second Edition Section 5 Troubleshooting Flow Charts S Disconnect wires to 0 boom retract directional infinite valve coil item and ohms ee test the resistance of the it ES valve coil See Repair d Section Continued from the previous page 2 5 to 3 5 ohms function Move function enable operates switch to either side and hold the boom retract toggle switch at the ground controls in the retract direction Manually override the directional valve by pushing in on the end of the valve spool Replace defective directional valve function inoperative Install a 0 to 5000 PSI Check for mechanical 345 bar pressure restrictions keeping gauge at the quick boom from retracting disconnect coupling on OR repair cylinder or the function manifold cylinder counterbalance and start the engine valves OR consult Move the function Genie Industries Service enable switch to either Department side and hold the boom retract toggle switch at the ground controls in the retract direction and check the pressure less than 2000 PSI function operates Exchange boom ex
55. page Move the function enable switch to either side and hold the boom extend toggle switch 9 to 10V TS21 on ground panel in the extend direction and check voltage at TB6 With keyswitch in 9 to 10V platform position and both Emergency Stop buttons pulled out to the On position activate footswitch and boom extend retract toggle switch TS8 on platform control panel in the extend direction and check voltage at TP6 oV Activate footswitch and check voltage at center terminal of TS8 12V or more Test toggle switch see bad Repair Section good Repair open in blk red wire circuit from TS8 to TP6 good If boom extend function is still inoperative replace CR15 and begin troubleshooting from beginning of chart OR consult Genie Industries Service Department Repair open in wht red wire circuit from TB6 to boom extend retract and turntable rotate left right proportional valve coil item Q OR repair open in brown ground wire circuit to valve coil Repair open in blk red wire from TP6 to TB6 Repair open in power supply circuit from TP24 to TS8 Replace extend retract toggle switch TS8 5 40 Genie Z 60 34 Part No 52856 Service Manual Second Edition Disconnect wires to boom extend directional valve coil item H and Continued from the previous page test the resistance of the valve coil See Repair Section Move functi
56. 0 3 meters per second Tip over hazard If the drive speed AWARNING with the primary boom raised or extended or the secondary boom raised exceeds 1 foot per second 0 3 meters per second immediately tag and remove the machine from service 18 Move the lift drive select switch to the lift position if equipped 19 Lower the primary boom to the stowed position Then extend the primary boom approximately 2 feet 61 cm 20 Move the lift drive select switch to the drive position if equipped 21 Press down the footswitch and slowly move the drive control handle to the full drive position Result The maximum achievable drive speed with the primary boom extended should not exceed 1 foot per second 0 3 meters per second Tip over hazard If the drive speed AWARNING with the primary boom raised or extended or the secondary boom raised exceeds 1 foot per second 0 3 meters per second immediately tag and remove the machine from service 22 Move the lift drive select switch to the lift position if equipped 23 Fully retract the primary boom Then raise the secondary boom approximately 2 feet 61 cm 24 Move the lift drive select switch to the drive position if equipped 25 Press down the footswitch and slowly move the drive control handle to the full drive position Result The maximum achievable drive speed with the secondary boom raised should not exceed 1 foot per second 0 3 meters per second
57. 1 s WHOJIY 1d OL H3MOd S18 22 ana 2199 eE WH H3MOd H LIMSAIJ TSIM ZSWSKIHM ez ZIHM H3uWGd H3ON3S ONINHVM ve H31HM OLFWSELM 10 45 52 H3 8 14 VIX AWIL 45 OYIM 92 H3 OUM Y3MOd Zura Su PANT WEP zz ragg Hadau virga WAV LIL ngaga Ha QMr aMz 9HHILWQH gt NUD 62 TWE semis 2199 Vorma aa 0 ie NEHM Ha aM avy QH 1M I Q3H LHM 43 034 Kd eo EE ina ENSHE ON 9m MOTD SIME ve 4 ON ON Wdy 5 se 1 318vo O O L6 ON 1HOIH H331S ES zrna se rms W3 NUd Q 13314331S ze nga svo se 1 lt 1 HOLIMS LINT L1HM or 1 0HO dnxold ISINA ZHWSPNS OO ip H3x8 90 8 vszri8 1HM HOIH 31v10H 318v Nun gt 808 H3MOd HOLIMS LINT be 8Z GH 8TZ LA SIHM tr H3 HKIHM SIMA SBHGIHONG NO 9BFGHOIE NO 9asu W3Ong NHo NOLLdO HOLVH3N39O Sp L1HWNHO PIM 8 034 LN 1 5 SLOVLNOO G3 2V1S e Genie Z 60 34 6 14 Section 6 Schematics Service Manual Diesel Models Platform C
58. 15 Place the hub on a flat surface and gently pry the bearing seal out of the hub Remove the rear bearing 16 Pack both bearings with clean fresh grease 17 Place the large inner bearing into the rear of the hub 18 Install a new bearing grease seal into the hub by pressing it evenly into the hub until it is flush Always replace the bearing grease seal when removing the hub 19 Slide the hub onto the yoke spindle Component damage hazard Do CAUTION not apply excessive force or damage to the lip of the seal may occur 20 Place the outer bearing into the hub 21 Install the washer and castle nut 22 Tighten the slotted nut to 35 foot pounds 47 Nm to seat the bearings PartNo 52856 Genie Z 60 34 4 45 Section 4 Scheduled Maintenance P rocedures Service Manual Second Edition RC CccK TABLE D PROCEDURES 23 Loosen the castle nut then re tighten to 8 foot pounds 11 Nm 24 Install a new cotter pin Bend the cotter pin to lock it in 25 Install the dust cap then the tire and wheel assembly Torque the wheel lug nuts to 125 foot pounds 169 5 Nm 4 46 Genie Z 60 34 Part No 52856 Service Manual Second Edition Section 5 Troubleshooting Flow Charts Troubleshooting Flow Charts Observe and Obey M Troubleshooting and repair procedures shall be completed by a person trained and qualified on the repair of this machine Immediately t
59. 34 7 29 Section 7 Repair Procedures Service Manual Second Edition JJ a SECONDARY BOOM COMPONENTS 2 Tag disconnectand plug the secondary boom lift cylinder hydraulic hoses Cap the fittings on the cylinder Bodily injury hazard S praying AWARNING 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 mounting fasteners from the secondary boom lift cylinder rod end pivot pin mounting bracket 4 Remove the retaining fasteners from the secondary boom lift cylinder pivot pins Use a slide hammer to remove the pins then remove the cylinder from the machine Crushing hazard The secondary AWARNING boom lift cylinder may become unbalanced and fall when it is removed from the machine if is not properly supported by the overhead crane 7 30 Genie Z 60 34 Part No 52856 Service Manual Second Edition Section 7 Repair Procedures 6 1 Turntable Covers How to Remove a Turntable Cover 1 Raise the turntable cover Support and secure the open cover with an overhead crane or forklift Do not lift the cover A CAUTION CAUTION Crushing hazard Due to its heavy weight do not attemptto support the cover by hand Component damage hazard Protectthe cover from damage by using carpet or padding on the crane or forklift forks
60. 60 34 52856 Service Manual Second Edition Section 7 Repair Procedures 9 2 Toggle Switches See 1 5 Toggle Switches 9 3 Wago Components How to Remove a Wago Component Electrocution h AWARNING F ectrocution azard Contact with electrically charged circuits could cause death or serious injury Remove all rings watches and other jewelry A small screwdriver is provided and should be used when removing a Wago component This screwdriver is located in the operator s manual storage box in the platform 1 Label the wiring from the component to be removed 2 Locate the removal tab on the bottom or top side of the component 3 Use a small narrow flat blade screwdriver to push in and release the wire from the component 4 Use the small narrow flat blade screwdriver to gently pry up on the tab of the component and remove it GROUND CONTROLS 9 4 Resistors How to Test the Resistor The resistor is used to maintain proper control of boom function speeds A 10 ohm resistor reduces voltage to the primary boom and secondary boom proportional valves A 15 ohm resistor reduces the voltage to the turntable rotate proportional valve Refer to the schematic legends for resistor locations and values 1 Turn the key switch to the orr position 2 Disconnect either end of one of the wires connected to the resistor to be tested 3 Connect the leads from an ohmmeter to each end or wiring of the
61. A potentiometer counterclockwise to increase injury Remove all rings watches voltage or clockwise to decrease voltage and other jewelry A potentiometer specifications all models Voltage setting 10 5 to 11 5V DC 7 Move the engine idle control switch to low idle turtle symbol 8 Press down the foot switch and then adjust the C potentiometer to obtain a Platform control box 0 1V DC to 0 5V DC voltage reading a horsepower limiter board 9 Move the engine idle control switch to foot switch activated high idle rabbit and foot switch 3 Connectthe black lead from a DC volt meter symbol to the no 2 terminal and the red lead to the no 10 terminal 10 Press down the foot switch and re adjustthe A potentiometer to the previous voltage setting in step 6 11 Be sure that the boom is in the stowed position engine rpm sensor then drive the machine and observe how the engine rpm reacts to drive control handle low drive speed limit switch movement If the engine surges or hunts adjust 1 the C potentiometer counterclockwise until not used surging is minimized outputto drive controller i 0 o o o o 0 o o g m a e 5 Under an extreme load an excessive counterclockwise Horsepower limiter board adjustment to the C a potentiometer maximum voltage potentiometer will cause outpu
62. Avoid spilling or contacting battery acid Neutralize battery acid spills with baking soda and water 18 Gasoline LPG models Remove the mounting fasteners from the 3 relays mounted to the engine side bulkhead 19 Gasoline LPG models Remove the mounting fasteners from the ECM mounted to the engine side bulkhead 20 Remove the mounting fasteners from both of the turntable bulkheads then remove both turntable bulkheads 21 Remove the hydraulic tank See 12 2 How to Remove the Hyaraulic Tank 22 Attach a lifting strap from an overhead crane to the lug on the primary boom lift cylinder then lift the primary boom lift cylinder to a vertical position 23 Tag disconnect and plug the primary boom lift cylinder hydraulic hoses Cap the fittings on the cylinder 24 Remove the pin retaining fasteners from the primary boom lift cylinder barrel end pivot pin Use soft metal drift to remove the pin then remove the cylinder from the machine Crushing hazard The primary AWARNING boom lift cylinder may become unbalanced and fall when it is removed from the machine if it is not properly supported by the overhead crane SECONDARY BOOM COMPONENTS 25 Tag disconnectand plug the secondary boom lift cylinder hydraulic hoses Cap the fittings on the cylinder Bodily injury hazard S praying AWARNING hydraulic oil can penetrate and burn skin Loosen hydraulic connections very slowly to allow the oil pressure to dissipate g
63. Control Relays teet ete e ome D PED ERE E ens 9 2 Toggle Switches See 1 5 Toggle Switches 22 204004 2 0 00 00 9 3 Wago Components 2 cre ee e eie REC c HR erc PE ER 9 4 ROSISTOFS dnt eee ede i ette us 9 5 Engine Fault Codes Gasoline LP G Models se Hydraulic Pumps 10 1 51 vehere ure ie des 10 2 Drive PUMP zb meet muon b tene e a mp dte oet Manifolds 11 1 Function Manifold 2 11 2 Valve Adjustments Function Manifold 2 2 11 3 Turntable Rotation Manifold Components 11 4 Auxiliary Steer Manifold Components 1000 11 5 Steer Manifold Components Non oscillating 11 6 Steer Oscillate Manifold Components Oscillating Models 11 7 2WD Drive Manifold Components 2 memes 11 8 Valve Adjustments 2WD Drive 2 11 9 4WD Drive Manifold Components sss memes 11 10 Valve Adjustments 4WD Drive Manifold 2 Fuel and Hydraulic Tanks 12 1 F el Tank s iu cte cete iate tia tet erue 12 2 Hydraulic A A eter OR RR Turntable Rotation Components 13 1 Turntable Rotation Hydraulic Motor sse mm
64. Inoperative 5 37 18 Primary Boom Extend Function Inoperative 5 40 19 Primary Boom Retract Function 5 42 20 Turntable Rotate Left Function Inoperative 5 44 21 Turntable Rotate Right Function Inoperative 5 48 22 AllPlatform Leveling Functions Inoperative 5 52 23 Platform Level Up Function Inoperative 5 53 24 Platform Level Down Function Inoperative 5 55 25 Platform Rotate Left Function Inoperative 5 57 26 Platform Rotate RightFunction 5 60 27 JibBoomUpFunction Inoperative 5 63 28 Jib Boom Down Function Inoperative 0 5 65 29 Steer Left Function Inoperative Non oscillating Models 5 67 30 SteerRightFunction Inoperative Non oscillating Models 5 69 31 Steer Left Function Inoperative Oscillating Models 5 71 32 Steer Right Functio
65. Tools are New parts engine engine service required required required required suggested A 1 Inspect the Manuals A 2 Inspect the Decals and Placards A 3 Inspect for Damage Loose or Missing Parts eS E PR 4 Check the Engine Oil Level A 5 Check the Engine Coolant Level Gasoline LP G Models A 6 Check for Fuel Leaks 7 Check the Hydraulic Oil Level A 8 Check for Hydraulic Leaks A 9 Check the Tire Pressure A 10 Test the Oscillate Lock out Oscillating Models A 11 Testthe Platform and Ground Controls A 12 Test the Auxiliary Power Operation A 13 Testthe Tilt Sensor A 14 Testthe Limit S witches 3 2 Genie Z 60 34 Part No 52856 Service Manual Second Edition May 2007 Section 3 Scheduled Maintenance Inspections REV B Table A continued Tools are required New parts required MAINTENANCE TABLES Warm Cold Dealer engine engine service required required suggested Every 100 hours perform the following two engine maintenance procedures A 15 Replace the Engine Oil and Filter Gasoline LPG Models A 16 Replace the Engine Air Filter Table B B 1 Check the Engine Belt B 2 Check the Radiator Gasoline LPG Models B 3 Check the Oil Cooler and Cooling Fins Deutz Diesel Models B 4 Check the Exhaust System ES Ej B 5 Check the Battery 6 Check the Hyd
66. adjustment screw and tighten the lock nut Check the Engine Valve Clearances Deutz Diesel Models Complete information to perform this procedure is available in the Deutz FL 1011F Workshop Manual Deutz Number 0297 7195 Genie part number 52229 38 Genie Z 60 34 Part No 52856 Service Manual Second Edition Section 4 Scheduled Maintenance Procedures D 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 conditions may require oil changes to be performed more often The machine uses Dexron equivalent hydraulic oil 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 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 Referto Section Two Hyaraulic Hose and Fitting Torque Specifications 1 Gasoline LPG models Turn the valve on the LPG tank clockwise to the orr position Then slow
67. allow the oil pressure to dissipate gradually Do not allow oil to squirt or spray 9 Pullthe hydraulic hoses up through the jib boom lift cylinder mounting bracket Component damage hazard CAUTION Hoses can be damaged if they are kinked or pinched 10 Remove the cable cover from the side of the jib boom 11 Attach a lifting strap from an overhead crane to the jib boom 12 Use a soft metal drift to remove the jib boom lift cylinder barrel end pivot pin 13 Remove the pin retaining fasteners from the jib boom pivot pin Use a soft metal drift to remove the pin then remove the jib boom from the primary boom Crushing hazard The jib boom AWARNING may become unbalanced and fall when itis removed from the machine if itis not properly attached to the overhead crane 14 Remove the pin retaining fasteners from the jib boom lift cylinder rod end pivot pin Do not remove the pin 15 Remove both of the jib boom leveling links from the primary boom 14 Genie Z 60 34 Part No 52856 Service Manual Second Edition Section 7 Repair Procedures 16 Attach a lifting strap from an overhead crane to the lug on the rod end of the jib boom lift cylinder 17 Use a soft metal driftto remove the jib boom lift cylinder rod end pivot pin then remove the jib boom lift cylinder from the primary boom Crushing hazard The jib boom AWARNING lift cylinder may become unbalanced and fall when it is removed from the machine if i
68. and obey manufacturer s instructions and safety rules employer s safety rules applicable governmental regulations You have the appropriate tools lifting equipment and a suitable workshop PartNo 52856 Genie Z 60 34 iii Section 1 Safety Rules Service Manual Second Edition SAFETY RULES Personal Safety Any person working on or around a machine must be aware of all known safety hazards P ersonal safety and the continued safe operation of the machine should be your top priority Read each procedure thoroughly This manual and the decals on the machine use signal words to identify the following Safety alert symbol used to alert personnel to potential personal injury hazards Obey all safety messages that follow this symbol to avoid possible injury or death 7 Red used to indicate the presence of an imminently hazardous situation which if not avoided will result in death or serious injury Orange used to indicate the presence of a potentially hazardous situation which if not avoided could result in death or serious injury AWARNING Yellow with safety alert symbol A CAUTION used to indicate the presence of a potentially hazardous situation which if not avoided may cause minor or moderate injury Yellow without safety alert symbol used to indicate the presense of a potentially hazardous situation which if not avoided may result in property damage CAUTION Gree
69. and start the counterbalance valve engine Move the OR consult Genie function enable switch to Industries Service either side and hold the Department primary boom up toggle switch at the ground controls in the up direction and check the pressure less than 2000 PSI function Exchange flow regulator operates valve item J with a like valve item O Check primary boom up function Replace defective flow regulator valve function inoperative Repair cylinder or cylinder counterbalance valve OR function manifold could have an internal defect Consult Genie Industries Service Department 5 28 Genie 2 60 34 Part No 52856 Service Manual Second Edition Section 5 Troubleshooting Flow Charts S CHART 14 Check continuity to Repair open in brown ground on brown ground ground wire circuit from wires to CR10 and CR10 and CR11 to CR11 ground Continued from page 5 27 right column Activate the primary Replace CR11 OR see boom up toggle switch Chart 33 OR consult TS19 at the ground Genie Industries Service controls in the up Department direction and check voltage at the primary boom up directional valve coil item G Disconnect wires to 0 a primary boom up infinite directional valve ohms Replace primary boom item G and test the up directional valve coil resistance of the valve item G coil See Repair Section 5 to 7 ohms
70. areas Hydraulic tank fittings hoses and turntable surface Engine compartment hydraulic filters fittings hoses pumps filter and turntable surface All hydraulic cylinders All hydraulic manifolds Primary secondary and jib booms The underside of the turntable The underside of the drive chassis Ground area under the machine TABLE A PROCEDURES A 9 Check the Tire Pressure This procedure does not need to be performed on machines equipped with the foam filled tire option AWARNING Bodily injury hazard An over inflated tire can explode and could cause death or Serious injury Tip over hazard Do notuse AWARNING temporary flat tire repair products To safeguard maximum stability achieve optimum machine handling and minimize tire wear itis essential to maintain proper pressure in all air filled tires 1 Check each tire with an air pressure gauge and add air as needed Tire Specifications Industrial Rough terrain Tire size 32x12 15NHS 15 19 5NHS 300 15NHS Pressure 110 psi 60 psi 7 59 bar 4 14 bar Part No 52856 Genie Z 60 34 4 5 Section 4 Scheduled Maintenance P rocedures Service Manual Second Edition TABLE A PROCEDURES A 10 Test the Oscillate Lock out oscillating axle models Proper axle oscillation lock out when the primary boom is raised extended or the turntable rotated is essential to safe machine operation If the lock out wedges do not extend w
71. at grn wht wire at TP19 at the platform controls 12V With keyswitch turned to OV Check voltage on center 0V platform control and terminal of TS5 both Emergency Stop buttons pulled out to the ON position activate footswitch and platform rotate toggle switch TS5 in the left direction and check voltage at the grn wht wire at the jib delay capacitor 12V Continued on the next page Chart 25 Repair open in grn wht wire from TS15 to TB19 to TP19 OR test toggle switch See Repair Section Repair open in red power wire circuit through controllers and function toggle switches to TS5 12V With keyswitch turned to joy platform control and both Emergency Stop buttons pulled out to the ON position activate footswitch and platform rotate toggle switch TS5 in the left direction and check voltage at TP19 Repair open in grn wht wire from TP19 to jib delay capacitor Activate footswitch and 12V platform rotate toggle switch TS5 in the left direction and check voltage at the grn wht wire on TS5 Repair open in grn wht wire from TS5 to TP19 oV Test toggle switch See Repair Section OR replace platform rotate toggle switch TS5 Part No 52856 Genie Z 60 34 5 57 Section 5 Troubleshooting Flow Charts E CHART 25 Continued from the previous page With keyswitch turned to platform control and both Emergency Stop buttons pulled out to
72. bar pressure restrictions keeping gauge at the quick secondary boom from disconnect coupling on moving OR repair the function manifold cylinder or cylinder item V and start the counterbalance valve engine Move the OR consult Genie function enable switch to Industries Service either side and hold the Department secondary boom up toggle switch at the ground controls in the up direction and check the pressure less than 2000 PSI function Exchange flow regulator operates valve item J with a like valve item O Check secondary boom up function Replace defective flow regulator valve function inoperative Repair cylinder or cylinder counterbalance valve OR function manifold could have an internal defect Consult Genie Industries Service Department Part No 52856 Genie Z 60 34 5 35 Section 5 Troubleshooting Flow Charts Service Manual Second Edition N CHART 16 no Check continuity to 7 ground on brown groun wires to CR10 Repair open in brown ground wire circuit to CR10 Continued from page 5 34 right column Activate the secondary boom up toggle switch Replace CR10 OR see TS18 at the ground Chart 33 OR consult controls in the up Genie Industries Service direction and check Department voltage at the secondary boom up directional valve coil item F Disconnect wires to 0 or secondary boom up infinite directional valve coil ohms it
73. boom down directional valve OR repair open in brown ground wire circuit to directional valve Repair open in grn blk wire from TP18 to TB18 Repair open in grn wire from TS6 to TP18 OR replace jib boom toggle switch TS6 Repair open in red wire from BP1 to CR13 OR repair open in brown ground wire circuit to CR13 Replace CR13 Part No 52856 Genie Z 60 34 Section 5 Troubleshooting Flow Charts Service Manual Second Edition CHART 28 Activate footswitch and Continued from the jib boom toggle switch previous page TS6 in the down direction and check voltage on the red and black wires at the jib platform rotate select valves item AC Replace CR13 function operate Install a 0 to 5000 psi 0 Exchange jib boom to 345 bar pressure platform rotate select gauge at the quick valves item AC disconnect coupling on Activate footswitch and the function manifold jib boom down function and activate the jib boom down function Replace defective valve function inoperative Check for mechanical restrictions keeping jib boom down function from operating OR repair or replace jib boom cylinder OR replace counterbalance valve OR 0 030 orifice item AB may be plugged OR jib boom platform rotate select manifold has an internal defect OR consult Genie Industries Service Department less than 2400 psi function Exchange jib boom operate cou
74. can be operated from the ground or platform controls and the activation of one or the other is accomplished with the key switch Failure ofthe key switch to activate the appropriate control panel could cause a hazardous operating situation 1 Pulloutthe 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 Checkany machine function from the ground controls Result The machine functions should not operate 4 Turn the key switch to ground control 5 Check any machine function from the platform controls Result The machine functions should not operate TABLE B PROCEDURES 6 Turn the key switch to the orr position O Result The engine should stop and no functions should operate Deutz Diesel models All functions should stop immediately The engine will shut off after 2 to 3 seconds B 13 Test the Emergency Stop Buttons Properly functioning Emergency Stop buttons are essential for safe machine operation An improperly operating Emergency Stop button will fail to shut off power and stop all machine functions resulting in a hazardous situation for ground and platform personnel As a safety feature selecting and operating the ground controls will override the platform controls including the platform Emergency Stop button 1 Start the engine from the ground contr
75. consult Genie Industries Service Department 12V or more Chart 23 Repair open in org wire from TB14 to platform level up directional valve coil item C OR repair open in brown ground wire circuit to valve coil Troubleshoot platform level toggle switches TS17 and TS7 on ground and platform control panels OR repair open in red power wire circuit to TS17 and TS7 OR repair open in org wire circuit from TS17 and TS7 to TB14 OR consult Genie Industries Service Department Part No 52856 Genie Z 60 34 Section 5 Troubleshooting Flow Charts Service Manual Second Edition T CHART 23 Disconnect the wires 0 from the platform level infinite up directional valve coil ohms item C and test the 2 of the valve coil Continued from the previous page Replace the platform level up directional valve coil item C 2 5 to 3 5 ohms Exchange platform level function up and down directional operates valve coils and activate the platform level up function Replace the defective directional valve coil function inoperative Exchange platform level function up and down operates counterbalance valves in the counterbalance valve sandwich item B and activate the platform level up function Replace the defective counterbalance valve function inoperative Install a 0 to 5000 2000 psi Check for mechanical 0 to 345 bar pressure 0 EIE rest
76. correctly and causes the ECM to detect a fault The ECM uses the signal pulses from the CKP and CMP sensors to initiate sequential fuel injection The EOM received an illegal instruction signal from one or more of the sensors and has gone into a default program and then return to normal operation The ECM received an illegal interruption signal from one or more engine sensors and has gone into a default program and then return to normal operation Under normal operation the ECM will store numbers into memory If this does not happen it will reset itself and set fault code 56 Battery supply voltage to the ECM is 8V DC or less Battery supply voltage to the ECM is 18V DC or more Check for shorted wires or poor terminal connections from the CKP and CMP sensors to the ECM OR replace the CKP or CMP sensor Check for shorted wires or poor terminal connections from the CKP and CMP sensors to the ECM OR replace the CKP or CMP sensor Replace the ECM Replace the ECM Replace the ECM Check battery and or alternator condition OR check for shorted wires or poor terminal connections from the battery to the ECM Check battery and or alternator condition OR check for shorted wires or poor terminal connections from the battery to the ECM Part No 52856 Genie Z 60 34 Section 5 Troubleshooting Flow Charts Service Manual Second Edition Chart 1 Engine Will Not Crank Over Be sure the
77. damage will occur If the tank valves are closed remove the key from the key switch and tag the machine to inform personnel ofthe condition CAUTION 2 Tag disconnect and plug the lift steer pump hydraulic hoses Cap the fittings on the pump Bodily injury hazard S praying AWARNING 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 Hydraulic Pumps 3 Remove the pump mounting bolts Carefully remove the pump CAUTION Component damage hazard Be sure to open the two hydraulic tank valves and prime the pump after installing the pump 10 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 The only adjustment that can be made to the pump is the neutral or null adjustment Any internal service to the pump should only be performed at an authorized Sundstrand S auer service center Call Genie Industries Service Departmentto 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 o
78. fire hazard Engine fuels are combustible P erform 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 The engine should be warmed to normal operating temperature Return the function enable toggle switch to the center position Locate the low idle mixture adjustment screw on the LPG regulator Adjustthe low idle mixture adjustment screw to obtain an air to fuel mixture ratio of 13 0 1 to 13 2 1 Preliminary setting turn low idle adjustment screw clockwise all the way in Turn low idle adjustment screw counterclockwise 2 3 4 turns C 13 before performing this procedure Move the fuel select switch to LPG fuel and startthe engine from the ground controls Locate the high idle mixture adjustment screw on the throttle body elbow thatattaches to the air cleaner Loosen the lock nut on the high idle mixture adjustment screw Load the system by activating the primary boom retract function then move the function enable toggle switch to the high idle rabbit symbol position Adjustthe high idle adjustment screw to obtain an air to fuel mixture ratio of 13 0 1 to 13 2 1 using an exhaust gas analyzer Preliminary setting is 1 4 inch of threads showing Measure from top of lock nutto top of adjustment screw If an exhaust gas analyzer is not available adjustto obtain peak or optimum rpm Hold the
79. ground valve coils Continued from the previous page Exchange jib boom Repair open in brown platform rotate select p ground wire circuit to valves item AC valve coils Activate footswitch and platform rotate left function function inoperative Activate platform rotate Repair open in grn wire left function and check from TB17 to platform the voltage on the grn rotate jib boom wire at the platform directional valve coil rotate jib boom item A directional valve item A Exchange the two valve function Replace the defective coils on the directional operates valve coil OR valve valve Check platform cartridge may be rotate left function defective function inoperative Repair or replace platform rotator OR 0 030 orifice item AB in jib manifold is plugged OR jib manifold may have an internal defect Consult Genie Industries Service Department Part No 52856 Genie Z 60 34 5 59 Section 5 Troubleshooting Flow Charts Service Manual Second Edition Chart 26 Platform Rotate Right Function Inoperative Be sure all other functions operate normally With the keyswitch turned to ground control and both Emergency Stop buttons pulled out to the ON position move the function enable switch to either side and activate the platform rotate toggle switch TS15 in the right direction and check voltage at grn wht wire at TP19 at the platform controls
80. in brown ground wire circuit from LS3 to ground OR repair or replace LS3 Repair open in wht wire from cable 6 from TB40 to primary boom up drive limit switch LS1 OR repair open in brown ground wire circuit from LS1 to ground OR repair or replace LS1 Repair open in wht wire from cable 8 from TB40 to secondary boom up drive limit switch LS4 OR repair open in brown ground wire circuit from LS4 to ground OR repair or replace LS4 Genie Z 60 34 Part No 52856 Service Manual Second Edition Section 5 Troubleshooting Flow Charts Drive Enable System Is Malfunctioning Be sure the boom is in the stowed position With keyswitch in platform position and both Emergency Stop buttons pulled out to the ON position and the boom rotated between the non steer tires activate footswitch and drive controller in forward direction Will unit drive yes With keyswitch in platform position and both Emergency Stop buttons pulled out to the ON position and the boom rotated between the steer end tires activate footswitch and drive controller in forward direction Will unit drive yes Check for continuity from TB30 to TB12 no continuity Repair open in red wire circuit from TB30 to rotator microswitch and from rotator microswitch to TB12 With keyswitch in platform position and both Emergency Stop buttons pulled out to the ON position activate footswitch and drive controlle
81. key switch Check if key switch internal cam is activating Replace key switch contact for ground ground contact controls no Replace key switch 1 2 5 24 Genie Z 60 34 Part No 52856 Section 5 Troubleshooting Flow Charts Chart 13 Service Manual Second Edition Platform Does engine start from yes n engine Test or replace foot the platform controls platform controls then switch see Repair Controls press down the foot Section OR repair open i switch and check in wht wire circuit from Inope rative voltage at TP24 foot switch to TP24 Ground 12V Controls no Operate Repair open in wht wire circuit from TP24 to Normal ly function toggle switches and function controllers Be sure all cables from ground oV control box through Check voltage at TB22 Repair open in red wire the cable track are in good condition with no kinks or abrasions 12V ov Check voltage at TP22 12V Check voltage at blk wire on input side of platform Emergency Stop button contact P2 12V With the key switch turned to platform controls and both Emergency Stop buttons pulled out to the on position check the voltage on the output side of the platform Emergency Stop button contact 12V Check voltage at TP23 ov 12V Repair open in blk wire circuit from platform Emergency Stop button to TP26 to foot switch OR replace foot switch OR consult Genie Indu
82. key switch is in the appropriate position Be sure that both Emergency Stop buttons are pulled out to the oN position Be sure the circuit breakers are not tripped Be sure the battery is fully charged less than Check battery voltage 12V 12V or more With the keyswitch turned to ground controls and both Emergency Stop buttons are pulled out to the ON position check the voltage at the center terminal on the start toggle switch TS12 12V Hold the start toggle switch to either side and check the voltage at either side terminal on start switch 12V Hold the start switch to either side and check voltage at terminal TB33 12V Hold the start switch to either side and check voltage at terminal 3 on ignition start module 12V Check voltage at terminal 6 on the ignition start module 12V Continued on the next page Check battery condition OR check alternator OR check battery cables OR replace the battery Trace circuit back through the key switch emergency stop button and 2 repair open Replace start toggle switch 7512 Repair open in blk wire circuit from start toggle switch TS12 to TB33 Repair open in blk wire circuit from TB33 to terminal 3 on ignition start module Repair open in red power supply wire circuit from CB1 to CR1 to CR2 then to terminal 46 to on ignition start module Genie Z 60 34 Part No 52856 Servi
83. leveling Automatic platform self leveling throughout the full cycle of boom raising and lowering is essential for safe machine operation The platform is maintained at level by the platform leveling slave cylinder which operates in a closed loop hydraulic circuit with the master cylinder located atthe base ofthe boom A platform self leveling failure creates an unsafe working condition for platform and ground personnel 1 Start the engine from the ground controls and lower the boom into the stowed position 2 Hold the function enable toggle switch to either side and adjustthe platform to a level position using the platform level toggle switch 3 Raise and lowerthe primary boom through a full cycle O Result The platform should remain level at all times to within 5 degrees B 16 Test the Horn A functional horn is essential to safe machine operation The horn is activated atthe platform controls and sounds at the ground as a warning to ground personnel An improperly functioning horn will preventthe operator from alerting ground personnel of hazards or unsafe conditions 1 Turn the key switch to platform control and pull out the Emergency Stop button to the ON position at both the ground and platform controls 2 Push down the horn button atthe platform controls Result The horn should sound If necessary the horn can be adjusted to obtain the loudest volume by turning the adjustment screw near the wire termina
84. maintain the engine s running condition at its highest efficiency while at the same time keeping exhaust emissions to a minimum When a sensor fails or returns signals that are outside of set parameters the ECM will store a fault code in memory that relates to the appropriate sensor and will turn on the Check Engine Light See Repair Section How to Retrieve Engine Fault Codes Use the Fault Code Chart on the following pages to aid in identifying the fault 5 2 Genie 2 60 34 Part No 52856 Service Manual Second Edition Section 5 Troubleshooting Flow Charts Fault Codes Fault PIN MEE NEN Throttle Position TP sensor low voltage Manifold Absolute Pressure MAP sensor low voltage Engine speed exceeded 4000 RPM Throttle Position TP sensor high voltage Fuel pump low voltage Heated Oxygen HO sensor low voltage Engine Coolant Temperature ECT sensor high voltage Manifold Absolute Pressure MAP sensor high voltage Faulty TP sensor OR sensor wires shorted shorted to ground or poor terminal connection Faulty MAP sensor OR sensor wires shorted to ground or poor terminal connection Obstruction in throttle body OR faulty ECM The ECM senses a signal from the TP sensor that is greater than 4 9V DC OR the TP sensor wiring is shorted to ground OR there is a poor terminal connection OR the TP sensor is bad Faulty MAP sensor OR sensor wires shorted to ground or poor term
85. more Re adjust controller see Repair Section OR replace controller BP2 OR consult Genie Industries Service Department Chart 17 Repair open in red wht wire circuit from TB3 to secondary boom up down proportional valve coil item N OR repair open in brown ground wire circuit to valve coil Repair open in red wht wire from TP3 to TB3 Repair open in power supply circuit from TP24 to BP2 OR repair open in brown ground wire circuit from ground to BP2 Part No 52856 Genie Z 60 34 5 37 Section 5 Troubleshooting Flow Charts J CHART 17 Continued from the previous page With key switch turned to ground controls and both Emergency Stop buttons pulled out to the ON position move the function enable switch to either side and hold the secondary boom down toggle switch TS18 at the ground controls in the down direction and check voltage on blu blk 11 wire on secondary boom up down directional valve coil item F 12V or more Continued on the next page Service Manual Second Edition Move the function enable switch to either side and hold the secondary boom down toggle switch TS18 at the ground controls in the down direction and check voltage at TB11 With key switch turned to platform controls and both Emergency Stop buttons pulled out to the ON position activate the footswitch and secondary boom function controller BP2 on platform control panel in
86. non steering wheels then center a lifting jack under the steer axle 3 Raise the machine 6 inches 15 cm and place blocks under the drive chassis for support 4 Remove the lug nuts then remove the tire and wheel assembly 5 Check for wheel bearing wear by attempting 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 Skip to step 11 if there is no movement 6 Remove the dust cap mounting fasteners then remove the dust cap from the hub 7 Remove the cotter pin from the castle nut 8 Tighten the castle nutto 35 foot pounds 47 Nm to seatthe bearings 9 Loosen the castle nut then re tighten to 8 foot pounds 11 Nm TABLE D PROCEDURES 10 Check for wheel bearing wear by attempting to move the wheel hub side to side then up and down Result If there is side to side or up and down movement continue to step 12 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 Result If there is no side to side or up and down movement continue with step 12 and grease the wheel bearings 11 Remove the dust cap mounting fasteners then remove the dust cap from the hub 12 Remove the cotter pin from the castle nut 13 Remove the castle nut 14 Pull the hub off ofthe spindle The washer and outer bearing should fall loose from the hub
87. not lift 4 Fill the hub with oil from the top hole until the oil level is even with the bottom of the side hole Then re install the plugs 5 Repeatsteps 1 through 4 forthe other non steer torque hub 4 Remove the motor brake mounting bolts and then remove the motor and brake from the capacity per hub 40 fluid ounces torque hub and setthem to the side 1 2 liters Type SAE 90 multipurpose hypoid gear oil API service classification GL5 Turntable Rotate Torque Hub 1 Secure the turntable from rotating with the turntable rotation lock a electrical rotary coupler unlocked locked b motor brake mounting bolt motor 2 Raisethe secondary boom until the platform d torque hub mounting bolt end of the lower secondary boom arm is 8 feet e f torque hub 2 4m off the ground g brake 5 Remove the torque hub mounting bolts and then remove the torque hub from the machine PartNo 52856 Genie Z 60 34 4 33 Section 4 Scheduled Maintenance P rocedures Service Manual Second Edition TABLE C PROCEDURES 6 Remove the plug from the side of the torque hub Then drain the oil from the hub 7 Install the torque hub Torque the hub mounting bolts to 180 foot pounds 244 Newton meters 8 Install the brake and motor onto the torque hub 9 Fill the hub with oil from the side hole until the oil level is even with the bottom of the hole Then install the plug 8 fluid ounces 0 24 liters C
88. on each non steer wheel hub brake disengage position brake engage position 5 Manually rotate each non steering wheel Result Each non steering wheel should rotate with minimum effort 6 Re engage the torque hubs by turning over the hub disconnect caps Rotate each wheel to check for engagement Liftthe machine and remove the jack stands MR AWARNING ll sion hazard Failure to re engage the torque hubs could cause death or serious injury and property damage Steer wheels 4WD models 7 Chock the non steering wheels to prevent the machine from rolling 8 Center a lifting jack of ample capacity 20 000 Ibs 9072 kg under the drive chassis between the steer tires 9 Lift the wheels off the ground and then place jack stands under the drive chassis for support PartNo 52856 Genie Z 60 34 4 31 Section 4 Scheduled Maintenance P rocedures Service Manual Second Edition TABLE C PROCEDURES 10 Locate the free wheel valve on the bottom of the drive pump 11 Open the free wheel valve located on the drive pump by turning it counterclockwise two turns a drive pump b free wheel valve C screwdriver d lift pump 12 Manually rotate each steer wheel Result Each steer wheel should rotate with minimum effort 13 Close the free wheel valve on the drive pump by turning it clockwise 14 Liftthe machine and remove the jack stands The free wheel valve should always remain closed
89. out to the ON position activate footswitch and steer rocker switch on drive controller DP1 in left direction and check voltage at the controller terminal with the blu wire attached Repair or replace steer microswitch on drive controller Consult Genie Industries Service Department Repair open in blu 36 wire circuit that runs from TB36 to steer left directional valve coil Replace steer left directional valve coil item Il OR repair open in brown ground wire to steer left valve coil Chart 31 Repair open in blu 36 wire circuit from drive controller DP1 to TP36 then to TB36 Part No 52856 Genie Z 60 34 5 71 Section 5 Troubleshooting Flow Charts Service Manual Second Edition N CHART 31 Install a 0 to 5000 PSI Check for mechanical 0 to 345 bar pressure restrictions keeping gauge at the quick steer left function from disconnect coupling on operating OR repair or the boom function replace steer cylinders manifold and activate OR replace flow the steer left function regulator valve item X OR consult Genie Industries Service less than 2400 PSI Department Continued from the previous page Repair or replace steer cylinders OR steer manifold could have an internal defect Consult Genie Industries Service Department 5 72 Genie Z 60 34 Part No 52856 Service Manual Second Edition Section 5 Troubleshooting Flow Charts Steer Right Function I
90. properly supported Component damage hazard Be sure to open the two hydraulic tank valves and prime the pump after installing the pump Service Manual Second Edition How to Prime the Pump 1 Connect a 0 to 600 psi 0 to 41 bar pressure gauge to the test port on the drive pump Gasoline LPG models Close the valve on the LPG tank then disconnect hose from the tank Then move the fuel select switch to the LPG position Deutz Diesel models Hold the manual fuel shutoff valve clockwise to the cLosep position AR AR C ee jm klar D 1 51 manual fuel shutoff valve 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 Gasoline LPG models Connect the LPG hose to the LPG tank and open the valve on the tank Start the engine from the ground controls and check for hydraulic leaks Genie Z 60 34 Part No 52856 Service Manual Second Edition Section 7 Repair Procedures pu M He J This page intentionally left blank PartNo 52856 Genie Z 60 34 7 41 Section 7 Repair Procedures Service Manual Second Edition Manifolds 11 1 Function Manifold Components The function manifold is located behind the ground Index Schematic No Description Item 1 3 position 4 way 003 valve
91. pump shaft pump coupler flex plate with raised spline engine flywheel 7 16 inch gap a b d e f How to Remove the Flex Plate 1 Disconnect the wiring plug at the electronic displacement controller EDC located on the drive pump 2 Supportthe drive pump with an appropriate lifting device Then remove all ofthe pump mounting plate to engine bell housing bolts 3 Carefully pull the pump away from the engine and secure it from moving 4 Remove the flex plate mounting fasteners then remove the flex plate from the engine flywheel How to Install the Flex Plate 1 Install the flex plate onto the engine flywheel with the raised spline towards the pump Torque the flex plate mounting bolts to 34 ft lbs 46 Nm Install the pump coupler onto the pump shaft with the set screw toward the pump Leave a 7 16 inch 11 mm gap between the pump coupler and pump end plate Apply Loctite removable thread sealant to the pump coupler set screw Torque the set screw to 45 165 61 Nm CAUTION Component damage hazard Do not force the drive pump during installation or the flex plate teeth may become damaged Install the pump and torque the pump mounting plate fasteners to 34 ft lbs 46 Nm Genie Z 60 34 Part No 52856 Service Manual Second Edition Section 7 Repair Procedures 7 3 Oil Temperature and Oil Pressure Gauges The oil temperature gauge is an electrical gauge The sending unit has li
92. readings the same 0 or infinite ohms Check the resistance of the Replace the EDC m Cc 20 to 24 ohms Adjust the drive pum Defective Sundstrand null neutral Consult no improvement drive pump contact Genie Industries Service Sundstrand authorized Department repair facility symptoms improve Re adjust drive joystick controller OR if problem still persists consult Genie Industries Service Department Part No 52856 Genie Z 60 34 5 83 Section 5 Troubleshooting Flow Charts Service Manual Second Edition Chart 36 Traction Any type of traction _ Function Inoperative SERRE Be sure all other functions operate normally 5 84 Genie 2 60 34 Part No 52856 Service Manual Second Edition Section 5 Troubleshooting Flow Charts Chart 37 Machine Will With the boom in the a ees the org wire continuity Repair short in org wire stowed position engine continuity from TB40 and check to ground Not Drive At off and the keyswitch continuity from the org turned to the OFF wire to ground Full Speed position check continuity from TB40 to Be sure all other ground no continuity functions operate normally Disconnect the wht wire Repair short in wht wire ai from cable 7 and check ny from cable 7 to ground continuity from the wht continu OR replace primary not raised above or wire from cable 7 wire boom extend drive limit extended beyond t
93. red wht wire circuit from TB3 to primary boom up down proportional valve coil N OR repair open in brown ground wire circuit to valve coil Repair open in red wht wire from TP3 to TB3 Repair open in power supply circuit from TP24 to BP1 OR repair open in brown ground wire circuit from ground to 1 Genie Z 60 34 Part No 52856 Service Manual Second Edition Continued from the previous page With key switch turned to ground controls and both Emergency Stop buttons pulled out to the ON position move the function enable switch to either side and hold the primary boom up toggle switch TS19 at the ground controls in the down direction and check voltage on red blk 2 wire on primary boom up down directional valve coil item G 12V or more Continued on the next page Section 5 Troubleshooting Flow Charts NS Move the function enable switch to either side and hold the primary boom up toggle switch TS19 at the ground controls in the down direction and check voltage at TB2 With key switch turned to platform controls and both Emergency Stop buttons pulled out to the ON position activate the footswitch and primary boom function controller BP1 on platform control panel in down direction and check voltage TB2 oV Activate footswitch and primary boom function controller BP1 on platform control panel in down direction and check voltage TP2 oV
94. system A 1 Manuals B 21 Drive brakes A 2 Decals and placards B 22 Drive speed stowed A 3 Damage loose or missing parts A 4 Engine oil level A 5 Engine coolant Gas LP G A 6 Fuel leaks A 7 Hydraulic oil level A 8 Hydraulic leaks B 23 Alarm package B 18 Engine idle select B 19 Fuel select Gas LP G B 24 Hydraulic oil analysis Perform every 500 hours B 25 simone engine oil simone filter Deutz Checklist C YNR A 9 Tire pressure Refer to Table C A 10 Oscillate Lock out C 1 Boom wear pads A 11 Platform and ground controls A 12 Auxiliary power A 13 Tilt sensor A 14 Limit switches Perform every 100 hours A 15 Replace engine oil and filter Gas LPG A 16 Replace air filter Checklist B Refer to Table B B 1 Engine belt B 2 Check radiator Gas LP G B 3 Oil cooler and fins Diesel B 4 Exhaust system B 5 Battery B 6 Hydraulic tank filter B 7 Electrical wiring B 8 Tires and wheels B 9 Brake configuration B 10 Torque hub oil level B 11 Engine RPM B 12 Key S witch B 13 Emergency Stop B 14 Ground control override C 2 Turntable bearing bolts C 3 Free wheel configuration C 4 Grease rotation bearing C 5 Torque hub oil C 6 Hydraulic tank filter C 7 Drive loop hydraulic filter C 8 Fuel filter Deutz diesel C 9 Fuel filters Gas LP G C 10 P
95. terminal 3 on drive joystick to ground continuity Replace drive joystick controller OR consult Genie Industries Service Department no Check continuity from terminal 3 on drive joystick to ground Repair open in brown ground wire circuit from terminal 3 on drive joystick to ground continuity Replace drive joystick controller OR consult Genie Industries Service Department Part No 52856 Genie Z 60 34 5 81 Section 5 Troubleshooting Flow Charts CHART 34 Continued from the previous page Activate the footswitch and hold the drive joystick in the full forward position and check the voltage across the wht 12 wire and the wht blk 431 wire on EDC Troubleshoot drive forward and drive reverse functions separately OR replace pump OR consult Genie Industries Service Department Service Manual Second Edition With the footswitch activated and the drive joystick in the full forward position move the drive enable toggle switch TS10 to either side and check the voltage across the wht 1H2 wire and the wht blk 310n EDC Connect the positve lead from a voltmeter to terminal 5 on the joystick and with the footswitch activated and the drive joystick in the full forward position move the drive enable toggle switch TS10 to either side and hold the negative lead from the voltmeter onto the blu wht wire on TS10 and check the voltage Connect the po
96. the ON position activate footswitch and platform rotate toggle switch TS5 in the left direction and check voltage at the red wire at the jib delay capacitor 12V Activate footswitch and platform rotate toggle switch TS5 in the left direction and check voltage on the red wire at terminal 86 on CR14 12V Activate footswitch and platform rotate toggle switch TS5 in the left direction and check voltage on the red and black wires at terminal 87 on CR14 12V Activate footswitch and platform rotate toggle switch TS5 in the left direction and check voltage on the red and black wires at the jib platform rotate select valves item AC 12V Test the resistance of the valve coils Continued on the next page Service Manual Second Edition Replace the jib delay capacitor OR repair open in brown ground wire from capacitor to ground Repair open in red wire from jib delay capacitor to CR14 Replace relay CR14 OR repair open in power supply from P2 to CR14 OR repair open in brown ground wire to CR14 Repair open in cable containing red and black wires from CR14 to jib boom platform rotate select valves Replace defective valve coil Genie Z 60 34 Part No 52856 Service Manual Second Edition Section 5 Troubleshooting Flow Charts S CHART 25 Check continuity from inuity Repair open in brown brown ground wires on ground wire circuit to valve coils to
97. the extension cylinder hydraulic hoses Cap the fittings on the cylinder Bodily injury hazard S praying AWARNING 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 15 Attach a 5 ton 4 536 kg overhead crane to the center point of the primary boom Liftthe primary boom enough to access the primary boom lift cylinder rod end pivot pin 16 Attach a similar lifting device to the primary boom lift cylinder 17 Place a 24 inch 61 cm long block of wood across the lower secondary boom leveling links to support the primary boom lift cylinder 18 Remove the pin retaining fasteners from the primary boom lift cylinder rod end pivot pin Use a soft metal driftto remove the pin Crushing hazard The primary AWARNING boom lift cylinder and the primary boom will fall if they are not properly supported 19 Lower the rod end ofthe primary boom lift cylinder onto the support block placed across the lower secondary boom leveling links 20 Remove the pin retaining fasteners from the primary boom pivot pin 21 Remove the primary boom pivot pin with a soft metal drift then carefully remove the primary boom from the machine and place iton a structure capable of supporting it Crushing hazard If the overhead crane is not properly attached the boom may become unbalanced and fall when it is removed from the machine
98. the left direction and check voltage at TP6 oV Activate footswitch and check voltage at terminal on BP1 12V or more Re adjust controller see Repair Section OR replace controller BP1 OR consult Genie Industries Service Department Repair open in wht red wire circuit from TB6 to turntable rotate left right and boom extend retract proportional valve coil Q OR repair open in brown ground wire circuit to valve coil 12V Repair open in wht red wire from TP6 to TB6 Repair open in power supply circuit from TP24 to BP1 OR repair open in brown ground wire circuit from ground to 1 5 44 Genie Z 60 34 Part No 52856 Service Manual Second Edition Continued from the previous page With key switch in ground position and both Emergency Stop buttons pulled out to the ON position move the function enable switch to either side and hold the turntable rotate left right toggle switch TS20 on ground panel in the left direction and check voltage on wht blk wire on boom function directional valve coil item E 12V Continued on the next page Section 5 Troubleshooting Flow Charts Move the function enable switch to either side and hold the turntable rotate left right toggle switch TS20 on ground panel in the left direction and check voltage at TB5 With key switch in platform position and both Emergency Stop buttons pulled out to the ON posit
99. 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 atfull speed and note the time when the machine reference point crosses the finish line Drive speed stowed position high range 2WD 4WD Gasoline LP G models 40 7 8 sec 40 ft 6 1 sec 12 2m 7 8 sec 12 2m 6 1 sec Deutz Diesel models 40 ft 9 1 sec 40 ft 7 sec 12 2 9 1 sec 12 2m 7 sec B 23 Test the Alarm Package Optional Equipment The alarm package includes Travel alarm Descent alarm Flashing beacon Alarms and a beacon are installed to alert operators and ground personnel of machine proximity and motion The alarm package is installed on the turntable covers The alarms and beacon will operate with the engine running or not running 1 Turn the key switch to ground control and pull out the Emergency Stop button to the position at both the ground and platform controls Result The flashing beacon should be and flashing 2 Move the function enable switch to either side and activate the primary boom toggle switch in the pown position hold for a moment and then release it Result The descent alarm should sound when the switch is held down 3 Move the function enable switch to either side and activate
100. the non steering wheels Turntable secured with the turntable rotation lock Key switch in the orr position with the key removed Wheels chocked 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 Selectthe appropriate repair procedure after troubleshooting the problem Perform disassembly procedures to the point where repairs can be completed Then to re assemble perform the disassembly steps in reverse order Symbols Legend Safety alert symbol used to alert personnel to potential personal injury hazards Obey all safety messages that follow this symbol to avoid possible injury or death Red used to indicate the presence of an imminently hazardous situation which if not avoided will result in death or serious injury Orange used to indicate the AWARNING presence of a potentially hazardous situation which if not avoided could result in death or serious injury Yellow with safety alert symbol ACAUTION used to indicate the presence of a potentially hazardous situation which if not avoided may cause minor or moderate injury Yellow without safety alert symbol used to indicate the presence of a potentially hazardous situation which if not avoided may result in property damage CAUTION Green used to indicate operation or maintenance information Indicates that
101. the orr position 2 Disconnecteither end of one of the wires 4 222 1 u ILLI connected to the resistor to be tested DPDT 101010 3 Connectthe leads from an ohmmeter to each end or wiring of the resistor being tested SSS Test Desired result 4 Compare the ohmmeter reading with the resistance rating printed the resistor Left position terminal 1 to 2 3 4 5 amp 6 no continuity infinite 1 5 terminal 2 to 3 continuity zero Toggle Switches LLL terminal2t04 5 amp 6 no continuity Toggle switches used for single function switching terminal 3 to 4 5 amp 6 no continuity are single pole double throw SP DT switches Dual function switching requires a double pole terminal 4 to 5 amp 6 no continuity double throw DP DT Switch terminal 5 to 6 continuity Center position There are no terminal combinations How to Testa Toggle Switch that will produce continuity Continuity is the equivalent of 0 to infinite 3 ohms A simple continuity tester Right position may not accurately test the switch terminal 1 to 2 continuity This procedure covers fundamental switch testing zero Q n not ificall ly to all varieties of 2 terminal 1 to 3 4 5 amp 6 no continuity 99 infinite 1 Turn the key switch to the oFF position Tag terminal 2 to 3 4 5 amp 6 no continuity and disconnect all wiring from the toggle switch to be tested ter
102. to the radiator 7 Openthe drain valve on the engine block and allow the coolantto drain into a container After the fluid is drained close the drain valve 8 Replace all coolanthoses and clamps TABLE D PROCEDURES 9 Fill the radiator with the proper coolant mixture anti freeze and water for your climate until it is full 10 Fill the coolant recovery tank to the NonMAL range 11 Clean up any coolant spilled during this procedure 12 Start the engine from the ground controls run it for 30 seconds and then turn it off 13 Inspect for leaks and then check the fluid level in the coolant recovery tank Add water if needed 14 Start the engine from the ground controls and let it run until it reaches normal operating temperature 15 Tum the engine off 16 Allow engine to cool and check the fluid level in the coolant recovery tank Add water if needed Ford Engine Coolant capacity 11 5 quarts 10 9 liters PartNo 52856 Genie Z 60 34 4 41 Section 4 Scheduled Maintenance P rocedures Service Manual Second Edition TABLE D PROCEDURES D 3 Change the Fuel Hoses Maintaining the fuel hoses in good condition is essential to safe operation and good engine performance Failure to detect a worn cracked or leaking fuel hose may cause an unsafe operating condition Explosion and fire hazard Engine fuels are combustible Replace the fuel lines in an open well Explosion and fire hazard Fuel Injecti
103. uz P ism LI SEE 5 1 oc E Or tH zc eee aN a ee DNO NC RR CN een T n EE INE al i He HX yBl DE 4 gt 2 ENT e xl 1 NEN ee E Ld gt ut 5 E si L L 20411 91 sep i dp pa 8E E e 5i id 1 ES EN 8SE EE dE La ED o HS T ud GO 1 n 7 88 uz E zl tr 6 19 2 60 34 PartNo 52856 CASE DRAINS Service Manual Second Edition Section 7 Repair Procedures Observe and Obey M Repair procedures shall be completed by a person trained and qualified on the repair of this machine M Immediately tag and remove from service a damaged or malfunctioning machine Repair any machine damage or malfunction before operating the machine Before Repairs Start M Read understand and obey the safety rules and operating instructions in the Genie Z 60 34 Operator s Manual M Be sure that all necessary tools and parts are available and ready for use M Read each procedure completely and adhere to the instructions Attempting shortcuts may produce hazardous conditions M Unless otherwise specified perform each repair procedure with the machine in the following configuration Machine parked on a flat level surface Boom in stowed position Turntable rotated with the boom between
104. voltage at blk red oy wire on RPM select switch TS4 and TS14 12 Check voltage at TB35 ov 12V Check voltage at oV terminal 430 on CR3 12V Check voltage to oV terminal 486 on CR3 12V no continuit Check continuity from ground to brown wire at terminal 485 on CR3 continuity Check voltage to oV terminal 87 on CR3 12V Continued on the next page Chart 8 Check high idle adjustment see Maintenance section OR see Deutz workshop manual to troubleshoot fuel injection system Check voltage on red wire at center terminal o RPM select switch Repair open in circuit supplying 12V to center f oV terminal of switch 12V Replace toggle switch Repair open in blk red wire circuit from toggle switch to TB35 Repair open in blk red wire circuit from TB35 to terminal 30 on CR3 Repair open in wht wire circuit from terminal 87 on CR2 to terminal 86 on CR3 Repair open in brown ground wire circuit to terminal 85 on CR3 Replace CR3 relay Part No 52856 Genie Z 60 34 5 19 Section 5 Troubleshooting Flow Charts Service Manual Second Edition CHART 8 Continued from the previous page Check voltage at oV terminal 86 on CR4 12V Check continuity from bad ground to brown wire at terminal 85 on CR4 good Check voltage to oV terminal 30 on CR4 12V Check voltage at the blk red wire on the 2 speed so
105. 2 SWING 6 WHT RED 3 Q SWING RIGHT 5 WHT BLK 3 8 A X R SWING LEFT 4 WHT 3 HED BLK 2 Hun PRIMARY 3 RED WHT 8 Hn PRIMARY DN 2 RED BLK 3 _ e PRIMARY UP 1 RED 3 WHT BLK 5 a N a lt o WHT 4 5 gt Es yl m oc tr e 12 3 4 s e v 8 o t0 fw Q 99 WHT RED 6 v 2 a Q4 z 6 5 5 ORG 14 9 9 2 RED BLK 28 ft g a a cn ORG BLK 15 C o W N 5 2 ORG RED 16 amp 2 lt BLK RED 9 6 15 Genie Z 60 34 Part No 52856 Service Manual Second Edition Section 6 Schematics IMEEM C RC A QQQQQC HQ Part No 52856 Genie Z 60 34 6 16 Section 6 Schematics Service Manual Second Edition Hydraulic Symbols Legend 2 Pressure gauge a Filter Fixed displacement pump Bi directional variable displacement pump d Bi directional motor 2 2 speed bi directional motor Om Pump prime mover engine or motor Cylinder MANNWAN Accumulator YE 0 035 Orifice with size X Variable orifice or shut off valve n x Check valve E Relief valve Priority flow divider olf Wy Solenoid operated dump valve L a Dif
106. 26 Move the lift drive select switch to the lift position if equipped 27 Lower the secondary boom to the stowed position Drive Speed maximum raised or extended All models 1 foot per second 0 3 meter per second 4 10 Genie Z 60 34 Part No 52856 Service Manual Second Edition Section 4 Scheduled Maintenance Procedures Drive Enable Limit Switch The drive enable limit switch is located in the electrical rotary coupler The switch activates a signal light to inform the operator in the platform that the primary boom is past either of the non steering wheels and stops drive movement unless the drive enable override switch is used An improperly functioning drive enable limit switch will allow the machine to operate in an unsafe position 1 Start the engine from the platform controls Then rotate the turntable to the left until the primary boom is pastthe left non steering wheel Result The drive enable indicator light should be on Drive function should not operate until the drive enable override switch is activated 2 Rotate the turntable to the right until the primary boom is pastthe right non steering wheel Result The drive enable indicator light should be on Drive function should not operate until the drive enable override switch is activated TABLE A PROCEDURES Rotation Oscillate Lock out Limit Switch oscillating axle models The rotation oscillate lock out switch is located in
107. 34 kg 10004 kg Ground clearance 9 in 12in 22 9 cm 30 5 cm Operational dimensions Maximum platform height 60 ft 60 ft 18 3m 18 3m Maximum horizontal reach 34 ft 34 ft 10 36 m 10 36 m Maximum turntable tailswing 0 0 Wheelbase 7 ft11lin 7 ft9 in 2 41 2 36m Minimum turning circle 26 ft 10 in 38 ft 10 in outside 8 2m 11 8m Minimum turning circle 8 ft 22ft inside 2 3m 6 7 m Turntable rotation continuous continuous Platform rotation 180 180 Platform dimensions 6 ft 8 ft Standard Optional Length 6 ft 8 ft 1 83 m 2 44 m Width 30 in 36 in 76 2 cm 91 4 cm Maximum capacity 500 Ibs 500 Ibs 227 kg 227 kg 8 ft platform not available for 2WD Ind machines Specifications Tires and Rough wheels Industrial Terrain Ind RT Tire size 32x12 15NHS 15 19 5NHS 300 15NHS Tire ply rating 20 12 Load range L F Tire contact area 73 sq in 68 sq in 470 sq 439 sq cm Overall tire diameter 32 9 in 40 in 83 6 cm 102 cm Tire pressure 110 psi 60 psi 7 58 bar 4 14 bar Wheel diameter 15 2 in 19 5 in 38 6 cm 49 5 cm Wheel width 9 75 in 12 25 in 24 8 cm 31cm Wheel lugs 9 5 8 18 9 9 5 8 18 Lug nut torque 125 ftlbs 125 ftlbs 169 5 Nm 169 5 Nm Fluid capacities Fuel tank 20 gallons 76 liters LPG tank 33 5 pounds 15 2 kg Hydraulic tank 45 gallons 170 liters Hydraulic system 53 gallons including tank 201 liters Drive torque hub 40 fl oz 1 2 liters Turntable rotation 8 fl oz t
108. 43HWMT18 45 Guna se 1 1H9IH H331S ES sgal rma VIZIHM 129103315 2 Su ETE ze enema HWREBA 3NION3 JS1WnH ee VIHWITIB HG NHOTNd Er es FG3U TIB 318v2 T TK HOLIMS 2 or T940 91HM 5 29 LD dnold 5 ZHNSPNS OO 19 Lorg uo 31VLOH JI8VLNYNL oa zy H3MOd S E S ZGW 81217 SIHM tr W3 H1HM SaATvA 9848IH G ND 9846HOIE ND 7 9Ggsu H39 8N86 NOLLdO HOLVH3N35 Sp L1HAVNHO PIW CO 9p 8 038 28 Pd Y S ON ON 919 S S10VINOO a3xovis N mM LO 6 10 Section 6 Schematics Service Manual Platform Control Box Wiring Diagram Gasoline LPG Models
109. 6 Service Manual Second Edition Section 7 Repair Procedures 49 Remove the pin retaining fasteners from the ground controls side lower leveling link pivot pin atthe lower mid pivot 50 Use a soft metal drift to remove the pin then remove the ground controls side lower secondary boom leveling link from the machine Crushing hazard The ground AWARNING controls side lower secondary boom leveling link may become unbalanced and fall when it is removed from the machine if it is not properly supported by the overhead crane 51 Attach a lifting strap from an overhead crane to the compression link 52 Remove the pin retaining fasteners from the compression link pivot pin atthe lower secondary boom Use a soft metal drift to remove the pin then remove the compression link from the machine AWARNING Crushing hazard The compression link may become unbalanced and fall when it is removed from the machine if it is not properly supported by the overhead crane 53 Attach a 5 ton 4 536 kg overhead crane to the lower mid pivot 54 Remove the pin retaining fasteners from the lower secondary boom pivot pin atthe lower mid pivot Use a soft metal driftto remove the pin then remove the lower mid pivot from the machine Crushing hazard The lower mid AWARNING pivot may become unbalanced and fall when itis removed from the machine if itis not properly supported by the overhead crane 55 Remove the hose and cable covers
110. CR2 12V Continued on the next page Chart 3 Check battery condition OR check alternator OR check for short circuits OR check battery cables OR replace the battery 0 infinite ohms Replace the fuel solenoid Turn the machine off and isolate the fuel solenoid Check the resistance of the solenoid 3 50 ohms See Deutz service manual for troubleshooting fuel system Repair open in wht 21 wire from CR2 to fuel solenoid Repair open in red wire circuit from battery to CB1 to to CR2 Part No 52856 Genie Z 60 34 5 11 Section 5 Troubleshooting Flow Charts Service Manual Second Edition eee eee CHART 3 Hold the start switch to Hold the start switch to Repair open in blk wire Continued from the either side and check either side and check 12V from terminal 486 on previous pale voltage at terminal 86 voltage at terminal 9 on CR to terminal 9 on of CR2 the ignition start module the ignition start module oV Check voltage at Repair open in power terminal 6 and 7 on supply wires to terminal ignition start module 6 and 7 on ignition start module 12V Check continuity no Repair open in brown ground to brown wire at continuity ground wire circuit to 12V terminal 5 on ignition terminal 5 on ignition start module start module continuity Replace the ignition start module OR consult Genie Industries Service Department no c
111. CV valve Gas LPG C 11 Spark plugs Gas LPG C 12 Air LPG mixture C 13 Valves Deutz diesel ChecklistD YN R Refer to Table D D 1 Hydraulic oil D 2 Engine coolant Gas LP G D 3 Change fuel hoses D 4 Valves Gas LP G D 5 Compression Gas LP G D 6 PCV hose Gas LP G D 7 Fuel injection Deutz D 8 Toothed belt Deutz D 9 Timing belt Gas LP G D 10 Steer axle bearings 2WD models B 15 P latform leveling B 16 Horn B 17 Foot switch Part No 52856 Genie Z 60 34 Section 3 Scheduled Maintenance Inspections Service Manual Second Edition M This page intentionally left blank 3 8 Genie Z 60 34 Part No 52856 Service Manual Second Edition Section 4 Scheduled Maintenance Procedures Scheduled Maintenance Procedures Observe and Obey M Maintenance inspections shall be completed by a person trained and qualified on the maintenance of this machine Scheduled maintenance inspections shall be completed daily quarterly annually and every 2 years as specified on the Maintenance Inspection Report Failure to perform each procedure AWARNING as presented and scheduled may cause death serious injury or substantial damage M Immediately tag and remove from service a damaged or malfunctioning machine M Repair any machine damage or malfunction before operating machine Keep records on all inspections for three years
112. Do not lift 3 Check to ensure that each turntable bearing bolt is torqued in specified order to 210 foot pounds 285 Newton meters 10 1 15 8 14 16 9 2 4 Remove the strap from the lower secondary boom arm Then lower the secondary boom to the stowed position Genie Z 60 34 Part No 52856 Service Manual Second Edition Section 4 Scheduled Maintenance Procedures 5 Check to ensure that each bearing mounting bolt under the drive chassis is torqued in specified order to 210 foot pounds 285 Newton meters 10 15 C 3 Check the Free wheel Configuration 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 Collision hazard Selecta work AWARNING site that is firm and level Component damage hazard If the machine must be towed do not exceed 2 mph 3 2 km h Non steering wheels All models CAUTION 1 Chock the steer wheels to prevent the machine from rolling 2 Center a lifting jack of ample capacity 20 000 1 5 9072 kg under the drive chassis between the non steer tires 3 Liftthe wheels off the ground and then place jack stands under the drive chassis for support TABLE C PROCEDURES 4 Disengage the torque hubs by turning over the torque hub disconnect caps
113. Genie Industries Technical Publications Genie Z 60 34 Service Manual from serial number 1090 to 4000 Second Edition First Printing Rev Part No 52856 E May 2007 Introduction Service Manual Second Edition Genie Z 60 34 Important Read understand and obey the safety rules and operating instructions in the Genie Z 60 34 Operator s Manual before attempting any maintenance or repair procedure This service manual covers the Genie Z 60 34 2WD and 4WD models introduced in 1998 This manual provides detailed scheduled maintenance information for the machine owner and user It also provides troubleshooting 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 ata Genie dealer service center 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 other manuals Please write or
114. LIVE PWR WATER TEMP SWITCH VPWR PINK BLK 16awg FUEL PUMP OUTPUT VREF BLK WHT 10awg BATT BLK WHT 10awg BATT DATA LINK DRIVE BY WIRE SIGNAL INPUT AUXILARY INPUT WHT PUR 18awg SELF TEST INPUT TAN LB 18awg GOV SPD CONT BLK Y 18awg GOV SPD CONT PINK LG 18awg FAULT LT BRN WHT 20awg FUEL SELECT DATA LINK CONNECTOR DATA LINK CONNECTOR DB BL 16awg STARTER INPUT DRIVE BY WIRE SIGNAL RETURN OIL PRESSURE SWITCH NOTE SHOWS USED WIRES D Service Manual Section 6 Schematics Ford LRG 425 EFI Engine Wire Harness C B A MATING FACE L ij 1 i i RED LB 16awg STARTER OUTPUT L i i i i i SHOWN
115. LS 3 Visually inspect the primary boom extend drive limit switch located atthe pivot end of the primary boom Inspect for the following Broken or missing actuator arm Missing fasteners Loose wiring Start the engine from the ground controls and extend the primary boom approximately 2 feet 0 6 m Turn the engine off PartNo 52856 Genie Z 60 34 4 9 Section 4 Scheduled Maintenance P rocedures Service Manual Second Edition TABLE A PROCEDURES 10 Manually activate the primary boom extend drive limit switch O Result The primary boom extend drive limit switch arm should move freely and spring return to center A distinct click should be felt and heard 11 Startthe engine from the platform controls and fully retract the primary boom 12 Move the lift drive select switch to the drive position if equipped 13 Press down the footswitch and slowly move the drive control handle to the full drive position Result The machine should move at normal drive speeds 14 Move the lift drive select switch to the lift position if equipped 15 Press down the footswitch Then raise the primary boom approximately 2 feet 61 cm 16 Move the lift drive select switch to the drive position if equipped 17 Press down the footswitch and slowly move the drive control to the full drive position O Result The maximum achievable drive speed with the primary boom raised should not exceed 1 foot per second
116. Nm Hex size 13 16 inch Temperature switch point 300 F 149 C Cil pressure switch specifications Torque 8 18 ft Ibs 11 24 Nm Hex size 11 16 inch Oil pressure switch point 7 psi 0 48 bar PartNo 52856 Genie Z 60 34 7 33 Section 7 Repair Procedures Service Manual Second Edition Ford LRG 425 EFI Engine 8 1 Timing Adjustment The ignition timing is controlled by the ECM and can only be adjusted by re programming the ECM If timing adjustment or service is required please contact Genie Industries Service Department OR your local Ford dealer 8 2 RPM Adjustment Refer to Maintenance Procedures B 11 Check and Adjust the Engine RPM 8 3 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 1 16 inch gap Flex Plate Removal 1 Disconnectthe wiring plug atthe electronic displacement controller EDC located on the drive pump 2 Supportthe drive pump with an appropriate lifting device Then remove all of the pump mounting plate to engine bell housing bolts 3 Carefully pull the pump away from the engine and secure it from moving CAUTION Component damage hazard Hoses can be damaged if they are kinked or pinched 4 Remove the flex plate mounting fastener
117. No 52856 Service Manual Second Edition Section 7 Repair Procedures MANIFOLDS E J AG NA RF K 0 PartNo 52856 Genie Z 60 34 7 45 Section 7 Repair Procedures Service Manual Second Edition MANIFOLDS 11 2 Valve Adjustments Function Manifold How to Adjust the System Relief Valve Perform this procedure with the boom in the stowed position 1 Connecta 0 to 5000 psi 0 to 345 bar pressure gauge to the test port item 22 on the function manifold 2 Startthe engine from the ground controls 3 Hold the function enable switch to the HIGH IDLE position and activate and hold the retract switch with the boom fully retracted Observe the pressure reading on the pressure gauge System relief valve specifications Pressure 2400 psi 165 bar 4 Turn the engine off Use a wrench to hold the relief valve and remove the cap item 23 function manifold 5 Adjustthe internal hex socket Turn it clockwise to increase the pressure or counterclockwise to decrease the pressure Then install the relief valve cap Tip over hazard Do not adjust AWARNING the relief valve higher than specified 6 Repeatsteps 2 through 5 and recheck relief valve pressure How to Adjust the Primary Boom Down Relief Valve Perform this procedure with the boom in the stowed position 1 Connecta 0 to 5000 psi 0
118. R manifold has an internal defect Consult the Genie Industries Service Department Chart 11 Part No 52856 Genie Z 60 34 5 23 Section 5 Troubleshooting Flow Charts Service Manual Second Edition Chart 12 Ground Controls Inoperative Platform Controls Operate Normally no Does the engine start from the ground controls Be sure all other functions operate normally including the platform controls With both Emergency Stop buttons pulled out to the ON position check voltage at red wire on the input side of the ground controls contact of the key switch KS1 the red wire checked should originate from the Emergency Stop button 12V With the keyswitch turned to ground controls and both Emergency Stop buttons are pulled out to theon position check voltage at red wire at the output side of the ground controls contact on the key switch 12V Repair open in red wire circuit from key switch to function enable toggle switch to each function toggle switch Start the engine from the ground controls Move the function enable toggle switch to either side and check the voltage on the center terminal of the jib boom toggle switch TS16 Repair open in red wire circuit from key switch to function enable toggle switch to each function toggle switch 12V Troubleshoot each function individually Repair open in red wire circuit from emergency stop button to the
119. Second Edition Section 5 Troubleshooting Flow Charts All Lift and Steer Functions Inoperative Drive Functions Operational Be sure the hydraulic suction line shutoff valve for the lift steer pump is in the OPEN position Be sure all grounding wires for the hydraulic manifold valves are free of corrosion and have full continuity to ground Install a 0 to 5000 PSI 345 bar pressure to the test port item V on the function manifold Start engine move the function enable toggle Switch to the high RPM side and hold the boom retract function toggle switch and check the hydraulic pressure Adjust the function manifold system relief valve item W all the way in clockwise counting the number of turns Move the function enable switch to the high RPM side and hold the boom retract toggle switch and recheck the pressure Check the function pump see Repair section Replace the function pump Check steer functions steering inoperative Troubleshoot each function individually or consult Genie Industries Service Department Move the function enable switch to the high RPM side and hold the boom retract switch and readjust the relief pressure to 2400 psi 165 bar Repair or replace differential sensing valve item S OR repair or replace flow regulator valve item X OR manifold has an internal defect consult Genie Industries Service Department Replace the relief valve item W O
120. Secondary boom down Primary and secondary boom up down Turntable rotate left right and primary boom extend retract prevents overflowing the proportional valve Torque 30 35 in lbs 3 4 Nm 30 35 in lbs 3 4 Nm 11 13 ftlbs 15 18 Nm 30 35 in lbs 3 4 Nm 30 35 in Ibs 3 4 Nm 30 35 in Ibs 3 4 Nm 30 35 in lbs 3 4 Nm 11 13 ftlbs 15 18 Nm 10 12 ftlbs 14 16 Nm 25 30 ft lbs 34 41 Nm 25 30 ft lbs 34 41 Nm 25 30 ft lbs 34 41 Nm 10 12 ftlbs 14 16 Nm 10 12 ftlbs 14 16 Nm 25 30 ft lbs 34 41 Nm Description Hex size Torque SAE No 4 3h6 13 ft lbs 18 Nm SAE No 2 1 8 50 in Ibs 6 Nm SAE No 6 1 4 18 ft lbs 24 Nm 7 42 Genie Z 60 34 PartNo 52856 Service Manual Second Edition Section 7 Repair Procedures MANIFOLDS E J AG NA RF 8 K 0 PartNo 52856 Genie Z 60 34 7 43 Section 7 Repair Procedures Service Manual Second Edition MANIFOLDS Function Manifold Components continued Index Schematic No Description Item Function Torque 17 Proportional solenoid valve Quads Turntable rotate left right and primary boom extend retract 10 12 ft Ibs 14 16 Nm 18 Flow regulator valve 0 6 2 3 Rao Platform level 10 12 ft lbs 14 16 Nm 19 D
121. Section 4 Scheduled Maintenance P rocedures Service Manual Second Edition Table C Procedures C 1 Check the Primary Boom Wear Pads Maintaining the primary 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 1 Start the engine from the ground controls then extend the primary boom 1 foot 30 cm 2 Measure each wear pad Replace the wear pad if itis less than 9 16 inch If the wear pad is not less than 9 16 inch shim as necessary to obtain zero clearance and zero drag 3 Extend and retract the primary 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 primary boom inner and outer tubes C 2 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 until the platform end of the lower secondary boom arm is 8 feet 2 4 m off the ground 2 Attach the lifting strap from an overhead crane to the platform end of the lower secondary boom arm for support
122. Start the engine then retract the boom and check the pressure 250 psi Check voltage at TB43 0V 12V 12V Check voltage at TB44 oV Check voltage at the blk 9 wire on the oscillate 12V solenoid valve item HH Lower the boom to the e stowed position and turn 5400 the engine off Install a 0 to 3000 psi 207 bar H gauge to the test port on the function manifold then place a block between the rod end wedge on the oscillate cylinder and the wedge stop on the axle to prevent the cylinder from extending Start the engine and raise the primary boom 2 feet 0 6 m Check the pressure on the gauge 2400 psi Adjust the oscillate relief valve item GG to 250 psi 17 bar OR check to make sure LS3 is being activated OR replace LS3 contact Remove the block and check for mechanical restrictions keeping oscillate cylinder from retracting OR replace oscillate cylinder Repair open in wht wire with diode from TB21 to TB43 Adjust LS1 so that it is activated when the primary boom is raised 2 feet 0 6 m OR repair LS1 or replace LS1 contact Replace CR9 Adjust system relief valve item W to 2400 psi 165 bar Remove the block and check for mechanical restrictions keeping oscillate cylinder from extending OR replace oscillate cylinder 5 76 7 60 34 Part No 52856 Service Manual Second Edition Continued from the previous page
123. The horsepower limiter board is responsible for governing drive pump output It senses engine rpm from the alternator The horsepower limiter board senses drops in rpm normally due to increased drive resistance rough terrain or incline and decreases voltage to the drive controller which in turn decreases voltage to the drive pump thereby reducing pump output to maintain optimum engine rpm and horsepower Three adjustments are required for optimum performance How to Adjust the Horsepower Limiter Board The engine rpm must be correct before performing this procedure See Maintenance Procedure B 11 Check and Adjust the Engine RPM Do not adjust the horsepower limiter board unless the static battery voltage is above 12V DC and the alternator is operating properly with 12 5 to 14 5V DC output Gasoline LPG models P erform this procedure in gasoline mode 1 Remove the fasteners from the platform control box lid 7 6 Genie Z 60 34 Part No 52856 Service Manual Second Edition Section 7 Repair Procedures pu C AA U J HJ PLATFORM CONTROLS 2 Open the control box lid and locate the 5 Move the engine idle control switch to foot horsepower limiter board switch activated high idle rabbit and foot switch AWARNING Electrocution hazard Contact Symbol with electrically charged circuits 6 Press down the foot switch and adjustthe could result in death or serious
124. Y i AND VALVE Part No 52856 Genie Z 60 34 NOTE CIRCUIT CONNECTION TO TP24 IS FOR UNITS WITHOUT GENERATOR OPTION RED RED TP25 RED FS1 a Service Manual TP22 B Electrical Schematic Gasoline LPG Models Section 6 Schematics BLK RED 1 bie HIGH RPM i ENGINE SPEED 99 3i t FUNCTION ENABLE 3 HIGH RPM B gt S GRN WHT 4 GENERATOR OPTION E P B 8g 5 m z T BK 7 RD 7 WHT 5 m BLK 5 ae PRIMARY LIFT 89 x o 5 9 Dx 2 ze i pe 45 m x 5 Oe Ge OSCILLATE LOCKOUT 90 qM S CEPLATFORMLEVEL DISABLE OPTION f k E MEN IEEE 3 x x n 29 3 gt MES gt lt BK 6 222 RD 6 E 2 OSCILLATE RELAY E 9 z x t 5 5 Qe C OSC VALVE a gt WHT 8
125. Y BOOM COMPONENTS 3 Install the new shims under wear pad to obtain zero clearance and zero drag 4 Usea round punch to align the shim to the wear pad Install the mounting fasteners 5 Extend and retract the primary boom through an entire cycle Check for tight spots that could cause scraping or binding Always maintain squareness between the primary boom outer and inner tubes How to Remove the Primary Boom AWARNING 29 injury hazard This procedure requires specific repair skills lifting equipment and a suitable workshop Attempting this procedure without these skills and tools could cause death or serious injury and significant component damage Dealer service is strongly recommended 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 Referto Section Two Hyaraulic Hose and Fitting Torque Specifications 1 Remove the platform See 2 1 How to Remove the Platform 2 Remove the jib boom See 3 1 How to Remove the Jib Boom 3 Remove the hose and cable clamp from the upper mid pivot 4 Remove the primary boom drive speed limit switch from the upper mid pivot at the pivot end ofthe primary boom Do not disconnectthe wiring Remove the primary extension boom drive speed limit switch mounted on the inside of the pivot end of the primar
126. Z 60 34 4 39 Section 4 Scheduled Maintenance P rocedures Service Manual Second Edition TABLE D PROCEDURES 13 Supportthe hydraulic tank with 2 lifting straps Place one lifting strap at each end ofthe tank and attach the lifting straps to an overhead crane 14 Remove the hydraulic tank from the machine Crushing hazard The hydraulic AWARNING may become unbalanced and fall if itis not properly supported and secured to the overhead crane 15 Remove the suction strainers from the tank and clean them using a mild solvent 16 Rinse outthe inside of the tank using a mild solvent 17 Install the suction strainers using a thread sealant on the threads 18 Install the drain plug using a thread sealanton the threads 19 Install the hydraulic tank onto the machine 20 Install the two suction hoses and the supply hose for the auxiliary power unit 21 Fill the tank with hydraulic oil until the level is within the top 2 inches 5 cm of the sight gauge Do not overfill 22 Clean up any oil that may have spilled and open the hydraulic tank valves CAUTION Component damage hazard Be sure to open the two hydraulic tank valves and prime the pump after installing the hydraulic tank The pump needs to be primed before starting the engine See Repair procedure 11 2 How to Prime the Pump Always use pipe thread sealant when installing the drain plug Use only Dexron quivalent hydraulic fluid Hydraulic syst
127. _ d x a BLK 3 EXTEND BOOM mb RETRACT BLK WHT 3 2 2 lad d m BOOM EXTEND LLL EXTEND BLK WHT fr retract BOOM 8 aa Y B Ble BEIIWEITA BOOM RETRACT bs BLK RED 4 o e Ey WHT RED 3 E WHT BLK 3 iB tr o WHT 3 n WHT 5 x WHT 4 TURNTABLE ROTATE RIGHT RIGHT TURNTABLE WHT BLK 7 LEFT ROTATE E 7 z 8 WHUBEKA TURNTABLE ROTATE LEFT i 4 i 1 1 a WHTIRED M TURNTABLE ROTATE 1251 pit amp EXTEND RETRACT 8 FLOW CONTROL RED m CR11 5 ur RED PRIMARY BOOM UP SUME PRIMARY o RED BLK DOWN BOOM m ED BLK 3 LE at PRIMARY BOOM DOWN 2 1 RED WHT4 PRIMARY BOOM amp FLOW CONTROL m RED 3 gt RED BLK 3 E B RED WHT 3 a 5 BLU BLK 3 BLU 3 BLK CR10 piu amp BLU mE H SECONDARY BOOM UP SECONDARY e BLK pown 800 F BLU BLK 4 SECONDARY BOOM DOWN E RED WHT n aM ORG 3 PLATFORM LEVEL ORG BLK 3 ORG M ORG 4 amp PLATFORM LEVEL UP PLATFORM ORG BEK j 5 DOWN PLATFORM LEVEL DOWN 1 o m 2 ORG RED4 a 1 PLATFORM LEVEL FLOW CONTROL ORG RED 3 E 5 CE PLATFORM LEVEL T GANS DISABLE OPTION oz re let JIB BOOM g DOWN
128. a specific resultis expected after performing a series of steps PartNo 52856 Genie Z 60 34 7 1 Section 7 Repair Procedures Service Manual Second Edition Platform Controls 1 1 Joystick Controllers Maintaining joystick controllers atthe proper settings is essential to safe machine operation Every joystick controller should operate smoothly and provide proportional speed control over its entire range of motion CETTE Platform control box a horsepower limiter board b terminal strip c drive proportional controller d secondary boom proportional controller e primary boom proportional controller f turntable rotate proportional controller Primary Boom Up Down Controller Adjustments Do not adjust joystick controllers unless the static battery voltage is above 12V DC and the alternator is operating properly with 13 6 to 14 5V DC output AWARNING Electrocution hazard Contact with electrically charged circuits could result in death or serious injury Remove all rings watches and other jewelry 1 Check the battery condition with a volt meter The reading should be 12V DC or more to accurately adjustthe controller 2 Turn the key switch to platform control and pull out the Emergency Stop button to the position at both the ground and platform controls Do not start the engine Open the plat
129. ables out of the lower mid pivot and lay them off to the side CAUTION Component damage hazard Cables and hoses can be damaged if they are kinked or pinched 43 Place blocks under each of the lower secondary boom leveling links for support atthe turntable pivot end 44 Remove the pin retaining fasteners from both of the upper mid pivotto lower secondary boom leveling link pivot pins Use a soft metal drift to remove the pins then remove the upper mid pivot from the machine Crushing hazard The upper mid AWARNING pivot may become unbalanced and fall when itis removed from the machine if itis not properly supported by the overhead crane 45 Attach a lifting strap from an overhead crane to the center of the engine side lower secondary boom leveling link 46 Remove the pin retaining fasteners from the engine side lower leveling link pivot pin atthe lower mid pivot 47 Use a soft metal driftto remove the pin then remove the engine side lower secondary boom leveling link from the machine Crushing hazard The engine side AWARNING lower secondary boom leveling link may become unbalanced and fall when itis removed from the machine if itis not properly supported by the overhead crane 48 Attach a lifting strap from an overhead crane to the center of the ground controls side lower CAUTION Cables and hoses can be secondary boom leveling link damaged if they are kinked or pinched 7 28 Genie Z 60 34 Part No 5285
130. ag 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 flat level surface Boom in stowed position Turntable rotated with the boom between the non steering wheels Turntable secured with the turntable rotation lock Key switch in the orr position with the key removed Wheels chocked Before Troubleshooting Read understand and obey the safety rules and operating instructions printed in the Genie Z 60 34 Operator s Manual Be sure that all necessary tools and test equipment are available and ready for use Read each appropiate flow chart thoroughly Attempting shortcuts may produce hazardous conditions Be aware of the following hazards and follow generally accepted safe workshop practices Crushing hazard When testing or replacing any hydraulic component always support the structure and secure it from movement Electrocution hazard Contact with electrically charged circuits may result in death or serious injury Remove all rings watches and other jewelry Bodily injury hazard Spraying AWARNING 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 Perform al
131. air open in brown platform rotate select p ground wire circuit to valves item AC valve coils Activate footswitch and platform rotate right function function inoperative Activate platform rotate Repair open in grn blk right function and check ov wire from TB18 to the voltage on the grn platform rotate jib boom blk wire at the platform directional valve coil rotate jib boom item A directional valve item A Exchange the two valve function Replace the defective coils on the directional operates valve coil OR valve valve Check platform cartridge may be rotate right function defective function inoperative Repair or replace platform rotator OR 0 030 orifice item AB in jib manifold is plugged OR jib manifold may have an internal defect Consult Genie Industries Service Department 5 62 Genie 2 60 34 Part No 52856 Service Manual Second Edition Section 5 Troubleshooting Flow Charts Jib Boom Up Function Inoperative Be sure all other functions operate normally With the keyswitch turned to ground control and both Emergency Stop buttons pulled out to the ON position move the function enable switch to either side and activate the jib boom toggle switch TS16 in the up direction and check voltage at the grn wire on the jib boom up directional valve item A 12V With the keyswitch turned to platform control and both Emergency Stop buttons pull
132. al Second Edition Section 4 Scheduled Maintenance Procedures 7 Move and hold the drive enable toggle switch to either side and slowly move the drive control handle off center Collision hazard Always use the ACAUTION color coded direction arrows on the platform control panel and the drive chassis to identify which direction the machine will travel Result The drive function should operate 8 Rotate the turntable in the opposite direction until the primary boom is pastthe other non steering wheel O Result The drive enable indicator light should come on and remain on while the boom is anywhere in the range shown 9 Repeatsteps 6 and 7 B 21 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 Hydrostatic brakes and hydraulically released individual wheel brakes can appear to operate normally when they are actually not fully operational Collision hazard Be sure that the AWARNING machine is not free wheel or partial free wheel configuration Refer to B 9 in this section 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 Startthe engine from the platform controls TABLE B PROCEDURES 3 Move the engine idle control switch to foot switch activated
133. apacity Type SAE 90 multipurpose hypoid gear oil API service classification GL5 C 6 Replace the Hydraulic Tank Return Filter Replacement of the hydraulic tank return filter is essential for good machine performance and service life A dirty or clogged filter may cause the machine to perform poorly and continued use may cause component damage Extremely dirty conditions may require that the filter be replaced more often Bodily injury hazard Beware of ACAUTION hot oil Contact with hotoil may cause severe burns Perform this procedure with the engine off 1 Place a suitable container under the hydraulic tank return filter 2 Remove the filter with an oil filter wrench 3 Apply a thin layer of oil to the new oil filter gasket 4 Install the new filter Genie part no 46014 and tighten it securely by hand Clean up any oil that may have spilled during the installation procedure 5 Startthe engine from the ground controls 6 Inspectthe filter and related components to be sure that there no leaks C 7 Replace the Drive Loop Hydraulic Filter Replacing the drive loop hydraulic filter is essential to good machine performance and service life A dirty or clogged filter may cause the machine to perform poorly and continued use may cause component damage Extremely dirty conditions may require that the filter be replaced more often Bodily injury hazard Beware of ACAUTION hot oil Contact with hot o
134. approximately 5 seconds then release it Repeatthis three times Crushing hazard Keep clear of AWARNING the platform during rotation 5 Hold the platform rotate switch to the left for approximately 5 seconds then release it 6 Fully rotate the platform to the left and continue holding the platform rotate switch until air stops coming out of the bleed valve Immediately release the platform rotate switch and close the top bleed valve PLATFORM COMPONENTS Rotate the platform to the right until it is centered Connect the clear hose to the bottom bleed valve and open it Rotate the platform to the right and continue holding the platform rotate switch until air stops coming out of the bleed valve AWARNING Crushing hazard Keep clear of the platform during rotation 10 Close the bottom bleed valve and remove the hose 11 Turn off the engine and clean up any hydraulic oil that may have spilled 12 Start the engine from the ground controls Rotate the platform full right then full left and inspect the bleed valves for leaks PartNo 52856 Genie Z 60 34 7 13 Section 7 Repair Procedures Service Manual Second Edition 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 assembly or fitting the O ring on the fitting and or hose end must be replaced and then torqued to specification during install
135. arrel end pivot pin Use a soft metal drift to remove the pin 7 Lowerthe master cylinder down and out of the upper mid pivot and remove it from the machine Crushing hazard The master AWARNING cylinder may become unbalanced and fall when itis removed from the machine if itis not properly attached to the overhead crane 7 24 Genie Z 60 34 Part No 52856 Service Manual Second Edition Section 7 Repair Procedures Secondary Boom Components 7 WI 0 c CO 5 1 Secondary Boom How to Disassemble the Secondary Boom AWARNING 2 y injury hazard This procedure requires specific repair skills lifting equipment and a suitable workshop Attempting this procedure without these skills and tools could cause death or serious injury and significant component damage Dealer service is strongly recommended Follow the disassembly steps to the point required to complete the repair Then re assemble the secondary boom by following the disassembly steps in the reverse order Cay 1 oO o 7A Secondary Boom 353 3 jib boom extension tube primary boom upper leveling link upper secondary boom upper mid pivot turntable pivot primary boom lift cylinder lower leveling link lower secondary boom secondary boom lift cylinder lower mid pivot compression link jib boom leveling link PartNo 52856 G
136. ation Referto Section Two Hyaraulic Hose and Fitting Torque Specifications Remove the platform See 2 1 How to Remove the Platform Remove the platform mounting weldment the platform leveling slave cylinder and the platform rotator See 2 3 How to Hemove the Platform Rotator S upport the platform pivot weldment with an appropriate lifting device Remove the pin retaining fasteners from the platform pivot weldment to jib boom pivot pin Use a soft metal driftto remove the pin then remove the platform pivot weldment from the jib boom Crushing hazard The platform ACAUTION pivot weldment may become unbalanced and fall when it is removed from the machine if it is not properly supported 5 Tag disconnect and plug the jib boom lift cylinder hydraulic hoses Cap the fittings on the cylinder Bodily injury hazard S praying AWARNING 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 6 Remove the pin retaining fasteners from the jib boom lift cylinder barrel end pivot pin Do not remove the pin 7 Tag disconnect and plug all the hydraulic hoses from the jib boom manifold Cap the fittings on the manifold 8 Tagand disconnectthe wiring from the jib boom manifold Bodily injury hazard S praying AWARNING hydraulic oil can penetrate and burn skin Loosen hydraulic connections very slowly to
137. ay require periodic replacement The burn skin Loosen hydraulic yoke must be removed before the torque hub can connections very slowly to allow be removed The wheel motor on 4WD models is the oil pressure to dissipate an integral part of the torque hub gradually Do not allow oil to squirt or spray When removing a hose assembly or fitting the O ring on the fitting 3 Loosen the wheel lug nuts Do not remove and or hose end must be replaced them and then torqued to specification 4 Blockthe non steering wheels and then during installation Refer to Section Two Hydraulic Hose and Fitting Torque Specifications 5 Raisethe machine approximately 10 inches 25 4 cm and place blocks underthe chassis for support center a lifting jack of ample capacity under the steering axle 6 Remove the lug nuts then remove the tire and wheel assembly 7 Remove the pin retaining fasteners from the yoke pivot pin yoke pivot pin retaining bolt oscillating axle tie rod steering cylinder pivot pin torque hub yoke se FTO a0 7 70 Genie Z 60 34 Part No 52856 Service Manual Second Edition Section 7 Repair Procedures 8 Place a block between the oscillate cylinder lock out wedge and the chassis on the same side as the yoke torque hub being serviced block torque hub yoke oscillating axle lock out wedge chassis 9 Supportand secure the yoke torque hub assembly to a lift
138. b manifold 9 Remove the cable clamp from the platform rotator 10 Remove the cable cover from the side of the jib boom 11 Tag disconnect and plug the hydraulic hoses from the jib boom manifold Cap the fittings on the jib boom manifold Bodily injury hazard S praying AWARNING 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 12 Remove the hose clamps from the top ofthe jib boom 13 Remove the hose and cable clamp from the primary boom at the pivot end 14 Remove the retaining fastener from the cable track tube at the platform end of the primary extension boom 15 Remove the fasteners from the side panel on the lower cable track then remove the panel Pull all of the cables out of the channel Genie Z 60 34 Part No 52856 Service Manual Second Edition Section 7 Repair Procedures 16 Place blocks between the lower cable track and the upper cable track tube and secure them together AWARNING Crushing hazard If the lower cable track and upper cable track tube are not properly secured together the cable track may become unbalanced and fall when itis removed from the machine 17 Attach a lifting strap from an overhead crane to the cable track 18 Remove the cable track guide fasteners from the platform end of the primary boom 19 Remove the cable track mounting fasteners
139. ce Department OR your local Ford dealer Gasoline LPG models REV B Deutz Diesel models This procedure will require two people 1 Connect an rpm gauge to the engine and then start the engine from the ground controls O Result Low idle should be 1500 rpm Skip to step 4 if the low idle rpm is correct 2 Loosen the low idle lock nut then turn the low idle adjustment screw clockwise to increase the rpm or counterclockwise to decrease the rpm Tighten the low idle lock nut and recheck the solenoid boot high idle adjustment nut yoke lock nut yoke low idle adjustment screw low idle lock nut 3 Move the function enable toggle switch to the high idle rabbit symbol position at the ground controls O Result High idle should be 2300 rpm Low idle 1600 rpm If high idle rpm is correct disregard High idle 2500rpm adjustment step 4 4 22 Genie Z 60 34 Part No 52856 Service Manual Second Edition Section 4 Scheduled Maintenance Procedures 4 Loosen the yoke lock nut then 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 Diesel models Low idle 1500 rpm High idle 2300 rpm B 12 Test the Key Switch Proper key switch action and response is essential to safe machine operation The machine
140. ce Manual Second Edition Section 5 Troubleshooting Flow Charts CHART 1 Hold the start switch to Check ground wire to Repair open in brown either side and check terminal 5 on ignition ground wire to ignition voltage at terminal 1 on start module start module ignition start module Continued from the previous page Consult Genie Industries Service Department Hold the start switch to Repair open in blk wire either side and check from terminal 1 on voltage at terminal 86 ignition start module to on CRI CRI Check voltage at terminal 30 on CR1 Repair open in red wire circuit from battery to CB1 to CR1 terminal 30 Hold the start switch to Check brown ground Repair open in brown either side and check wire to terminal 85 on ground wire circuit to voltage at terminal 87 CRI CRI on 1 Replace CR1 relay Hold the start switch to Repair open in blk wire either side and check circuit from CR1 to voltage at the black wire starter solenoid on the starter solenoid Check voltage at starter cable Repair open in battery cable to starter Repair or replace starter or starter solenoid Part No 52856 Genie 2 60 34 5 7 Section 5 Troubleshooting Flow Charts Service Manual Second Edition Chart 2 Engine Cranks Over But Will Not Start Gasoline LPG Models Be sure to check the engine oil level and fill as needed Be sure to check fuel levels and th
141. ce the defective directional valve coil function inoperative Exchange platform level function up and down operates counterbalance valves in the counterbalance valve sandwich item B and activate the platform level down function Replace the defective counterbalance valve function inoperative Install a 0 to 5000 2000 psi Check for mechanical 0 to 345 bar pressure EIE restrictions keeping gauge at the quick platform level down disconnect coupling on function from operating the function manifold OR replace slave and activate the platform cylinder OR replace level down function slave cylinder counterbalance valves OR consult Genie Industries Service less than 2000 psi Department Replace flow regulator valve item R OR test master cylinder see Chart 22 OR repair or replace slave cylinder or slave cylinder counterbalance valves OR function manifold may have an internal defect Consult Genie Industries Service Department 5 56 Genie 2 60 34 Part No 52856 Service Manual Second Edition Section 5 Troubleshooting Flow Charts Platform Rotate Left Function Inoperative Be sure all other functions operate normally With the keyswitch turned to ground control and both Emergency Stop buttons pulled out to the ON position move the function enable switch to either side and activate the platform rotate toggle switch TS15 in the left direction and check voltage
142. ch to the orr position and separate the wiring quick disconnect plug from the platform toe board 2 Remove the foot switch guard mounting fasteners from the platform 3 Remove the foot switch mounting fasteners that attach the foot switch to the footswitch guard 4 Remove the cover plate from the bottom of the foot switch to access the foot switch wire terminals 5 notpress down the foot switch Connect leads from an ohmmeter or continuity tester to each terminal combination listed and check for continuity Test Desired result N C to C continuity zero N C to N O no continuity infinite C to N O no continuity 3 Press down the foot switch Connect the leads from an ohmmeter or continuity tester to each terminal combination listed below and check for continuity Test Desired result N C toC no continuity infinite Q N C to N O no continuity C to N O continuity zero Q N O N C e e 2 red white black 7 8 Genie Z 60 34 Part No 52856 Service Manual Second Edition Section 7 Repair Procedures PLATFORM CONTROLS 1 4 Center Right Resistors The resistors are used on 4WD machines to maintain low range drive speed The resistors are located in the platform control box Refer to the schematic legends for resistor locations and values How to Test the Resistors OA aao SPDT Ge 4 5 6 1 Turn the key switch to
143. circuit hydraulic loop that keeps the platform level through the entire range of boom motion The master cylinder is located inside the upper mid pivot at the base of the primary boom AWARNING 29 injury hazard This procedure requires specific repair skills lifting equipment and a suitable workshop Attempting this procedure without these skills and tools could cause death or serious injury and significant component damage Dealer service is strongly recommended Perform this procedure with the boom in the stowed position 4 Tag disconnect and plug the hydraulic hoses from the master cylinder Cap the fittings on the When removing a hose assembly or fitting the O ring on the fitting and or hose end must be replaced Bodily injury hazard S praying and then torqued to specification AWARNING hydraulic oil can penetrate and cylinder during installation burn skin Loosen hydraulic Referto Section Two Hyaraulic connections very slowly to allow Hose and Fitting Torque the oil pressure to dissipate Specifications gradually Do not allow oil to 1 Remove the pin retaining fasteners from the SEI master cylinder rod end pivot pin Use a soft 5 Attach a lifting strap from an overhead crane to metal drift to remove the pin the lug on the rod end of the master cylinder 2 Raise the secondary boom until the upper 6 Remove the pin retaining fasteners from the mid pivot is above the turntable covers master cylinder b
144. corrosion preventative sealant will help eliminate corrosion on the battery terminals and cables B 6 Check the Hydraulic Tank Return Filter Condition Indicator Maintaining the hydraulic tank return filter in good condition is essential to good system performance and safe machine operation The filter condition indicator will show when the hydraulic flow is bypassing a clogged filter If the filter is not frequently checked and replaced impurities will remain in the hydraulic system and cause component damage 1 Startthe engine from the platform controls 2 Movethe engine speed control switch to high idle rabbit symbol 3 Inspectthe filter condition indicator a filter condition indicator b filter c hydraulic tank Result The filter should be operating with the plunger in the green area If the display shows the plunger in the red area this indicates that the hydraulic filter is being bypassed and the filter should be replaced See C 6 Replace the Hydraulic Tank Return Filter 4 18 Genie Z 60 34 Part No 52856 Service Manual Second Edition Section 4 Scheduled Maintenance Procedures B 7 Inspect the Electrical Wiring Maintaining electrical wiring in good condition is essential to safe operation and good machine performance F ailure to find and replace burnt chafed corroded or pinched wires could result in unsafe operating conditions and may cause component damage Electrocution hazard
145. could cause death or serious injury Use extreme caution when overriding a machine function Identify the direction of machine movement before overriding a valve 7 48 Genie Z 60 34 Part No 52856 Service Manual Second Edition Section 7 Repair Procedures MANIFOLDS 11 3 Turntable Rotation Manifold Components 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 Turntable rotation brake release 10 13 ft lbs 14 18 Nm 2 Counterbalance valve CC uos Turntable rotate right 35 40 165 47 54 Nm 3 Counterbalance valve DD Turntable rotate 35 40 ft lbs 47 54 Nm PartNo 52856 Genie Z 60 34 7 49 Section 7 Repair Procedures Service Manual Second Edition MANIFOLDS 11 4 Auxiliary Steer Manifold Components Non oscillating Models The auxiliary steer manifold is mounted to the auxiliary pump Index Schematic No Description Item Function Torque 1 2 position 3 way solenoid valve Enables steer left right function while using auxiliary power 30 35 in Ibs 3 4 Nm O How to Check the Resistance of a Valve Coil 1 Turn the key switch to the orr position and disconnect th
146. cuit board Connect the black lead to ground 6 Setthe threshold Press down the foot switch then slowly move the control handle off center until the momenta voltage reading appears Adjustthe voltage to 3V DC Turn the threshold trimpot adjustment screw clockwise to increase the voltage or counterclockwise to decrease the voltage 7 Setthe hi range Press down the foot switch fully retract the boom then move the control handle all the way to the leftor right Adjust the voltage to 5 8V DC Turn the hi range trimpot adjustment screw clockwise to increase the voltage or counterclockwise to decrease the voltage PartNo 52856 Genie Z 60 34 7 5 Section 7 Repair Procedures Service Manual Second Edition PLATFORM CONTROLS 8 Startthe engine and move the engine idle control switch to foot switch activated high idle rabbit and foot switch symbol Rotate the turntable to the FULL RIGHT position Engine should be at normal operating temperature 9 Starta timer and record how long it takes the turntable to rotate to the Lert position Adjust the max out trimpot to achieve a 130 to 140 second cycle time Turn the hi range trimpot adjustment screw clockwise to increase the speed or counterclockwise to decrease the speed Turntable rotation specifications Threshold 3V DC Turntable rotation hi range 5 8V DC Cycle time 130 to 140 seconds Ramp rate 3 seconds 1 2 Horsepower Limiter Board
147. d check the voltage on the org blk 4 1wire on the alterator Repair open in org blk 7108V 41 wire from alternator to TB41 to TP41 to terminal 3 on horsepower limiter board oV Repair or replace alternator Genie Z 60 34 Part No 52856 Service Manual Second Edition Section 5 Troubleshooting Flow Charts Activate the footswitch and hold the drive joystick in the full Continued from the previous page forward position and check the voltage at terminal 6 on the drive joystick controller 9to 12V Connect the positve lead from a voltmeter to terminal 4 on the joystick and the negative lead to terminal 5 on the joystick Activate the footswitch and hold the drive joystick in the full forward position and check the voltage across the 4 and 5 terminals on the drive joystick controller Connect the positve lead from a voltmeter to terminal 5 on the joystick and the negative lead to terminal 4 on the joystick Activate the footswitch and hold the drive joystick in the full reverse position and check the voltage across the 5 and 4 terminals on the drive joystick controller 2V Continued on the next page CHART 34 Repair open in wire from terminal 10 on horsepower limiter board to terminal 6 on the drive joystick no Check continuity from continuity terminal 3 on drive joystick to ground Repair open in brown ground wire circuit from
148. d engine performance and safe machine operation There are three settings Low idle turtle symbol allows the operator to control individual boom functions only Drive functions do not operate at low idle High idle rabbit symbol allows the operator to contro multiple boom and or drive functions simultaneously This setting maintains a consistent high idle and is usually selected only when the generator option is being used 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 Pullout the Emergency Stop button to the ON position at both the ground and platform controls Ww TABLE B PROCEDURES Start the engine from the ground controls then move the function enable toggle switch to the high idle rabbit symbol position and hold in the ON position Result The engine should change to high idle Release the function enable toggle switch Result The engine should return to low idle Turn the key switch to platform controls Atthe platform controls move the engine idle control switch to high idle rabbit symbol Do not press down the footswitch Result The engine should change to high idle Move the engine idle control switch to low idle turtle symbol Result The engine should change to low idle Move the engine idle control switch to foot Switch activated high idl
149. d place a lifting jack of ample capacity under the steering axle 3 Raise the machine and place blocks under the chassis for support 4 Remove the lug nuts Then remove the tire and wheel assembly 5 Remove the dust cap mounting fasteners and remove the dust cap 6 Remove the cotter pin and castle nut 7 Pullthe 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 Remove the rear bearing How to Install the Hub and Bearings 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 grease 2 Place the large inner bearing into the rear of the hub 3 Press the bearing seal evenly into the hub until itis flush 4 Slide the hub onto the yoke spindle CAUTION Component damage Do not apply excessive force or damage to the lip ofthe seal may occur 5 Place the outer bearing into the hub 6 Install the washer and castle nut 7 Tighten the castle nutto 35 foot pounds 47 Nm to seatthe bearing 8 Loosen the castle nut then re tighten to 8 foot pounds 11 Nm 9 Install a new cotter pin Bend the cotter pin to lock it in 10 Install the dust cap then the tire and wheel assembly Torque the wheel lug nuts to 125 foot pounds 169 5 Nm 14 2 Steering Cylinders How to Remove a Steering Cyl
150. d replace defective switch Replace CR4 relay solenoid binds Check linkage or replace solenoid Part No 52856 Genie Z 60 34 5 21 Section 5 Troubleshooting Flow Charts Service Manual Second Edition Chart 10 All Functions Inoperative Engine Starts and Runs Check hydraulic Fill with Dexron fluid level equivalent hydraulic fluid Check pump suction line closed shutoff valves In the with valves closed it open position the valve may have damaged one handles should be or both pumps Please parallel with hose contact the Genie Industries Service Department Do the pumps feel excessively hot If engine has been run Open valves and start the engine Check all machine functions for correct operation On gasoline LPG Troubleshoot models close the valve inoperative boom on the LPG tank and functions and move the fuel select inoperative drive toggle switch TS13 to functions separately the LPG position On Deutz diesel models hold manual fuel shutoff lever to the closed position clockwise Remove function pump from main pump but leave all hoses connected Hold start switch and crank engine over while observing spline drive at rear of main pump spline does not turn Engine to pump flex plate coupling 15 defective OR main pump is defective Consult Genie Industries Service Department 5 22 Genie Z 60 34 Part No 52856 Service Manual
151. down direction and check voltage TB11 oV Activate footswitch and secondary boom function controller BP2 on platform control panel in down direction and check voltage 11 oV Activate footswitch and check voltage at terminal on BP2 12V or more Re adjust controller see Repair Section OR replace controller BP2 OR consult Genie Industries Service Department 12V or more 12V or more 12V or more Repair open in blu blk 11 wire circuit from TB11 to secondary boom down function directional valve coil F OR repair open in brown ground wire circuit to valve coil Troubleshoot the secondary boom down function toggle switch TS18 on ground control panel OR repair open in blu 10 wire circuit from TS18 to TB11 OR consult Genie Industries Service Department Repair open in blu blk wire from TP11 to TB11 Repair open in power supply circuit from TP24 to BP2 OR repair open in brown ground wire circuit from ground to BP2 Genie Z 60 34 Part No 52856 Service Manual Second Edition Section 5 Troubleshooting Flow Charts CHART 17 Disconnect wires to 0 or secondary boom down infinite directional valve coil ohms item F and test the resistance of the valve coil See Repair Section Continued from the previous page Replace secondary boom down directional valve coil item F 510 7 ohms Install a 0 to 5000 PSI C
152. e 2WD Steering Axle Components 14 T tex aida da aa edt d a oet ae 14 2 Steering Cylinders oie eee eee e Ha dete deed ng 1453 tide 39 39 42 46 49 50 51 52 54 56 58 60 61 61 64 67 68 69 PartNo 52856 Genie Z 60 34 Xi Service Manual Second Edition AREE RET TABLE OF CONTENTS Section Seven Repair Procedures continued 4WD Steering Axle Components 15 1 Yoke and Hub rtt tie Ea eee e ges 7 70 15 2 Steering Cylinders See 14 2 Steering Cylinders 7 68 15 3 Tie Rod See 14 3 Tie Rod 2 2000000000000000000000050 7 69 Oscillating Axle Components 16 1 Oscillating Axle Lock out 7 72 Non steering Axle Components 17 1 Drive Motor c dae v ee reU d Ed E E s 7 73 17 2 Torque Hub sione e e bt en ee aA d bc 7 73 xii Genie Z 60 34 Part No 52856 Service Manual Second Edition Section 2 Specifications Machine Specifications Stowed dimensions 2WD RT 2WD Ind 4WD RT Length 26 ft 26 ft 7 92 m 7 92 m Width 7ft 7 ft6 in 2 13m 2 29 m Height 8 ft 1 in 8ft4in 2 46m 2 54m Weight 21900 Ibs 22055 Ibs 99
153. e The sending unit has limit contacts that are factory set The contacts will open at approximately 8 psi 0 55 bar When the contacts close the engine will shut off to prevent damage Oil pressure will be indicated will be indicated when the engine is running CAUTION Component damage hazard Do not crank the engine with the low oil pressure light on FORD LRG 425 EFI ENGINE How to Remove the Water Temperature or Oil Pressure Gauge Sending Units Perform this procedure with the engine off 1 Remove the 2 engine pivot plate retaining bolts Then swing the engine out away from the machine to access the water temperature and oil pressure sending units 2 Openthe engine side cover and locate the water temperature and oil pressure switches 3 Disconnectthe wiring from the desired switch 4 Remove the switch from the engine block and then install the new switch Do not over tighten Burn hazard Contact with hot ACAUTION engine fluids or components may cause severe burns Always use pipe thread sealant when installing a switch Water temperature switch specifications Torque 8 18 ft Ibs 11 24 Nm Hex size 13 16 inch Temperature switch point 230 F 110 C Cil pressure switch specifications Torque 8 18 ft Ibs 11 24 Nm Hex size 11A6 inch Oil pressure switch point 8 psi 0 55 bar PartNo 52856 Genie Z 60 34 7 35 Section 7 Repair Procedures Service Manual Second Edition
154. e rabbit and foot switch symbol Result The engine should not change to high idle Press down the foot switch Result The engine should change to high idle PartNo 52856 Genie Z 60 34 4 25 Section 4 Scheduled Maintenance P rocedures Service Manual Second Edition TABLE B PROCEDURES B 19 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 when 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 the gasoline and LPG fuel levels and warming the engine to normal operating temperature 1 Move the fuel select switch to gasoline and then move the engine idle control switch to foot switch activated high idle rabbit and foot switch symbol 2 Startthe engine from the platform controls and allow it to run atlow idle 3 Press down the foot switch to allow the engine to run athigh idle Result The engine should start promptly and operate smoothly in low and high idle 4 Release the foot switch and shutthe engine off by pushing the Emergency Stop button in to the oFF position 5 Move the fuel select switch to LPG 6 Restartthe engine and a
155. e up direction and check voltage at TB3 With the keyswitch turned to platform controls and both Emergency Stop buttons pulled out to theon activate ootswitch and primary boom function controller 1 on platform control panel in up direction and check voltage at TP3 oV Activate footswitch and check voltage at terminal on BP1 12V or more Re adjust controller see Repair Section OR replace controller BP1 OR consult Genie Industries Service Department 11 12V 11 to 12V Repair open in red wht wire circuit from TB3 to primary boom up down proportional valve coil item N OR repair open in brown ground wire circuit to valve coil Repair open in red wht wire from TP3 to TB3 Repair open in power supply circuit from TP24 to BP1 OR repair open in brown ground wire circuit from ground to BP1 5 26 Genie Z 60 34 Part No 52856 Service Manual Second Edition Section 5 Troubleshooting Flow Charts MN CHART 14 With key switch turned to ground controls and both Emergency Stop buttons pulled out to the ON position move the function enable switch to either side and hold the primary boom up toggle switch TS19 at the ground controls in the 12V or up direction and check more voltage on red 1 wire on primary boom up down directional valve coil item G Move the function Repair open in red 1 enable switch to either wire circuit from TS19
156. e access cover mounting fasteners Table B Procedures All models 3 Inspect the engine belt for Cracking Glazing Separation Breaks 4 Replace belt if any damage is found Ford LRG 425 EFI engines are equipped with a serpentine belt and incorporate a self adjusting pulley tensioner No adjustment is required Deutz Diesel models 5 Check the engine belt for proper tension Deutz Diesel engine 6 Install the front engine access cover 7 Swing the engine in to its original position and install the 2 engine pivot plate retaining bolts 3 8 inch to 1 2 inch 9mmto 12 mm Belt deflection Deutz Diesel models Engine belts Genie part numbers Deutz Diesel models 32698 Gasoline LPG models 52580 PartNo 52856 Genie Z 60 34 Section 4 Scheduled Maintenance P rocedures Service Manual Second Edition TABLE B PROCEDURES B 2 Check the Radiator Gasoline LPG Models Maintaining the radiator in good condition is essential for good engine performance O perating a machine with a damaged or leaking radiator may result in engine damage Also restricting air flow through the radiator i e dirt or debris will affect the performance of the cooling system A frequent check allows the inspector to identify changes in the condition of the radiator that might indicate cooling system problems AWARNING 20dily injury hazard Do not inspect while the engine is running Remove the key to secure from op
157. e controller DP1 to TP37 then to TB37 Part No 52856 Genie Z 60 34 5 73 Section 5 Troubleshooting Flow Charts Service Manual Second Edition N CHART 32 Install a 0 to 5000 PSI Check for mechanical 0 to 345 bar pressure restrictions keeping gauge at the quick steer right function from disconnect coupling on operating OR repair or the boom function replace steer cylinders manifold and activate OR replace flow the steer right function regulator valve item X OR consult Genie Industries Service less than 2400 PSI Department Continued from the previous page Repair or replace steer cylinders OR steer manifold could have an internal defect Consult Genie Industries Service Department 5 74 Genie Z 60 34 Part No 52856 Service Manual Second Edition Section 5 Troubleshooting Flow Charts Chart 33 Oscillate Start the engine from no Check voltage at TB43 0V Repair open in wht wire Function the ground controls and with diode from TB21 to 2 extend the primary TB43 Inoperative boom approximately 2 12V feet 0 6 m Does the oscillate cylinder fully Be sure all other extend Check voltage at 1846 L12Y Adjust LS3 so that it is function operate not activated when the normally boom is extended 2 feet 0 6 m OR repair 1153 oV or replace LS3 contact Be sure that the machine is on a firm level surface 12V n blk Replace CR9 9 wire on the oscillate Be su
158. e engine coolant level Be sure that the radiator overflow tank is at the FULL mark Perform following tests in gasoline mode only See Repair Section How to Retrieve Fault Codes ls there a fault HES code stored in the ECM memory With the keyswitch m turned to ground 11V controls and both Emergency Stop buttons pulled out to the on position hold start switch to either side and check battery voltage while engine is cranking more than 11V With the keyswitch in the position and both Emergency Stop buttons pulled out to the on position turn the keyswitch to ground controls and listen for the fuel pump to turnoN for approximately 2 seconds and then shut OFF Did the fuel pump turn ON yes Remove 1 spark plug good and ground spark plug spark body Crank engine and observe spark weak or no spark Continued on the next page Check for poor terminal connections OR check for shorted or damaged wires that go from the ECM to the sensor that is causing the fault OR replace the sensor OR consult Genie Industries Service Department Check battery condition OR check alternator OR check for short circuits OR check battery cables OR replace the battery Testthe fuel pump relay See Repair Section OR replace the fuel pump Consult Genie Industries Service Department Refer to the fault code chart in this section for a description of the fault and recommended repa
159. e motors in forward and reverse 25 30 ft lbs 34 41 Nm 7 Flow divider combiner valve UU ast Controls flow to non steer end drive motors in forward and reverse 2 25 30 ft lbs 34 41 Nm 8 Orifice 0 070 in 1 78 mm VV Rear drive motor circuit 9 Orifice 0 070 in 1 78 mm WW Equalizes pressure on both sides of flow divider combiner valve Index no 2 10 Shuttle valve 3 position 3 way Charge pressure circuit that gets hot oil out of low pressure side of drive pump and allows low pressure flow path for brake release and 2 speed motor shift 15 18 ftlbs 20 24 Nm 11 Diagnostic fitting Yes Testing 12 Check valve sene ZZ uns Works in conjunction with Index no 4 in the high speed divider bypass circuit 10 12 ft lbs 14 16 Nm Plug Torque Specifications Description Hex size Torque SAE No 2 1 8 50 in lbs 6 Nm SAE No 4 3 16 13 ftlbs 18 Nm 7 58 Genie Z 60 34 Part No 52856 Section 7 Repair Procedures Service Manual Second Edition MANIFOLDS Genie Z 60 34 PartNo 52856 Section 7 Repair Procedures Service Manual Second Edition MANIFOLDS 11 10 Valve Adjustments 4WD Drive Manifold How to Adjust the Charge Pressure Relief Valve
160. e wires from the valve coil to be tested 2 Connectthe leads from an ohmmeter to the valve coil terminals Xy Valve coil specifications 2 position 3 way solenoid valve 10V 4 to 60 schematic item EE 7 50 Genie Z 60 34 Part No 52856 Service Manual Second Edition Section 7 Repair Procedures Epu MM C A S M MANIFOLDS 11 5 Steer Manifold Components Non oscillating Models The steer manifold is mounted inside the drive chassis atthe steer end Index Schematic No Description Item Function Torque 1 3 position 4 way 003 valve EF Steer 3 6 30 35 in lbs 3 4 Nm How to Check the Resistance of a Valve Coil 1 Turn the key switch to the orr position and O disconnect the wires from the valve coil to be tested 2 Connectthe leads from an ohmmeter to the valve coil terminals 0 0 aat Valve coil specifications 3 position 4 way D03 valve 10V 2 5 to 3 20 schematic item FF PartNo 52856 Genie Z 60 34 7 51 Section 7 Repair Procedures Service Manual Second Edition pu JJA MJ MANIFOLDS 11 6 Steer Oscillate Manifold Components Oscillating Models The steer oscillate manifold is mounted inside the drive chassis atthe steer end Index Schematic No Descript
161. ed from the previous page 12V or more Continued on page Service Manual Second Edition Move the function enable switch to either side and hold the secondary boom up toggle switch TS18 at the ground controls in the up direction and check voltage at TB10 12V or more Turn the keyswitch to ground controls and start the engine Check voltage at TB43 12V or more With the engine still running check voltage on wht wire at LS2 12V or more Check voltage on blk 0 wire at LS2 12V or more Check voltage on blk 0 wire at CR10 12V or more Continued on page Repair open in blu 10 wire circuit from TS18 to TB10 Repair open in wht wire circuit from TB21 to TB43 OR replace the diode at TB43 Repair open in wht wire circuit from TB43 to 152 Be sure that LS2 is being activated when the secondary boom is in the stowed position OR replace LS2 contact Repair open in blk wire from LS2 to CR10 5 34 Genie 2 60 34 Part No 52856 Service Manual Second Edition Section 5 Troubleshooting Flow Charts S CHART 16 Disconnect wires to 0 or secondary boom up infinite directional valve coil ohms item F and test the resistance of the valve coil See Repair Section Continued from page 5 34 left column Replace secondary boom up directional valve coil item F 5 to 7 ohms Install a 0 to 5000 PSI Check for mechanical 345
162. ed out to theon osition activate the footswitch and the jib boom toggle switch TS6 in the up direction and check voltage at TB17 12V Continued on the next page Move the function enable switch to either side and activate the jib 12V boom toggle switch TS16 in the up direction and check voltage at TB17 Repair open in red power wire circuit from keyswitch to TS16 OR ene toggle switch 516 Activate the footswitch 12V and the jib boom toggle switch TS6 in the up direction and check voltage at TP17 With the keyswitch turned to platform 12V control and both Emergency Stop buttons pulled out to the on position activate the footswitch and check the voltage on the center terminal of the jib boom toggle switch TS6 Check the voltage at oV terminal 430 on CR13 P 12V Check the voltage at ov terminal 87a on CR13 12V Repair open in red wire from terminal 87a on CR13 to TS8 OR consult Genie Industries Service Department Chart 27 Repair open in grn wire from TB17 to jib boom up directional valve OR repair open in brown ground wire circuit to directional valve Repair open in grn wire from TP17 to TB17 Repair open in grn wire from TS6 to TP17 OR replace jib boom toggle switch TS6 Repair open in red wire from BP1 to CR13 OR repair open in brown ground wire circuit to CR13 Replace CR13 Part No 52856 Genie Z 60 34 Sec
163. ed to ground control and both Emergency Stop buttons pulled out to the ON position move the function enable switch to either side and activate the jib boom toggle switch TS16 in the down direction and check voltage at the grn blk wire on the jib boom up directional valve item A 12V With the keyswitch turned to platform control and both Emergency Stop buttons pulled out to the ON osition activate the footswitch and the jib boom toggle switch TS6 in the down direction and check voltage at TB18 12V Continued on the next page Move the function enable switch to either side and activate the jib 12V boom toggle switch TS16 in the down direction and check voltage at TB18 Repair open in red power wire circuit from keyswitch to TS16 OR ene toggle switch 516 Activate the footswitch 12V and the jib boom toggle switch TS6 in the down direction and check voltage at TP18 With the keyswitch turned to platform 12V control and both Emergency Stop buttons pulled out to the on position activate the footswitch and check the voltage on the center terminal of the jib boom toggle switch TS6 Check the voltage at oV terminal 430 on CR13 P 12V Check the voltage at ov terminal 87a on CR13 12V Repair open in red wire from terminal 87a on CR13 to TS8 OR consult Genie Industries Service Department Chart 28 Repair open in grn blk wire from TB18 to jib
164. ee loa E m E pod CE EJ ESL E 9 4 EE E y cc ed S W i Bo BN R EA 58 a zi 2 FN fe rad i S _ 3 in 5 LL 5 4 c cr i 5 a 4 o t P I JA 2 5 oH d lt FED d 6 18 Genie Z 60 34 Part No 52856 CASE DRAINS Section 6 Schematics 4WD Hydraulic Schematic Service Manual ce N st
165. em Hydraulic tank capacity 45 gallons 170 liters Hydraulic system 53 gallons capacity including tank 200 6 liters Hydraulic fluid Dexron equivalent Genie Z 60 34 Part No 52856 Service Manual Second Edition Section 4 Scheduled Maintenance Procedures D 2 Change or Recondition the Engine Coolant Gasoline LPG Models Replacing or reconditioning the engine coolant is essential to good engine performance and service life Old or dirty coolant may cause the engine to perform poorly and continued use may cause engine damage Extremely dirty conditions may require coolantto be changed more frequently Bodily injury hazard Beware of ACAUTION hot engine parts and coolant Contact with hot engine parts and or coolant will cause severe burns Perform this procedure with the engine off and cooled 1 Remove the 2 engine pivot plate retaining bolts and swing the engine out away from the machine 2 Puton protective clothing and eye wear 3 Disconnectthe coolant return hose at the radiator and drain the coolant return tank into a suitable container 4 Slowly remove the radiator cap from the radiator Bodily injury hazard Allow any ACAUTION pressure to dissipate gradually before removing the radiator cap 5 Open the drain valve on the radiator and allow all the coolantto drain into a suitable container 6 Afterall the coolanthas drained close the drain valve Connect the coolant return hose
166. em F and test the resistance of the valve coil See Repair Section Replace secondary boom up directional valve coil item F 510 7 ohms Repair open in brown ground wire circuit to secondary boom up directional valve coil item F OR begin troubleshooting from beginning of chart 5 96 Genie 2 60 34 Part No 52856 Service Manual Second Edition Section 5 Troubleshooting Flow Charts Secondary Boom Down Function Inoperative Be sure all other functions operate normally With the key switch turned to ground controls and both Emergency Stop buttons pulled out to theon position move the function enable switch to either side and hold the secondary boom down toggle switch TS18 at the ground controls in the down direction and check voltage on red wht wire on secondary boom up down proportional valve coil item N 12V or more Continued on the next page Move the function enable switch to either 1110 side and hold the 12V secondary boom down toggle switch TS18 at the ground controls in the down direction and check voltage at TB3 11 to With the keyswitch 12V turned to platform controls and both Emergency Stop buttons pulled out to the oN activate ootswitch and secondary boom function controller BP2 on platform control panel in down direction and check voltage at TP3 oV Activate footswitch and check voltage at terminal on BP2 12V or
167. en hydraulic connections very slowly to allow the oil pressure to dissipate gradually Do not allow oil to squirt or spray 7 Use a soft metal drift to remove the rod end pivot pin Then remove the slave cylinder from the machine How to Bleed the Slave Cylinder 1 Connecta hydraulic hose between the two test ports at the barrel end of the slave cylinder 2 Start the engine from the ground controls and raise the jib boom to a horizontal position PLATFORM COMPONENTS 3 Hold the function enable toggle switch to either side and move the platform level switch up and down through two platform leveling cycles to remove any air that might be in the system 4 Turn the engine orr 5 Remove the hydraulic hose from the test ports Move the platform level switch up and down through a platform leveling cycle and inspect the test ports for leaks 2 3 Platform Rotator The platform rotator is a hydraulically activated helical gear assembly used to rotate the platform 90 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 platform rotator is installed orthe platform rotator is disassembled proper alignment can be achieved by rotating the rotator all the wa
168. en the steer wheels 2 Measure the steer tires front to front and back to back using a measuring fixture Toe in specification 2WD STEERING AXLE COMPONENTS Center a lifting jack of ample capacity under the steering axle then raise the machine Loosen the jam nut on the adjustable end of the tie rod Remove the pin retaining fasteners from the pivot pin at the adjustable end of the tie rod Slide the tie rod off the yoke and adjust it by turning the end One turn on the adjustable end equals approximately 1 8 inch 3 2 mm change in the front and rear measurements Slide the tie rod onto the yoke Install the pivot pin then install the pin retaining fasteners Tighten the jam nut against the tie rod Lower the machine and recheck the front and back measurements step 2 If further adjustment is needed repeat steps 3 through 8 0 1 8 inch 6 35 mm PartNo 52856 Genie Z 60 34 7 69 Section 7 Repair Procedures Service Manual Second Edition 4WD Steering Axle Components 15 1 1 Remove the pin retaining fasteners from the Yoke and Hub steering cylinder and the tie rod pivot pins 2 disconnect and plug the hydraulic hoses How to Remove the Yoke from the drive motor Cap the fittings on the drive motor and Hub AWARNING Bodily injury hazard S praying The yoke installation utilizes bushings and a thrust hydraulic oil can penetrate and washer that m
169. ency Stop open in brown ground buttons pulled out to the wire from capacitor to ON position activate ground footswitch and platform rotate toggle switch TS5 in the right direction and check voltage at the red wire at the jib delay capacitor 12V Activate footswitch and Repair open in red wire platform rotate toggle from jib delay capacitor switch TS5 in the right to CR14 direction and check voltage on the red wire at terminal 86 on CR14 12V Activate footswitch and Replace relay CR14 OR platform rotate toggle repair open in power switch TS5 in the right supply from P2 to CR14 direction and check OR repair open in brown voltage on the red and ground wire to CR14 black wires at terminal 87 on CR14 12V Activate footswitch and Repair open in cable platform rotate toggle containing red and black Switch TS5 in the right wires from CR14 to jib direction and check boom platform rotate voltage on the red and select valves black wires at the jib platform rotate select valves item AC 12V Oor infinite Test the resistance of ohms Replace defective valve the valve coils coil Continued on the next page Part No 52856 Genie Z 60 34 5 61 Section 5 Troubleshooting Flow Charts Service Manual Second Edition S CHART 26 Check continuity from inuity Repair open in brown brown ground wires on ground wire circuit to valve coils to ground valve coils Continued from the previous page Exchange jib boom Rep
170. enie Z 60 34 Section 7 Repair Procedures Service Manual Second Edition SECONDARY BOOM COMPONENTS When removing a hose assembly 11 Remove the pin retaining fasteners from both or fitting the O ring on the fitting and or hose end must be replaced and then torqued to specification during installation Refer to Section Two Hydraulic Hose and Fitting Torque Specifications Remove the platform See 2 1 How to Remove the Platform Remove the primary boom See 4 2 How to Remove the Primary Boom Remove all four pin retaining fasteners from the two upper leveling link pivot pins Do not remove the pins Attach a lifting strap from an overhead crane at the center of the engine side upper leveling link Remove the engine side upper leveling link from the machine Repeat this step for the ground controls side upper leveling link Crushing hazard The leveling link AWARNING may become unbalanced and fall when it is removed from the machine if it is not properly supported by the overhead crane Remove the pin retaining fasteners from the compression link at the upper secondary boom Use a soft metal drift to remove the pin Attach a securing strap from the upper mid pivot to upper leveling link pivot pin mounting tube to secure the upper mid pivot from moving Attach a 5 ton 4 536 kg overhead crane to the center of the upper secondary boom Remove the lift interlock limit switch from the inside of
171. er terminal of RPM switch Part No 52856 Genie Z 60 34 5 17 Section 5 Troubleshooting Flow Charts Service Manual Second Edition Chart 7 Engine Low Idle Inoperative Gasoline LPG Models See Repair Section How to Retrieve Fault Codes 15 there a fault code stored in the ECM memory Start engine and switch rpm select switch to low idle turtle symbol Check voltage at TB35 Replace ECM or consult Genie Industries Service Department Check for poor terminal connections OR check for shorted or damaged wires that go from the ECM to the sensor that is causing the fault OR replace the sensor OR consult Genie Industries Service Department Isolate the ground and platform RPM toggle switches TS4 and TS14 check individually and replace defective switch Refer to the fault code chart in this section for a description of the fault and recommended repairs 5 18 Genie Z 60 34 Part No 52856 Service Manual Second Edition Section 5 Troubleshooting Flow Charts Engine High Idle Inoperative Deutz Diesel Models Be sure mechanical linkage is not binding or defective Be sure 2 speed solenoid grounding wires are free of corrosion and have full continuity to ground Start the engine then switch rpm select switch to high idle rabbit solenoid pulls in symbol and check if 2 speed solenoid pulls in solenoid does not pull in Check
172. erates items DD and at the turntable rotation motor counterbalance valve manifold Activate turntable rotate right function Replace defective counterbalance valve function inoperative Check for mechanical restrictions keeping turntable rotate right function from operating OR replace shuttle valve item BB OR consult Genie Industries Service Department Part No 52856 Genie Z 60 34 5 51 Section 5 Troubleshooting Flow Charts Service Manual Second Edition Chart 22 All Platform Remove both hydraulic deed n i hoses from the function counterbalance valves Leveling manifold ports PL1 amp i mB manifold i PL2 Plug the hoses item B Functions and cap the manifold i fittings Move the Inoperative function enable switch to B Il oth either side and activate e sue e other the primary boom up functions operate function and check to see if platform levels normally Plumb a 0 to 5000 psi Check for mechanical 0 to 345 bar pressure restrictions OR replace gauge into master the slave cylinder cylinder rod end counterbalance valves hydraulic hose hose connected to port PL2 using a tee fitting Activate primary boom up function and check the pressure less than 2000 PSI Install a 0 to 5000 psi 0 to 345 bar pressure gauge into the barrel end hydraulic hose from the master cylinder and raise the primary boom one inch at a time Continually monitor the p
173. eration Bodily injury hazard Beware of ACAUTION hot engine parts and coolant Contact with hot engine parts and or coolant may cause severe burns 1 Remove the 2 engine pivot plate retaining bolts Then swing the engine out away from the machine to access the radiator a engine pivot plate b pivot plate retaining bolts 2 Inspectthe radiator for leaks and physical damage 3 Clean the radiator fins of debris and foreign materials 4 Swing the engine back to its original position and install the 2 engine pivot plate retaining bolts B 3 Check the Oil Cooler and Cooling Fins Deutz Diesel Models Maintaining the oil cooler in good condition is essential for good engine performance Operating a machine with a damaged oil cooler may result in engine damage Also restricting air flow through the oil cooler will affect the performance of the cooling system AWARNING Bodily injury hazard Do not inspect while the engine is running Remove the key to secure from operation Bodily injury hazard Beware of ACAUTION hot engine components Contact with hot engine components may cause severe burns Oil Cooler 1 Remove the fasteners from the engine side cover then remove the cover 4 16 Genie Z 60 34 Part No 52856 Service Manual Second Edition 2 Inspectthe oil cooler for leaks and physical damage Ss N Q SN 504 oil cooler b cylinder head cooling fins C fan blower
174. ervice Department Repair open in blu 36 wire circuit that runs from TB36 to steer left directional valve coil Replace steer left directional valve coil item FF OR repair open in brown ground wire to steer left valve coil Chart 29 Repair open in blu 36 wire circuit from drive controller DP1 to TP36 then to TB36 Part No 52856 Genie Z 60 34 5 67 Section 5 Troubleshooting Flow Charts Service Manual Second Edition N CHART 29 Install a 0 to 5000 PSI Check for mechanical 0 to 345 bar pressure restrictions keeping gauge at the quick steer left function from disconnect coupling on operating OR repair or the boom function replace steer cylinders manifold and activate OR replace flow the steer left function regulator valve item X OR consult Genie Industries Service less than 2400 PSI Department Continued from the previous page Repair or replace steer cylinders OR steer manifold could have an internal defect Consult Genie Industries Service Department 5 68 Genie Z 60 34 Part No 52856 Service Manual Second Edition Section 5 Troubleshooting Flow Charts Steer Right Function Inoperative Non Oscillating Models Be sure all other functions operate normally With key switch in platform position and both Emergency Stop buttons pulled out to the ON position activate footswitch and steer rocker switch on drive controller DP1 in rig
175. ervice Department Crank engine and check voltage at org blk 41 wire on alternator Repair open in org blk 41 wire circuit from alternator to TB41 to terminal 2 on ignition start module Disconnect red wire from terminal 4 on ignition start module and check voltage at terminal 4 Test auxiliary power toggle switches TS1 and TS11 See Repair Section Refer to the fault code chart in this section for a description of the fault and recommended repairs Check alternator wiring OR repair or replace alternator OR contact Genie Industries Service Department Replace ignition start module OR consult Genie Industries Service Department 5 10 Genie Z 60 34 Part No 52856 Service Manual Second Edition Section 5 Troubleshooting Flow Charts Engine Cranks Over But Will Not Start Deutz Diesel Models Be sure to check the engine oil level and fill as needed Be sure to check fuel level Be sure that the battery is fully charged Hold the start switch to 955 either side and check 11V battery voltage while engine is cranking 11V or more Disable the starter by removing the blk wire at soy the starter solenoid Hold the start switch to either side and check the voltage at positive terminal on fuel shutoff solenoid oV Hold start switch and check voltage at wht 12V 21 wire on terminal 87 of CR2 oV Check voltage at red wire on terminal 30 of
176. esistor 100 25 watt R4 Resistor 120 25 watt TS1 TS11 1522 Gas LPG Toggle switch DPST 2 position momentary TS1 TS11 Diesel Toggle switch DPST 2 position momentary TS2 6 10 12 14 16 Gas LPG Toggle switch SPDT 3 position momentary TS2 6 10 12 14 16 21 22 Diesel Toggle switch SPDT 3 position momentary TS9 20 Toggle switch DPST 2 position maintained TS13 Gas LPG Toggle switch DPST 2 position maintained Toggle switch 3 position maintained TS5 7 8 15 17 18 19 20 21 Toggle switch DPDT 3 position momentary Manufacturer ELECTRICAL COMPONENTS Manufacturer Qty Part Number Part No 52856 Genie Z 60 34 Section 6 Schematics Service Manual Second Edition Electrical Symbols Legend 178 940 Wire color with cable number 7820 Terminal m Quick disconnect terminal BLK 21 21 T circuits connect at terminal T circuits connect r Connection no terminal Circuits crossing no connection Diode Battery 15AMP ho _ Circuit breaker Solenoid or relay coil Horn Tilt sensor As NC T Limit switch normally closed held open P1 a
177. extension cylinder extends and retracts the primary boom extension tube It can only be removed from the platform end of the primary boom The 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 29 injury hazard This procedure requires specific repair skills lifting equipment and a suitable workshop Attempting this procedure withoutthese skills and tools could cause death or serious injury and significant component damage Dealer service is strongly recommended 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 Two Hydraulic Hose and Fitting Torque Specifications 1 Remove the platform See 2 1 How to Remove the Platform 2 Remove the jib boom See 3 1 How to Remove the Jib Boom 3 Extend the primary boom approximately 5 feet 1 5 m until the extension cylinder rod end pivot pins are accessible 4 Remove the extension boom end cap mounting fasteners PRIMARY BOOM COMPONENTS Place blocks under the extension cylinder for Support Remove the external snap rings from the extension cylinder rod end pivot pins Use a soft metal drift to remove the pins If the function is operational use auxilia
178. fax to the Technical Publications team Genie Industries PO Box 97030 Redmond WA 98073 97030 USA Fax Number 425 895 6333 Please visitthe Genie Industries Web Site at http www genielift com Technical P ublications Department e mail techpub genieind com If you have any questions please call Genie Industries Genie North America Telephone 425 881 1800 Toll Free 800 536 1800 in U S A Toll Free 800 426 8089 in Canada Fax 425 556 8649 Genie Europe Office Telephone 44 01636 605030 Office FaxF ax 44 01636 611090 Parts Telephone 44 01636 605002 Parts Fax 44 01636 611091 Genie Industries Copyright 1999 by Genie Industries Second Edition First Printing March 1999 Genie and Z are Registered Trademarks of Genie Industries in the USA and many other countries These machines comply with ANSI SIA 92 5 1992 69 Printed on recycled paper Printed in U S A li Genie Z 60 34 Part No 52856 Service Manual Second Edition Section 1 Safety Rules Safety Rules Danger Failure to obey the instructions and safety rules in this manual and the Genie Z 60 34 Operator s Manual will cause death or serious injury Many ofthe hazards identified in the operator s manual are also safety hazards when maintenance and repair procedures are performed Do Not Perform Maintenance Unless You are trained and qualified to perform maintenance on this machine M You read understand
179. ferential sensing valve Solenoid operated proportional valve Solenoid operated 2 pos 3 way directional valve 9 M duo LEA 6 4 Pilot operated flow control valve Solenoid operated 2 pos 4 way directional valve Solenoid operated 3 pos 4 way directional valve DO1 d 2 pos 3 way shuttle valve UM E 3 pos 4 way directional valve Sequencing valve ril 1 Unloader valve Pressure compensating valve Genie Z 60 34 Part No 52856 Section 6 Schematics 2WD Hydraulic Schematic Service Manual
180. fins 3 Clean the oil cooler of debris and foreign material Cooling and Fan Blower Fins 4 Inspect the fan blower fins for physical damage 5 Clean the fan blower fins of debris and foreign material 6 Inspectthe head cooling passages and fins for physical damage or foreign material using a flashlight 7 Clean the cylinder head cooling passages of debris and foreign material 8 Install the engine side cover 9 Swing the engine back to its original position and install the 2 engine pivot plate retaining bolts Section 4 Scheduled Maintenance Procedures TABLE B PROCEDURES B 4 Check the Exhaust System Maintaining the exhaust system is essential to good engine performance and service life Running 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 Bodily injury hazard Beware of ACAUTION hot engine components Contact with hot engine components may cause severe burns 1 Deutz Diesel models Remove the 2 engine pivot plate retaining bolts Then swing the engine out away from the machine to access the exhaust system a engine pivot plate b pivot plate retaining bolts 2 All models Be sure that all nuts and bolts are tight 3 Inspectall welds for cracks 4 Inspectfor exhaust leaks i e carbon buildup around seams and j
181. form control box lid and locate the primary boom up down controller ramp rate adjustable trimpot lo range adjustable trimpot terminal R activates hi range not used terminal X not used terminal ground terminal positive terminal A proportional output threshold adjustable trimpot hi range adjustable trimpot ra Setthe preliminary ramp rate Turn the trimpot adjustment screw counterclockwise 15 turns or until you hear a repeated click Connect the red 4 lead from a volt meter to the A terminal on the controller printed circuit board Connect the black lead to ground Setthe threshold Press down the foot switch then slowly move the control handle off center until the momenta voltage reading appears Adjustthe voltage to 4 4V DC Turn the threshold trimpot adjustment screw clockwise to increase the voltage or counterclockwise to decrease the voltage 7 2 Genie Z 60 34 Part No 52856 Service Manual Second Edition Section 7 Repair Procedures 7 Setthe hi range Press down the foot switch then move the control handle all the way to the up position Adjust the voltage to 6 5V DC Turn the hi range trimpot adjustment screw clockwise to increase the voltage or counterclockwise to decrease the voltage 8 Setthe lo range Press down the foot switch then move the control handle all the way to the pown position Adjust the voltage to 6V DC Turn the lo range trimpot adj
182. from the lower secondary boom 56 Attach a 5 ton 4 536 kg overhead crane to the center point of the lower secondary boom SECONDARY BOOM COMPONENTS 57 Remove the pin retaining fasteners from the lower secondary boom pivot pin at the turntable pivot Use a soft metal driftto remove the pin then remove the lower secondary boom from the machine hi f AWARNING Crushing hazard The lower secondary boom may become unbalanced and fall when itis removed from the machine if it is not properly supported by the overhead crane 5 2 Secondary Boom Lift Cylinder The secondary boom lift cylinder raises and lowers the secondary boom The secondary boom lift cylinder is equipped with counterbalance valves to prevent movement in the event of a hydraulic line failure How to Remove the Secondary Boom Lift Cylinder AWARNING 22 injury hazard This procedure requires specific repair skills lifting equipment and a suitable workshop Attempting this procedure withoutthese skills and tools could cause death or serious injury and significant component damage When removing a hose assembly or fitting the O ring on the fitting and or hose end must be replaced and then torqued to specification during installation Refer to Section Two Hyaraulic Hose and Fitting Torque Specifications 1 Attach a lifting strap from an overhead crane to the lug on the rod end of the secondary boom lift cylinder PartNo 52856 Genie Z 60
183. from the air cleaner canister 6 Remove the air filter retaining fastener then remove the filter 7 Clean the inside of the canister and the gasket with a damp cloth 8 Insert the new filter and install the mounting fastener 9 Replace the end cap on the canister then install the retaining ring Be sure that the arrows on the air cleaner end cap point in the up direction 10 Install the gas strutonto the ball stud on the cover Then install the retaining clip on the gas strut Air filters Genie part numbers Ford LRG 425 EFI Engine 27916 Deutz FAL 1011F Engine 27916 4 14 Genie Z 60 34 Part No 52856 Service Manual Second Edition Section 4 Scheduled Maintenance Procedures B 1 Check the Engine Belt Maintaining the engine belt is essential to good engine performance and service life The machine will not operate properly with a loose or defective belt and continued use may cause component damage AWARNING Bodily injury hazard Do not inspect while the engine is running Remove the key to secure from operation Bodily injury hazard Beware of ACAUTION hotengine components Contact with hot engine components may cause severe burns Deutz Diesel models 1 Remove the 2 engine pivot plate retaining bolts Then swing the engine out away from the machine to access the front engine access cover mounting fasteners a engine pivot plate b pivot plate retaining bolts 2 Remove the front engin
184. from the fuel shutoff valve to the fuel pump d hose from the fuel pump to the fuel filter e hose from the fuel filter to the injection pump f hose from the injection pump to the injectors 4 42 Genie Z 60 34 Part No 52856 Service Manual Second Edition Section 4 Scheduled Maintenance Procedures Gasoline LPG Models Explosion and fire hazard Electronic Fuel Injection EFI systems operate ata very high pressure Fuel may be expelled under pressure if the hoses are removed too quickly Loosen the fuel lines very slowly to allow the fuel pressure to dissipate gradually Wrap a cloth around fuel hoses to absorb leaking fuel before disconnecting them 5 Locate the fuel pressure regulator filter and the fuel pump on the engine pivot plate behind the engine 6 Remove and replace all ofthe fuel hoses and clamps according to the following hose routing diagram From tank Fuel Pump Pre Filter Pressure To engine Regulator filter Return to tank Gasoline LPG models a high pressure hose from fuel pump to regulator filter b hose from fuel pre filter to fuel pump C hose from fuel tank to fuel pre filter d high pressure hose from regulator filter to engine e hose from regulator filter to tank 7 Clean up any fuel that may have spilled during this procedure TABLE D PROCEDURES 8 Startthe engine from the ground controls then inspect the fuel filter and hoses for leaks Ex
185. fuel injectors 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 7 Check the Hydraulic Oil Level Maintaining the hydraulic oil at the proper level is essential to machine operation Improper hydraulic oil levels can damage hydraulic components Daily checks allow the inspector to identify changes in oil level that might indicate the presence of hydraulic system problems 1 sure that the boom is in the stowed position then visually inspect the sight gauge located on the side of the hydraulic oil tank Result The hydraulic oil level should be within the top 2 inches 5 cm of the sight gauge Hydraulic oil specifications Hydraulic oil type Dexron equivalent Tank capacity 45 gallons 170 liters Hydraulic system 53 gallons including tank 201 liters 4 4 Genie Z 60 34 Part No 52856 Service Manual Second Edition Section 4 Scheduled Maintenance Procedures A 8 Check for Hydraulic Leaks Detecting hydraulic fluid leaks is essential to operational safety and good machine performance Undiscovered leaks can develop into hazardous situations impair machine functions and damage machine components Bodily injury hazard S praying AWARNING hydraulic oil can penetrate and burn skin 1 Inspect for hydraulic oil puddles dripping or residue on or around the following
186. g gauge at the quick steer right function from disconnect coupling on operating OR repair or the boom function replace steer cylinders manifold and activate OR replace flow the steer right function regulator valve item X OR consult Genie Industries Service less than 2400 PSI Department Continued from the previous page Repair or replace steer cylinders OR steer manifold could have an internal defect Consult Genie Industries Service Department 5 70 Genie Z 60 34 Part No 52856 Service Manual Second Edition Section 5 Troubleshooting Flow Charts Steer Left Function Inoperative Oscillating Models Be sure all other functions operate normally With key switch in platform position and both Emergency Stop buttons pulled out to the ON position activate footswitch and steer rocker switch on drive controller DP1 in left direction and check voltage on TB36 12V or more With key switch in platform position and both Emergency Stop buttons pulled out to the ON position activate footswitch and steer rocker switch on drive controller DP1 in left direction and check voltage on blu 36 wire on steer directional valve coil item 11 Disconnect wires to steer left directional valve coil item II and test the resistance of the valve coil Continued on the next page 12V or more 4 5 to 5 3 ohms With key switch in platform position and both Emergency Stop buttons pulled
187. g 9 vo1 a38 0HO dn ABVWIHd 45 O8RiHdau verona NMOG WOOG AYN 45 gaxgau 3rig a3u 4181 24 WOOB 5 Iva e TA Li Y zao 1HOIH 31v10H NYNL d S1HM OLHM v EHM IHM J319Y2 143131V10H 45 X8 LM 1 s 1 TYXISIHM V6I LHWNHO 999 Lo C C 03 LOW 95 amp 1 TUM l 4518 Sar 215 151 19v413 W008 TSIM GIlWS SHME IHME VITNED NHOH 6 18 dn WOO AHVQNOO3S asma oF ena _osvorena WOO8 4 5 OQ 2181 451 3 18VN3 INYA CELLEN 21 H 3 1HM S 1H9r1318VN3 i GSH TIB _ SLINN 9NILYTIIOSO RQ 9 dn 73431 1V1d d S ad YO vr DHO T5HO NON ISL 77 NMOQ 13 31 25 1900 st 539580 TOFIH OHO SHPIMEHNNOO VIHM E MOTH 75 1009790 _ ocsei aueo i VSOrIBAHM 8151 1j3131v10H 5 Zr NHO YNYS 5 5 31v10H 45 PENS oO SATA gir ds 6 2 92 1281 ATddNS AH3LLVB AZI 5 02 Haag SH H3MOd NOILINO SIHIFd SIHM VEFFS OIM 12 H3 IHM 18 2
188. h new 0 66 in 16 8 mm Brush length wear limit 0 25 in 6 35 mm Maximum commutator 0 005 inches run out 0 127 mm Battery Type 12V Group 31 Quantity 1 Cold cranking ampere 1000A 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 liters per minute Ignition System Spark plug type Motorcraft AWSF 52C 0 042 to 0 046 inches 1 07 to 1 18 mm Spark plug gap Engine coolant Capacity 111 2 quarts 10 9 liters Alternator Output 95A 14 5V Genie Z 60 34 Part No 52856 Service Manual Second Edition C C OCO QNS T Deutz Engine FAL 1011F Displacement Number of cylinders Bore and stroke 166 7 cu in 2 732 liters 4 3 58 x 4 13 inches Section 2 Specifications SPECIFICATIONS Injection pump pressure 4351 psi 300 bar Injector opening pressure 3626 psi 250 bar Fuel requirement diesel number 2 D 91 x 105 mm Alternator output 55A 14V Horsepower 56 3000rpm Starter motor Firing order 1 3 4 2 Current draw no load 90A Compression ratio 18 5 1 Brush length new 0 7480 in 19mm Compression pressure 362 to 435 psi P 25 to 30 bs Brush length minimum 0 5 in 12 7 mm Low idle 1200 rpm Battery High idle 2200 rpm g 12V Group 31 Governor centrifugal mechanical Quantity 1 Valve clearance cold
189. h serious injury or substantial damage M Immediately tag and remove from service a damaged or malfunctioning machine M Repair any machine damage or malfunction before operating machine Keep records on all inspections for three years About This Section The Schedule There are four types of maintenance inspections that must be performed according to a schedule daily quarterly annual two year To accountfor repeated procedures the Maintenance Tables and the Maintenance Inspection Report have been divided into four subsections A B C D Use the following chartto determine which group s of procedures are required to perform a scheduled inspection Inspection Table or Checklist Daily A Quarterly A B Annual A B C Two year A B C D Maintenance Tables The maintenance tables contained in this section provide summary information on the specific physical requirements for each inspection Complete step by step instructions for each scheduled maintenance procedure are provided in section 4 Scheduled Maintenance Procedures 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 52856 Genie Z 60 34 3 1 Section 3 Scheduled Maintenance Inspections Service Manual Second Edition Maintenance Tables
190. hazard S praying 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 The oscillating axle lock out cylinder extends the lock out wedges between the chassis and the oscillating axle when the boom is raised extended or the turntable is rotated The cylinder slides from side to side in a track on the oscillating axle and uses an externally mounted proximity switch to detect when the lock out wedges are 3 Remove the proximity switch mounting fully extended fasteners from the oscillating axle lock out cylinder How to Remove the Oscillating m T emove the retaining fasteners from the wedge Axle Lock out Cylinder block on the rod end of the oscillating axle Bodily injury hazard This lock out cylinder then slide the wedge block AWARNING procedure requires specific repair E skills and a suitable workshop 5 Slide the oscillating axle lock out cylinder to the Attempting this procedure without left then remove the cylinder these skills and tools could result in death or serious injury and significant component damage Dealer service is strongly recommended 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 Referto Section Tw
191. he engine 5 Clean the hose with a mild cleaning solvent 6 Dry the hose and inspect it for cracks and damage Replace the hose if itis damaged D 7 Check the Fuel Injection Pump and Injectors Deutz Diesel Models Complete information to perform this procedure is available in the Deutz FL 1011F Workshop Manual Deutz number 0297 7195 Genie partnumber 52229 D 8 Check the Toothed Belt Deutz Diesel Models Complete information to perform this procedure is available in the Deutz FL 1011F Operation Manual Deutz number 0297 7343 Genie part number 52883 D 9 Replace the Timing Belt Gasoline LPG Models Complete information to perform this procedure is available in the Ford LRG 425 EFI 2 5 Liter Industrial Engine Service Manual F ord number FPP 194 303 Genie partnumber 52695 Genie Z 60 34 Part No 52856 Service Manual Second Edition Section 4 Scheduled Maintenance Procedures D 10 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 Blockthe
192. he to ground switch LS3 drive limit switches no continuity Be sure the primary boom drive limit switch the wht wire Repair short in wht wire rom cable 6 and check zi from cable 6 to ground gt any continuity from the wht continun OR replace primary and is not activated wire from cable 6 wire boom up drive limit when the boom is in the to ground switch LS1 stowed position no continuity no continuity Be sure the secondary boom drive limit switch esl ne short in wht wire rom cable 8 chec zi from cable 8 to ground js cear ot any debris continuity from the wht OR replace secondary and is not activated wire from cable 8 wire boom up drive limit when the boom is in the to ground switch LS4 stowed position no continuity Be sure that the primary boom extend drive limit Consult Genie Industries switch arm is being Service Department activated when the boom is fully retracted ipi Re adjust horsepower Be sure the wiring to limiterboard see Repair limit switches is intact Secion OR replace and show no sign of horsepower limiter damage or corrosion board Be sure the free wheel valve is closed on the drive pump Part No 52856 Genie Z 60 34 5 85 Section 5 Troubleshooting Flow Charts Service Manual Second Edition Chart 38 Machine Drives At Full Speed With Platform Raised or Extended Be sure primar
193. heck for mechanical 345 bar pressure restrictions keeping gauge at the quick secondary boom from disconnect coupling on moving OR repair the function manifold cylinder or cylinder item V and start the counterbalance valve engine Move the OR oonsult Genie function enable switch to Industries Service either side and hold the Department secondary boom down toggle switch at the ground controls in the up direction and check the pressure less than 1600 PSI function Exchange flow regulator operates valve item J with a like valve item O Check secondary boom down function Replace defective flow regulator valve function inoperative Repair cylinder or cylinder counterbalance valve OR function manifold could have an internal defect Consult Genie Industries Service Department Part No 52856 Genie Z 60 34 5 39 Section 5 Troubleshooting Flow Charts Service Manual Second Edition Chart 18 Primary Boom Extend Function Inoperative Be sure all other functions operate normally With key switch in ground position and both Emergency Stop buttons pulled out to the ON position move the function enable switch to either side and hold the boom extend toggle switch TS21 on ground panel in the extend direction and check voltage on wht red wire on boom extend retract and turntable rotate left right proportional valve coil item Q 12V or more Continued on the next
194. hen remove the valve 5 Install the new PCV valve Connect the hose TABLE C PROCEDURES C 11 Replace the Spark Plugs Gasoline LPG Models Periodic replacement of the spark plugs is essential to good engine performance and service life Worn loose or corroded spark plugs will cause the engine to perform poorly and may result in component damage Perform this procedure with the engine off 1 Remove the 2 engine pivot plate retaining bolts and swing the engine out away from the machine to access the spark plugs 2 Label then disconnect the plug wires from the spark plugs by grasping the handle on the spark plug boot Do not pull on the plug wire Blow out any debris around spark plugs Remove all the spark plugs from the engine Adjust the gap on each new Spark plug Ui A UJ Install the new spark plugs then connect the wires Be sure that each spark plug wire is attached to the correct spark plug Spark plug specifications Spark plug type Motorcraft AWSF 52C 0 042 to 0 046 inches 1 07 to 1 18 mm Spark plug gap Spark plug torque 5 to 10 foot pounds 7to 14 Nm PartNo 52856 Genie Z 60 34 4 37 Section 4 Scheduled Maintenance P rocedures Service Manual Second Edition TABLE C PROCEDURES C 12 Check and Adjust the Air LPG Mixture Gasoline LPG Models Maintaining the proper air to fuel mixture during LPG operation is essential to good engine performance Explosion and
195. hen the primary boom is raised extended orthe turntable rotated the stability of the machine is compromised and it may tip over 1 Start the engine and raise the primary boom approximately 2 feet 61 cm Result The oscillation lock out wedges should fully extend a steer axle b oscillate lock out wedge c lock out wedge stop 2 Lowerthe primary boom to the stowed position O Result The oscillation lock out wedges should fully retract 3 Extend the primary boom approximately 2 ft 61 cm O Result The oscillation lock out wedges should fully extend 4 Fully retractthe primary boom Result The oscillation lock out wedges should fully retract 5 Raise the secondary boom approximately 2 feet 61 cm Result The oscillation lock out wedges should fully extend 6 Lower the secondary boom to the stowed position Result The oscillation lock out wedges should fully retract 7 Rotate the turntable so that the primary boom moves to one side of the drive chassis Result The oscillation lock out wedges should fully extend when the primary boom moves past either of the non steering wheels 8 Rotate the turntable back to the stowed position with the primary boom between the non steering wheels Result The oscillation lock out wedges should fully retract when the primary boom is between the non steering wheels A 11 Test the Platform and Ground Controls Testing the machine functi
196. hes are used to restrict drive speed when the primary boom is raised or extended and to signal the oscillate cylinder to extend the lock out wedges oscillating axle equipped machines An improperly functioning drive limit switch will allow the machine to operate in an unsafe position 1 With the engine off and the boom in the stowed position visually inspectthe primary boom drive limit switch for the following Broken or missing actuator arm Missing fasteners Loose wiring a lift interlock limit switch LS 2 hidden from view b primary boom drive limit switch LS 1 c secondary boom limit switch 154 2 Manually activate the primary boom drive limit switch Result The primary boom drive limit switch arm should move freely and spring return to center A distinct click should be felt and heard 3 Locate the secondary boom drive limit switch located atthe platform end ofthe lower secondary boom TABLE A PROCEDURES Visually inspect the secondary boom drive limit switch for the following Broken or missing actuator arm Missing fasteners Loose wiring Manually activate the secondary boom drive limit switch Result The secondary boom drive limit switch arm should move freely and spring return to center A distinct click should be felt and heard Locate the primary boom extend drive limit switch located inside the pivot end of the primary boom a primary boom extend limit switch
197. high idle rabbit and foot switch then lower the boom into the stowed position 4 Choose a pointon the machine i e contact patch of a tire as a visual reference for use when crossing the test line Bring the machine to top drive speed before reaching the test line Release the drive joystick when your reference point on the machine crosses the test line 6 Measure the distance between the test line and your machine reference point Braking high range paved surface 4 to 6 ft 1 2to 1 8m Stopping distance The brakes must be able to hold the machine on any slope itis able to climb B 22 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 1 Create start and finish lines by marking two lines on the ground 40 feet 12 2 m apart 2 Startthe engine from the platform controls PartNo 52856 Genie Z 60 34 Section 4 Scheduled Maintenance P rocedures Service Manual Second Edition TABLE B PROCEDURES 3 Move the engine idle control switch to foot switch activated high idle rabbit and foot switch then lower the boom into the stowed position 4 Choose a pointon
198. ht direction and check voltage on TB37 12V or more With key switch in platform position and both Emergency Stop buttons pulled out to the ON position activate footswitch and steer rocker switch on drive controller DP1 in right direction and check voltage on blu blk 437 wire on steer directional valve coil item FF Disconnect wires to steer right directional valve coil item FF and test the resistance of the valve coil Continued on the next page 12V or more 2 5 to 3 5 ohms With key switch in platform position and both Emergency Stop buttons pulled out to the ON position activate footswitch and steer rocker switch on drive controller DP1 in right direction and check voltage at the controller terminal with the blu blk wire attached Repair or replace steer microswitch on drive controller Consult Genie Industries Service Department Repair open in blu blk 37 wire circuit that runs from TB37 to steer right directional valve coil Replace steer right directional valve coil item FF OR repair open in brown ground wire to steer right valve coil Chart 30 Repair open in blu blk 37 wire circuit from drive controller DP1 to TP37 then to TB37 Part No 52856 Genie Z 60 34 Section 5 Troubleshooting Flow Charts Service Manual Second Edition N CHART 30 Install a 0 to 5000 PSI Check for mechanical 0 to 345 bar pressure restrictions keepin
199. ication during installation R efer to Section Two Hydraulic Hose and Fitting Torque Specifications 1 Secure the turntable from rotating with the turntable rotation lock 4 Tag disconnect and plug the hydraulic hoses from the brake and turntable rotation manifold Cap the fittings on the brake and turntable rotation manifold unlocked locked AWARNING 2 dily injury hazard 2 Raise the secondary boom until the platform 5 praying hydraulic oil can end of the lower secondary boom arm is penetrate and bum Skin Loosen approximately 8 feet 2 4 m off the ground hydraulic connections very slowly to allow the oil pressure to dissipate gradually Do not allow oil to squirt or spray 7 64 Genie Z 60 34 Part No 52856 Service Manual Second Edition Section 7 Repair Procedures TURNTABLE ROTATION COMPONENTS 5 Remove the motor brake mounting fasteners 2 Remove the motor brake mounting bolts and then remove the motor from the brake then remove the motor and brake from the torque hub and set them to the side Component damage hazard CAUTION Hoses can be damaged if they are kinked or pinched electrical rotary coupler motor brake mounting bolts motor turntable rotation manifold torque hub mounting bolt plug torque hub brake electrical rotary coupler motor brake mounting bolts motor turntable rotation manifold torque hub mounting bolt plug torque hub brake How t
200. ications MANIFOLDS How to Adjust the Secondary Boom Down Relief Valve Perform this procedure with the boom in the stowed position 1 Connecta 0 to 5000 psi 0 to 345 bar pressure gauge to the test port item 22 on the function manifold 2 Startthe engine from the ground controls 3 Hold the function enable switch to the HIGH IDLE position and activate and hold the secondary boom down switch with the secondary boom fully lowered Observe the pressure reading on the pressure gauge Secondary boom down relief valve specifications Pressure 1200 psi 83 bar Pressure 1600 psi 110 bar 4 Turn the engine off Use a wrench to hold the relief valve and remove the cap item 11 function manifold 5 Adjustthe internal hex socket Turn it clockwise to increase the pressure or counterclockwise to decrease the pressure Then install the relief valve cap Tip over hazard Do not adjust AWARNING the relief valve higher than specified 6 Repeatsteps 2 through 5 and recheck relief valve pressure 4 Turn the engine off Use a wrench to hold the relief valve and remove the cap item 13 function manifold 5 Adjustthe internal hex socket Turn it clockwise to increase the pressure or counterclockwise to decrease the pressure Then install the relief valve cap Tip over hazard Do not adjust AWARNING the relief valve higher than specified 6 Repeatsteps 2 through 5 and recheck relief valve pressure
201. ifferential sensing valve Senis Meters flow to functions 10 12 ft lbs 14 16 Nm 20 Flow regulator valve 1 5 gpm 5 7 Platform rotate jib boom 10 12 ft Ibs 14 16 Nm 21 Flow regulator valve 0 1 gpm 0 38 l min Usine Bleeds off differential sensing valves to tank 10 12 ft Ibs 14 16 Nm 22 Diagnostic Testing 23 Relief valve 2400 psi 165 bar W System 35 40 ft Ibs 47 54 Nm 24 Priority flow regulator valve 3 gpm 11 4 l min X aiit Steering 10 12 ft Ibs 14 16 Nm 25 Check valve Differential sensing circuit jib boom down platform rotate right 11 13 ft lbs 15 18 Nm 26 Check valve sssrin ELAN Differential sensing circuit J ib boom up platform rotate 11 13 ft lbs 15 18 Nm 27 Check valve BAN Differential sensing circuit Platform 11 13 ft Ibs 15 18 Nm Plug Torque Specifications Description Hex size Torque SAE No 4 3 16 13 ft lbs 18 Nm SAE No 2 1 8 50 in lbs 6 Nm SAE No 6 1 4 18 ft lbs 24 Nm 7 44 Genie Z 60 34 Part
202. ift cylinder barrel end pivot pin 8 Tag disconnect and plug the hydraulic hoses from the primary boom lift cylinder Cap the fittings on the cylinder Bodily injury hazard S praying AWARNING 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 9 Place another 24 inch 61 cm long block of wood across the lower secondary boom leveling links to support the primary boom lift cylinder when the barrel end pivot pin is removed 10 Support the barrel end ofthe primary boom lift cylinder with an appropriate lifting device 11 Remove the pin retaining fasteners from the primary boom lift cylinder barrel end pivot pin Then use a soft metal drift to remove the pin 12 Lower the barrel end of the cylinder onto the block that was placed on the lower secondary boom leveling links Then lower the secondary boom onto the boom rest 13 Carefully pull the lift cylinder toward the platform end ofthe secondary boom 14 Support and secure the cylinder to an appropriate lifting device Crushing hazard The primary AWARNING boom lift cylinder may fall when it is removed from the machine if it is not properly supported and secured to the lifting device 7 22 Genie Z 60 34 Part No 52856 Service Manual Second Edition Section 7 Repair Procedures 4 4 Primary Boom Extension Cylinder The primary boom
203. il may cause severe burns Perform this procedure with the engine off 1 Open the engine side turntable cover and locate the drive loop hydraulic filter mounted near the pump 2 Remove the filter housing by using a wrench on the nut provided on the bottom of the housing 3 Remove the filter element from the housing 4 Inspect the housing seal and replace it if necessary 5 Install the new filter Genie part no 20880 and hand tighten the housing onto the filter head Clean up any oil that may have spilled during the installation procedure 6 Startthe engine from the ground controls 7 Inspect the filter assembly to be sure that there are no leaks 8 Clean up any oil that may have spilled during the installation procedure 4 34 Genie Z 60 34 Part No 52856 Service Manual Second Edition Section 4 Scheduled Maintenance Procedures C 8 Replace the Diesel Fuel Filter Water Separator Deutz Diesel Models Replacing the diesel fuel filter is essential to good engine performance and service life A dirty or clogged filter may cause the engine to perform poorly and continued use may cause component damage Extremely dirty conditions may require that the filter be replaced more often Explosion and fire hazard Engine fuels are combustible Replace the fuel filter in an open well ventilated area away from heaters sparks flames and lighted tobacco Always have an approved fire extinguisher w
204. inal connection Voltage to fuel pump is greater than or equal to 2V DC below ignition voltage Water in the fuel misfiring cylinder plugged fuel filter OR the sensor wiring is shorted to ground OR there is a poor terminal connection OR the sensor is bad Engine is overheating OR sensor wires shorted to ground or poor terminal connections OR ECT sensor is bad operation Check for poor terminal connections or shorted wires from the TP sensor to the ECM OR replace the TP sensor Check for poor terminal connections OR wires shorted to ground OR replace MAP sensor Check for obstructions in the throttle body that could cause binding of the throttle assembly OR replace ECM Check for poor terminal connections or shorted wires from the TP sensor to the ECM OR replace the TP sensor Check for poor terminal connections or shorted wires from the MAP sensor to the ECM to ground OR replace MAP sensor Test the fuel pump relay see the Repair Section OR check for poor terminal connection from the fuel pump relay to fuel pump OR replace the fuel pump Check for water in the fuel misfiring cylinder or pugged fuel filter OR check for poor terminal connections or shorted wires from the HO sensor to the ECM to ground OR replace HO sensor Check engine coolant level OR check for shorted wires or poor terminal connections from the ECT sensor to the ECM OR replace the ECT sensor
205. inder There are two identical steering cylinders that work in parallel They are part ofthe same hydraulic circuit but move in opposite directions The tie rod maintains equal movement of the tires When removing a hose assembly or fitting the O ring on the fitting and or hose end must be replaced and then torqued to specification during installation Refer to Section Two Hyaraulic Hose and Fitting Torque Specifications 1 Tag disconnect and plug the hydraulic hoses from the steering cylinder Cap the fittings on the cylinder Bodily injury hazard Spraying AWARNING 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 68 7 60 34 Part No 52856 Service Manual Second Edition Section 7 Repair Procedures 2 Remove the pin retaining fasteners from the rod end pivot pin and the barrel end pivot pin Then remove the pivot pin from each end of the steering cylinder 3 Remove the steering cylinder from the machine 14 3 Tie Rod How to Remove the Tie Rod 1 Remove the pin retaining fasteners from the pivot pins from each end of the tie rod Then remove the pins 2 Remove the tie rod How to Perform the Toe in Adjustment Perform this procedure on a firm level surface Block the non steering tires and be sure that the machine is in the stowed position 1 Straight
206. ing jack 10 Use a soft metal drift to drive the yoke pivot pin down and out Crushing hazard The yoke torque ACAUTION hub assembly may become unbalanced and fall when the yoke pivot pin is removed if itis not properly supported and secured to the lifting jack 11 Place the yoke torque hub assembly on a flat surface with the torque hub down 4WD STEERING AXLE COMPONENTS 12 Remove the torque hub fasteners that attach the yoke to the torque hub Remove the yoke weldment from the torque hub Torque specifications Lug nut 125 ftlbs 169 5 Nm Torque hub mounting bolts 120 ftlbs 163Nm 15 2 Steering Cylinders How to Remove a Steering Cylinder This procedure is the same as the 2WD procedure See repair procedure 14 2 How to Remove a Steering Cylinder 15 3 Tie Rod How to Remove the Tie Rod This procedure is the same as the 2WD procedure See Repair Procedures 14 3 How to Remove the Tie Rod How to Perform the Toe in Adjustment This procedure is the same as the 2WD procedure See Repair P rocedures 14 3 How to Perform the Toe in Adjustment PartNo 52856 Genie Z 60 34 7 71 Section 7 Repair Procedures Service Manual Second Edition Oscillating Axle Components 16 1 2 Tag disconnect and plug the oscillating axle lock out h lic h th Oscillating Axle ock out cylinder hydraulic hoses Cap the fittings on the cylinder Lock out Cylinder AWARNING odily injury
207. ion enable switch to either 1110 side and hold the 12V secondary boom up toggle switch TS18 at the ground controls in the up direction and check voltage at TB3 11 to With the keyswitch 12V turned to platform controls and both Emergency Stop buttons pulled out to the oN Osition activate ootswitch and secondary boom function controller BP2 on platform control panel in up direction and check voltage at TP3 oV Activate footswitch and check voltage at terminal on BP2 12V or more Re adjust controller see Repair Section OR replace controller BP2 OR consult Genie Industries Service Department Chart 16 Repair open in red wht wire circuit from TB3 to secondary boom up down proportional valve coil item N OR repair open in brown ground wire circuit to valve coil Repair open in red wht wire from TP3 to TB3 Repair open in power supply circuit from TP24 to BP2 OR repair open in brown ground wire circuit from ground to BP2 Part No 52856 Genie Z 60 34 Section 5 Troubleshooting Flow Charts CHART 16 With key switch turned to ground controls and both Emergency Stop buttons pulled out to the ON position move the function enable switch to either side and hold the secondary boom up toggle switch TS18 at the ground controls in the up direction and check voltage on blu 1H0 wire on secondary boom up down directional valve coil item F Continu
208. ion activate footswitch and turntable rotate left right proportional controller BP1 on platform control panel in the left direction and check voltage TB5 oV Activate footswitch and turntable rotate left right proportional controller BP1 on platform control panel in the left direction and check voltage TP5 oV Activate footswitch and check voltage at terminal on BP1 12V or more Re adjust controller see Repair Section OR replace controller BP1 OR consult Genie Industries Service Department 12V or more 12V or more 12V or more CHART 20 Repair open in wht blk wire circuit from TB5 to turntable rotate left function directional valve coil item E OR repair open in brown ground wire circuit to valve coil Troubleshoot turntable rotate left right function toggle switch TS20 on ground control panel OR repair open in wht blk wire circuit from TS20 to TB5 OR consult Genie Industries Service Department Repair open in wht blk wire from TP5 to TBS Repair open in power supply circuit from TP24 to BP1 OR repair open in brown ground wire circuit from ground to 52856 Genie 7 60 34 5 45 Section 5 Troubleshooting Flow Charts Service Manual Second Edition CHART 20 Disconnect wires to turntable rotate left directional valve coil item E and test the resistance of the valve Continued from the previous page
209. ion Item Function Torque 1 3 position 4 way solenoid valve GG scs Steer left right 30 35 in Ibs 3 4 Nm 2 Relief valve 250 psi 17 2 bar HH usus Sequencing kisis 10 12 ft Ibs 14 16 Nm 3 2 position 4 way solenoid valve JT rn Oscillate 30 35 165 3 4 Nm How to Check the Resistance of a Valve Coil 1 Turn the key switch to the off position and disconnect the wires from the valve coil to be tested 2 Connectthe leads from an ohmmeter to the valve coil terminals Valve coil specifications 3 position 4 way solenoid valve 10V 4 5 to 5 30 schematic item GG 2 position 4 way solenoid valve 10V 4 5 to 5 30 schematic item II 7 52 Genie Z 60 34 Part No 52856 Service Manual Second Edition Section 7 Repair Procedures Epu M J U u M HH MANIFOLDS This page intentionally left blank PartNo 52856 Genie Z 60 34 7 53 Section 7 Repair Procedures Service Manual Second Edition MANIFOLDS 11 7 2WD Drive Manifold Components The drive manifold is mounted inside the drive chassis atthe non steer end in forward and reverse gets hot oil out of low pressure side of drive pump and allows low pressure flow path for brake release and 2 speed Index Schematic No Description Item Function 1 Relief valve 250 p
210. ional output threshold adjustable trimpot hi range adjustable trimpot ra 4 Setthe preliminary ramp rate Turn the trimpot adjustment screw counterclockwise 15 turns or until you hear a repeated click 5 Connectthe red lead from a volt meter to the A terminal on the controller printed circuit board Connectthe black lead to ground 6 Setthe threshold Press down the foot switch then slowly move the control handle off center until the momenta voltage reading appears Adjust the voltage to 4 3V DC Turn the threshold trimpot adjustment screw clockwise to increase the voltage or counterclockwise to decrease the voltage 7 Setthe hi range Press down the foot switch then move the control handle all the way to the up position Adjust the voltage to 8 5V DC Turn the hi range trimpot adjustment screw clockwise to increase the voltage or counterclockwise to decrease the voltage 8 Setthe lo range Press down the foot switch then move the control handle all the way to the DOWN position Adjustthe voltageto 8 5V DC Turn the lo range trimpot adjustment screw clockwise to increase the voltage or counterclockwise to decrease the voltage 9 Startthe engine and move the engine idle control switch to foot switch activated high idle rabbit and foot switch symbol Lower the secondarty boom to the stowed position Engine should be at normal operating temperature 10 Starta timer and record how long ittakes f
211. ires Does the oscillate cylinder fully retract The oscillate system should be operating correctly If it is not consult Genie Industries Service Department Section 5 Troubleshooting Flow Charts MN Rotate the turntable until the boom is past one of the non steer tires and turn the engine off Place a block between the rod end wedge and the cylinder barrel to prevent the cylinder from retracting Install a 0 to 1500 psi 103 bar pressure gauge at the quick disconnect coupling on the function manifold Start the engine then rotate the turntable until the boom is in between the non steer tires and check the pressure Remove the block and check for mechanical restrictions keeping oscillate cylinder from retracting OR replace oscillate cylinder CHART 33 Adjust the oscillate relief valve item GG to 250 psi 17 bar OR replace MS1 microswitch located inside of the electrical rotary coupler OR replace electrical rotary coupler Part No 52856 Genie Z 60 34 Section 5 Troubleshooting Flow Charts Service Manual Second Edition Chart 34 All Drive Functions Inoperative All Other Functions Operate Normally Be sure the rpm toggle switch is in the footswitch activated high idle position Be sure the hydraulic tank shut off valves are in the oPEN position Be sure machine is not in the free wheel configuration With the keyswitch less turned to platform than c
212. irs Genie Z 60 34 Part No 52856 Service Manual Second Edition Section 5 Troubleshooting Flow Charts Continued from the previous page CHART 2 Disable starter by See Ford LRG 425 EFI removing blk wire at the Service Manual for starter solenoid hold the troubleshooting the start switch to either ignition system OR side and check voltage consult Genie Industries at the light green wire on Service Department the ignition coil plug Repair open in light green wire from the ECM to ignition coil OR check for loose or bad connections from the ECM to the ignition coil OR replace the ignition coil OR consult Genie Industries Service Department Part No 52856 Genie 2 60 34 5 9 Section 5 Troubleshooting Flow Charts Service Manual Second Edition Chart 2A Engine Runs While Cranking Then Dies Be sure that all vacuum hoses are connected and show no signs of damage See Repair Section How to Retrieve Fault Codes 15 there a fault code stored in the ECM memory Hold start switch to either side and check voltage at terminal 42 on ignition start module Check voltage at terminal 4 on ignition start module Replace ignition start module OR consult Genie Industries Service Department Check for poor terminal connections OR check for shorted or damaged wires that go from the ECM to the sensor that is causing the fault OR replace the sensor OR consult Genie Industries S
213. is not properly supported and secured to the overhead crane 11 Remove the suction strainers from the tank and clean them using a mild solvent 12 Rinse out the inside of the tank using a mild solvent 13 Install the suction strainers using a thread sealant on the threads 14 Install the drain plug using a thread sealant on the threads 15 Install the hydraulic tank onto the machine 16 Install the two suction hoses and the supply hose for the auxiliary power unit 17 Fill the tank with hydraulic oil until the level is within the top 2 inches 5 cm of the sight gauge Do not overfill 18 Clean up any oil that may have spilled and open the hydraulic tank valves Component damage hazard CAUTION Be sure to open the two hydraulic tank valves and prime the pump after installing the hydraulic tank Always use pipe thread sealant when installing the drain plug Use only Dexron equivalent hydraulic fluid Hydraulic system Hydraulic tank capacity 45 gallons 170 liters Hydraulic system 53 gallons capacity including tank 201 liters Hydraulic fluid Dexron equivalent 7 62 Genie Z 60 34 Part No 52856 Service Manual Second Edition Section 7 Repair Procedures M J em m e M41 FUEL AND HYDRAULIC TANKS How to Prime the Pump Component damage hazard Be CAUTION sure thatthe hydraulic tank shutoff valves are in the position before pri
214. isconnect red wire from terminal 4 on 12V ignition start module and check voltage at terminal 4 oV Test auxiliary power toggle switches TS1 and TS11 See Repair Section CHART 3 Check oil level OR replace oil pressure sending unit OR refer to Deutz service manual for troubleshooting low oil pressure Check oil level OR replace engine temperature sending unit OR refer to Deutz service manual for troubleshooting a overheated engine Replace ignition start module OR consult Genie Industries Service Department Part No 52856 Genie Z 60 34 Section 5 Troubleshooting Flow Charts Service Manual Second Edition Chart 4 Engine Will Not Start On LPG But Will Start On Gasoline Gasoline LPG Models Be sure fuel select switch is switched to LPG Be sure the valve on the LPG tank is fully opened Be sure to check LPG fuel level See Repair Section How to Retrieve Fault Codes 15 there a fault code stored in the ECM memory Turn off the valve on the LPG tank then disconnect LPG supply line from LPG tank and Hep pressure from ine With keyswitch turned to ground controls and both Emergency Stop buttons pulled out to the ON position check voltage at LPG side blu red wire of fuel select switch TS13 With keyswitch turned to ground controls and both Emergency Stop buttons pulled out to the ON position check voltage at TB39 With keyswitch turned
215. ithin easy reach Perform this procedure with the engine off 1 Atthe fuel pump disconnect and plug the fuel hose that goes to the fuel tank 2 Remove the fuel filter with a filter wrench oil filter b fuel filter water separator TABLE C PROCEDURES Prime the fuel pump 3 Fill the new filter Genie part no 29560 with fresh diesel fuel and apply a thin layer of oil or diesel fuel to the new fuel filter gasket Install the new filter and tighten it securely by hand Clean up any diesel fuel that might have spilled during the procedure Connectthe fuel hose from the tank to the fuel pump Start the engine from the ground controls then inspect the fuel filter for leaks Explosion and fire hazard If a fuel leak is discovered keep any additional personnel from entering the area and do notoperate the machine Repair the leak immediately PartNo 52856 Genie Z 60 34 4 35 Section 4 Scheduled Maintenance P rocedures Service Manual Second Edition TABLE C PROCEDURES C 9 Replace the Gasoline Fuel Filters Gasoline LPG Models Replacing the gasoline fuel filter is essential to good engine performance and service life A dirty or clogged filter may cause the engine to perform poorly and continued use may cause component damage Extremely dirty conditions may require thatthe filter be replaced more often Explosion and fire hazard Engine fuels are combustible Replace the fuel filte
216. ition Section 4 Scheduled Maintenance Procedures A 4 Check the Engine Oil Level Maintaining the proper engine oil level is essential to good engine performance and service life Operating the machine with an improper oil level can damage engine components Check the oil level with the engine off 1 Checkthe oil dipstick Add oil as needed Result The oil level should be in the safe zone Ford LRG 425 EFI Engine 4 5 quarts Cil capacity including filter 4 3 liters Ford LRG 425 EFI Engine Oil viscosity requirements below 60 F 15 5 5W 30 10 F to 90 F 23 C to 32 C 5W 30 above 10 F 23 C 5W 30 above 25 F 4 C 10W 30 Use oils meeting API classification SH or SG Units ship with 10 40 CC SG Deutz FAL 1011F Engine 11 quarts Cil capacity including filter 10 5 liters Deutz FAL 1011F Engine Oil viscosity requirements below 60 F 15 5 C synthetic 5W 30 10 F to 90 F 23 C to 32 C 10W 40 above 4 F 34 C 15W 40 Engine oil should have properties of classification CC SE CD SE SF CC or SF CD grades Units ship with 10 40 CC SG TABLE A PROCEDURES A 5 Check the Engine Coolant Level Gasoline LPG Models Maintaining the engine coolantatthe proper level is essential to engine service life Improper coolant level will affect the engine s cooling capability and damage engine components Daily checks will allow the inspector to identify cha
217. k and starter then see Maintenance section for LPG adjustments OR consult Genie Industries Service Department Part No 52856 Genie Z 60 34 5 15 Section 5 Troubleshooting Flow Charts Service Manual Second Edition Chart 5 Engine Will Not Start On Gasoline But Will Start On LPG Gasoline LPG Models Be sure fuel select switch is switched to gasoline Be sure to check gasoline fuel level See Repair Section How to Retrieve Fault Codes 15 there a fault code stored in the ECM memory With keyswitch turned to ground controls and both Emergency Stop buttons pulled out to the ON position check voltage at LPG side blu red wire of fuel select switch TS13 Hold the start switch to either side and check voltage across the wires on the fuel pump without disconnecting the wires With the keyswitch in the OFF position and both Emergency Stop buttons pulled out to the ON position turn the keyswitch to ground controls and listen for the fuel pump to turnon for approximately 2 seconds Did the fuel pump turn on See Ford LRG 425 EFI service manual for fuel system troubleshooting OR consult Genie Industries Service Department Check for poor terminal connections OR check for shorted or damaged wires that go from the ECM to the sensor that is causing the fault OR replace the sensor OR consult Genie Industries Service Department Replace fuel select switch Replace the fue
218. l pump relay B of the engine harness OR consult Genie Industries Service Department Repair open in fuel pump wires from fuel pump relay B of the engine harness OR replace the fuel pump Refer to the fault code chart in this section for a description of the fault and recommended repairs 5 16 Genie Z 60 34 Part No 52856 Service Manual Second Edition Engine High Idle Inoperative Gasoline LPG Models See Repair Section How to Retrieve Fault Codes 15 there a fault code stored in the ECM memory Start the engine then move and hold the RPM toggle switch to the high idle rabbit symbol position for following tests Check voltage at blk red wire on RPM select switch TS4 and TS14 Check voltage at TB35 Repair open in brn blu wire from TB35 to ECM OR consult Genie Industries Service Department Section 5 Troubleshooting Flow Charts Check for poor terminal connections OR check for shorted or damaged wires that go from the ECM to the sensor that is causing the fault OR replace the sensor OR consult Genie Industries Service Department Check voltage at center terminal on RPM select switch TS4 and TS14 Replace rpm select toggle switch Repair open in blk red wire circuit from toggle switch to TB35 Chart 6 Refer to the fault code chart in this section for a description of the fault and recommended repairs Repair open in power supply circuit to cent
219. l to alert personnel of a procedure or hazard and could result in unsafe operating conditions 1 Referto the Decals section in the appropriate Genie Z 60 34 Operator s Manual and use the decal list and illustrations to determine that all decals and placards are in place 2 Inspectall decals for legibility and damage Replace any damaged or illegible decal immediately Contact your authorized Genie distributor or Genie Industries if replacement decals are needed A 3 Inspect for Damage Loose or Missing Parts Daily machine condition inspections are essential to safe machine operation and good machine performance Failure to locate and repair damage and discover loose or missing parts may result in an unsafe operating condition 1 Inspect the entire machine for damage and improperly installed or missing parts including Electrical components wiring and electrical cables Hydraulic hoses fittings cylinders and manifolds Fuel and hydraulic tanks Drive and turntable rotation motors and drive torque hubs Axle components Boom components and wear pads Dents or damage to machine Tires and wheels Engine and related components Limit switches Alarms horn and beacon if equipped Nuts bolts and other fasteners Platform entry mid rail or gate Cracks in welds or structural components Compartment covers and latches 4 2 Genie Z 60 34 Part No 52856 Service Manual Second Ed
220. l troubleshooting ona firm level surface Two persons will be required to safely perform some troubleshooting procedures Part No 52856 Genie 2 60 34 5 1 Section 5 Troubleshooting Flow Charts Service Manual Second Edition TROUBLESHOOTING FLOW CHARTS About This Section When a malfunction is discovered the flow charts in this section will help a service professional pinpoint the cause of the problem To use this section basic hand tools and certain pieces of test equipment are required voltmeter ohmmeter pressure gauges The location of terminals mentioned in this section can be found on the appropriate electrical or hydraulic schematics provided in Section 6 Schematics Since various degrees of a particular function loss may occur selecting the appropriate flow chart may be troublesome When a function will not operate with the same speed or power as a machine in good working condition refer to the flow chart which most closely describes the problem General Repair Process Malfunction Identify Troubleshoot discovered symptoms problem still exists Retum to Perform service problem repair solved Fault codes The ECM constantly monitors the engine by the use of sensors on the engine The ECM also uses signals from the sensors to initiate sequential fuel injection and make constant and instaneaous changes to ignition timing fuel delivery and throttle position to
221. lace pump OR replace relief valve Consult Genie Industries Service Department Repair open from TB27 to PR1 OR repair open in brown ground wire circuit to PR1 OR replace PR Repair open in red power supply wire from keyswitch KS1 to auxiliary toggle switch 12V or more Repair open in red 27 wire from TS11 to TB27 OR replace TS11 7911 Genie Z 60 34 Part No 52856 Service Manual Second Edition Section 5 Troubleshooting Flow Charts CHART 40 Check continuity from Replace negative cable negative terminal on from auxiliary pump to auxiliary power unit to ground ground Continued from the previous page Replace auxiliary pump motor 1 Part No 52856 Genie Z 60 34 5 89 Section 5 Troubleshooting Flow Charts Service Manual Second Edition E This page intentionally left blank 5 90 Genie Z 60 34 Part No 52856 Service Manual Second Edition Section 6 Schematics Observe and Obey M 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 M Repair any machine damage or malfunction before operating the machine Before Troubleshooting M Read understand and obey the safety rules and operating instructions printed in the Genie Z 60 34 Operator s Manual Be sure that all necessary too
222. le rotate left right proportional controller BP1 on platform control panel in the right direction and check voltage TB4 oV 12V or Activate footswitch and turntable rotate left right proportional controller BP1 on platform control panel in the right direction and check voltage oV Activate footswitch and check voltage at terminal on BP1 12V or more Re adjust controller see Repair Section OR replace controller BP1 OR consult Genie Industries Service Department CHART 21 Repair open in wht wire circuit from TB4 to turntable rotate right function directional valve coil item E OR repair open in brown ground wire circuit to valve coil Troubleshoot turntable rotate left right function toggle switch TS20 on ground control panel OR repair open in wht wire circuit from TS20 to TB4 OR consult Genie Industries Service Department Repair open in wht blk wire from TP4 to TB4 Repair open in power supply circuit from TP24 to BP1 OR repair open in brown ground wire circuit from ground to 52856 Genie 7 60 34 5 49 Section 5 Troubleshooting Flow Charts Service Manual Second Edition CHART 21 Disconnect wires to turntable rotate right directional valve coil item E and test the resistance of the valve Continued from the previous page coil See Repair Section Install a 0 to 5000 PSI 345 bar pressu
223. lenoid 12V solenoid moves in and out freely moves freely Replace 2 speed solenoid Note resistance across solenoid terminals should be approximately 0 3 ohms solenoid Check if 2 speed binds Repair open in blk red wire circuit from CR3 to CR4 Repair open in brown ground wire circuit to terminal 85 on CR4 Repair open in wht wire circuit from CR2 to CR3 to CR4 Replace CR4 relay OR repair open in blk red wire circuit from terminal 87 on CR4 to 2 speed solenoid Check linkage or replace solenoid 5 20 Genie Z 60 34 Part No 52856 Service Manual Second Edition Section 5 Troubleshooting Flow Charts Engine Low Idle Inoperative Deutz Diesel Models Check if mechanical linkage from 2 speed solenoid to fuel injection system is binding or defective Atthe platform controls start the engine and move the RPM select switch TS4 to maintained low idle turtle symbol Check voltage at blk red wire on rpm select switch Check voltage at the blk red wire on the 2 speed solenoid Check if 2 speed solenoid moves in and out freely Check adjustment of linkage and fuel injection system low idle See Maintenance section See Deutz workshop manual to troubleshoot fuel injection system OR consult Genie Industries Service Department moves freely Chart 9 Isolate the platform and ground RPM switches TS4 and TS14 check individually an
224. llow it to run at low idle 7 Press down the foot switch to allow the engine to run athigh 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 B 20 Test the Drive Enable System Proper drive enable system operation is essential to safe machine operation When the boom is pastthe non steering wheels drive movementis stopped and the indicator light turns on The drive enable switch must be to either side to reactivate the drive function and should inform the operator that the machine will move in the opposite direction thatthe drive and steer controls are moved An improperly functioning drive enable system may allow the machine to be moved into an unsafe position 1 Startthe engine from the platform controls 2 Move the lift drive select switch to the lift position if equipped 3 Press down the footswitch 4 Rotate the turntable until the primary boom moves past one of the non steering wheels Result The drive enable indicator light should come on and remain on while the boom is anywhere in the range shown 5 Move the lift drive select switch to the drive position if equipped 6 Move the drive control handle off center Result The drive function should not operate Genie Z 60 34 Part No 52856 Service Manu
225. ls and test equipment are available and ready for use Schematics About This Section There are two groups of schematics in this section An illustration legend precedes each group of drawings Electrical Schematics Electrocution hazard Contact with AWARNING electrically charged circuits may result in death or serious injury Remove all rings watches and other jewelry Hydraulic Schematics Bodily injury hazard S praying AWARNING 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 General Repair Process Malfunction Identify Troubleshoot discovered symptoms problem still exists Retum to Perform service problem repair solved Part No 52856 Genie Z 60 34 6 1 Section 6 Schematics Service Manual Second Edition x E Mn Electrical Components Item Description Genie Part Manufacturer Manufacturer Qty Part Number Part Number Battery 100 12V 30143 C3IXH 2 1 uses J oystick controller Dual axis 53073 OEM Controls EJ S5DM11179 1 2 J oystick controller Single 24495 OEM C
226. ls on the horn B 17 Test the Foot Switch A properly functioning foot switch is essential to safe machine operation Machine functions should activate and operate smoothly as long as the foot switch is pressed down and promptly stop when the foot switch is released The foot switch will also shift the engine into high idle if the idle select is switched to the rabbit and foot switch symbol An improperly functioning foot switch can cause an unsafe working condition and endanger platform and ground personnel The engine should not start if the foot switch is pressed down 1 Turn the keyswitch to platform controls and pull out the Emergency Stop button to the position at both the ground and platform controls 4 24 Genie Z 60 34 Part No 52856 Service Manual Second Edition Section 4 Scheduled Maintenance Procedures 2 Press down the footswitch and attempt to start the engine by moving the start toggle switch to either side Result The engine should not start 3 Donotpress down the footswitch and attempt to start the engine Result The engine should start 4 Do notpress down the footswitch Check the machine functions Result The machine functions should not operate 5 Press down the foot switch and operate the machine functions Result The machine functions should operate B 18 Test the Engine Idle Select A properly operating engine idle select switch is essential to goo
227. ly disconnect the hose from the LPG tank 2 Gasoline LPG models Open the clamps from the LPG tank straps and remove the LPG tank from the machine 3 Remove the fuel tank See 11 2 How to Remove the Fuel Tank Table D Procedures 4 Close the two hydraulic shutoff valves located atthe hydraulic tank closed Component damage hazard The CAUTION engine must not be started with the hydraulic tank shutoff valves in the cLosep 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 5 Place a suitable container underneath the hydraulic tank See capacity specifications below 6 Remove the drain plug from the hydraulic tank 7 Completely drain the tank into a suitable container See capacity specifications 8 Tag disconnect and plug the two suction hoses thatare attached to the hydraulic tank shutoff valves 9 Disconnectand plug the T fitting located at the return filter with the 2 hoses connected to it Cap the fitting on the return filter housing 10 Disconnect and plug the supply hose for the auxiliary power unit Cap the fitting on the hydraulic tank 11 Remove the retaining fasteners from the hydraulic tank hold down straps Remove the straps from the hydraulic tank 12 Remove the ground controls side turntable cover See 6 1 How to Remove a Turntable cover PartNo 52856 Genie
228. m the engine mounting leg 11 Install the new fuel pressure regulator filter Genie part no 52567 onto the engine mounting leg and install the hoses to the regulator filter CAUTION Component damage hazard Be sure the correct regulator filter is installed or component damage may occur 12 Turn the manual shutoff valve located atthe fuel tank to the position 13 Startthe machine from the ground controls then inspect the fuel filters and hoses for leaks Explosion and fire hazard If a fuel leak is discovered keep any additional personnel from entering the area and do notoperate the machine Repair the leak immediately Fuel filters Genie part numbers 52179 52567 Fuel pre filter Fuel pressure regulator filter Genie Z 60 34 Part No 52856 Service Manual Second Edition Section 4 Scheduled Maintenance Procedures C 10 Replace the PCV Valve Gasoline LPG Models Yearly replacement of the P CV valve is essential to good engine performance A malfunctioning P CV valve can impair crankcase ventilation and may cause engine damage Perform this procedure with the engine off 1 Open the engine side turntable cover 2 Remove the 2 engine pivot plate retaining bolts and swing the engine out away from the machine to access the PCV valve 3 Locate the PCV valve on the engine under the intake manifold a PCV valve b PCV valve hose 4 Remove the hose from the PCV valve t
229. minal 3 to 4 5 amp 6 no continuity 2 Connect leads of an ohmmeterto the switch terminal 4 to 5 continuity terminals in the following combinations listed terminal 4 to 6 no continuity below to check for continuity terminal 5 to 6 no continuity PartNo 52856 Genie Z 60 34 7 9 Section 7 Repair Procedures Service Manual Second Edition Platform Components 2 1 Platform How to Remove the Platform 1 Separate the footswitch quick disconnect plug from the platform toe board 2 Open the platform control box 3 Remove the platform control box mounting fasteners Then lower the control box and setit aside If your machine is equipped with an airline to platform option the airline must be disconnected from the platform before removal 5 Raise the jib boom slightly and place blocks under the platform mounting weldment Then 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 6 Remove the platform mounting fasteners and remove the platform from the machine Crushing hazard The platform AWARNING may become unstable and fall if it is not properly supported 2 2 Platform Leveling Slave Cylinder The slave cylinder and the rotator pivot are the two primary supports for the platform The slave cylinder keeps the platform level through the entire range of boom motion It operates ina closed circuit hydra
230. ming the pump The engine must not be started with the hydraulic tank shutoff valves in the cLosep 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 1 Connecta 0 to 600 psi 0 to 41 bar pressure gauge to the test port on the drive pump 2 Gasoline LPG models Close the valve on the LPG tank then disconnect the hose from the tank Then move the fuel select switch to the LPG position Deutz Diesel models Hold the manual fuel shutoff valve clockwise to the cLosep position a manual fuel shutoff valve 3 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 4 Gasoline LPG models Connect the LPG hose to the LPG tank and open the valve on the tank 5 Start the engine from the ground controls and check for hydraulic leaks Part No 52856 Genie Z 60 34 7 63 Section 7 Repair Procedures Service Manual Second Edition Turntable Rotation Components 13 1 3 Attach a lifting strap from an overhead crane to the platform end ofthe lower secondary boom Turntable Rotation Hydraulic arm for support Do not lift it Motor How to Remove the Rotation Hydraulic Motor When removing a hose assembly or fitting the O ring on the fitting and or hose end must be replaced and then torqued to specif
231. mit contacts that are factory set The contacts will close at approximately 300 F 149 C When the contacts close the engine will shut off to prevent damage and will not start until the temperature drops below the contact point Temperature will be indicated when the keyswitch is and the Emergency Stop button is pulled outto the ow position CAUTION Component damage hazard Do not crank the engine with the over temperature light on The oil pressure gauge is an electrical gauge The sending unit has limit contacts that are factory set The contacts will open at approximately 7 psi 0 48 bar When the contacts close the engine will shut off to prevent damage Oil pressure will be indicated when the engine is running CAUTION Component damage hazard Do not crank the engine with the low oil pressure light on DEUTZ ENGINE F4L 1011F How to Remove the Oil Temperature or Oil Pressure Gauge Sending Units Perform this procedure with the engine off 1 Oil temperature switch R emove the fasteners from the engine side cover then remove the cover 2 Disconnectthe wiring from the desired switch 3 Remove the switch from the engine block and then install the new switch Do not over tighten Burn hazard Contact with hot ACAUTION engine fluids or components may cause severe burns Always use pipe thread sealant when installing a switch Oil temperature switch specifications Torque 8 18 ft Ibs 11 24
232. mp 2400 psi relief pressure 165 5 bar Part No 52856 Genie Z 60 34 2 3 Section 2 Specifications Service Manual Second Edition SPECIFICATIONS Ford Engine LRG 425 EFI Displacement 153 cu in 2 5 liters Number of cylinders 4 3 78 x 3 4 inches 96 01 x 86 36 mm Bore amp stroke Horsepower gross intermittent 97 continuous 82 horsepower 2500 rpm 70 Firing order 1 3 4 2 Low idle 1600 rpm High idle 2500 rpm Compression ratio 9 4 1 Compression pressure approx Pressure psi of lowest cylinder must be at least 75 of highest cylinder 0 035 to 0 055 inches 0 889 to 1 397 mm Valve clearances collapsed tappet Lubrication system Oil pressure 40 to 60 psi operating temp 2000 rpm 2 75 to 4 1 bar Oil capacity 5 quarts including filter 4 7 liters Cil viscosity requirements Temperature below 60 F 15 5 5W 30 10 F to 90 F 23 C to 32 C 10W 30 Temperature above 10W 40 to 10W 50 10 F 23 C Temperature above 20W 40 20W 50 20 F 6 6 C Use oils meeting API classification SG labeled SG CC or SG CD as they offer improved wear protection Units ship with 10W 40 SG CC Starter motor Normal engine cranking speed 200 to 250 rpm Current draw normal load 140 200A Current draw maximum load 800A Current draw minimum 60 80A Maximum circuit voltage drop 0 5V DC while starting normal temperature Brush lengt
233. n Inoperative Oscillating 5 73 Viii Genie Z 60 34 Part 52856 Service Manual Second Edition Section Five Section Six Section Seven TABLE OF CONTENTS Troubleshooting Flow Charts continued 33 Oscillate Function Inoperative memes 5 75 34 Drive Functions Inoperative All Other Functions Operate Normally 5 80 35 Drive Forward Or Reverse Function Inoperative 5 83 36 Traction Function emm emen 5 84 37 Machine Will Not Drive At Full 5 5 85 38 Machine Drives At Full Speed With Platform Raised Or Extended 5 86 39 Drive Enable System Is 3 22 5 87 40 X Auxiliary Functions Inoperative ssssseeem meme 5 88 Schematics ro reet reete e ette ret iis 6 1 Electrical Components iei Mea aea Ce UR Den ER ee RA Us 6 2 Electrical S ymbols Legend i eie eet e ad e iR de Fl 6 4 Abbreviation Legend eee ek bee e 6 5 Ford Engine Harness Hee e AC E E E 6 6 Electrical Schematic Gasoline LP 6 7 Ground Control Box Wiring Diagram Gasoline LP G Models 6 9 Platform Control Box Wiring Diagram Gasoline LP G 4
234. n the bottom of the oil pan and allow all ofthe oil from the engine to drain into a suitable container See capacity specifications Do not remove the drain plug located on the side of the oil pan 3 Install the drain plug in the oil pan 4 Place a suitable container under the oil filter TABLE B PROCEDURES 5 Usean oil wrench and remove the oil filter a engine oil level dipstick b fuel filter water separator C filter 6 Apply a thin layer of oil to the gasket of the new filter Genie part no 49924 Then install the filter and tighten it securely by hand 7 Use a permanent ink marker to write the date and number of hours from the hour meter on the oil filter 8 Fillthe engine with new oil per specifications and install the oil filler cap 9 Startthe engine from the ground controls Allow the engine to run for 30 seconds then turn the engine off 10 Check the oil filter and oil pan drain plug for leaks 11 Check the engine oil level dipstick Add oil if needed Deutz Engine F4L 1011F Cil capacity including filter 11 quarts 10 5 liters Deutz Engine F4L 1011F Oil viscosity requirements Temperature below 60 F 15 5 synthetic 5W 30 10 F to 90 F 23 C to 32 C 10W 40 Temperature above 4 F 34 C 15W 40 Engine oil should have properties of AP I classification CC SE CD SE CC SF or CD SF grades Units shipped with 10 40 CC SG PartNo 52856 Genie Z 60 34
235. n used to indicate operation or maintenance information Be sure to wear protective eye wear and other protective clothing if the situation warrants it Be aware of potential crushing hazards such as moving parts free swinging or unsecured components when lifting or placing loads Always wear approved steel toed shoes Workplace Safety Be sure to keep sparks flames and W 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 N are properly maintained and ready for use Keep work surfaces clean and free of debris that could get into machine components and cause damage p Be sure that your workshop or work area AJI is properly ventilated and well lit Be sure any forklift overhead crane or other lifting or supporting device is fully capable of supporting and stabilizing the weight to be lifted Use only chains or straps that are in good condition and of ample capacity Be sure that fasteners intended for one PAN time use i e cotter pins and self locking nuts are not reused These components may fail if they are used a second time Desureto properly dispose of old oil or 2 other fluids Use an approved container Please be environmentally safe iv Genie Z 60 34 Part No 52856 Service Manual Second Edition Table of Contents Int
236. nance information Indicates that a specific resultis expected after performing a series of steps PartNo 52856 Genie Z 60 34 4 1 Section 4 Scheduled Maintenance P rocedures Service Manual Second Edition Table A Procedures A 1 Inspect the Manuals 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 1 Check to be sure that the storage container is present and in good condition 2 Check to make sure that the operator s responsibilities and safety manuals are present and complete in the storage container in the platform 3 Examine the pages of each manual to be sure that they are legible and in good condition 4 Always return the manuals to the storage container after use Contact your authorized Genie distributor or Genie Industries if replacement manuals are needed A 2 Inspect the Decals and Placards Maintaining all of the safety and instructional decals and placards 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 information An illegible decal will fai
237. nd start the counterbalance valve engine Move the OR oonsult Genie function enable switch to Industries Service either side and hold the Department primary boom down toggle switch at the ground controls in the down direction and check the pressure less than 1600 PSI function Exchange flow regulator operates valve item J with a like valve item O Check primary boom up function Replace defective flow regulator valve function inoperative Repair cylinder or cylinder counterbalance valve OR function manifold could have an internal defect Consult Genie Industries Service Department 5 32 Genie 2 60 34 52856 Service Manual Second Edition Section 5 Troubleshooting Flow Charts Secondary Boom Up Function Inoperative Be sure all other functions operate normally Be sure LS2 limit switch is being activated when the secondary boom is in the stowed position If secondary boom raises approximately 2 feet 0 6 m and stops refer to Chart 33 With the key switch turned to ground controls and both Emergency Stop buttons pulled out to the ON position move the function enable switch to either side and hold the secondary boom up toggle switch TS18 at the ground controls in the up direction and check voltage on red wht wire on primary boom up down proportional valve coil item N 12V or more Continued on the next page Move the funct
238. ng fasteners from the jib boom lift cylinder barrel end pivot pin Use a soft metal drift to remove the barrel end pivot pin PartNo 52856 Genie Z 60 34 7 15 Section 7 Repair Procedures Service Manual Second Edition EEE nn JIB BOOM COMPONENTS 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 Crushing hazard The jib boom AWARNING lift cylinder may become unbalanced and fall when it is removed from the machine if it is not properly attached to the overhead crane 7 16 Genie Z 60 34 Part No 52856 Service Manual Second Edition Section 7 Repair Procedures C J J H M JIB BOOM COMPONENTS 3 3 Jib Boom Platform Rotate Manifold Components 1 Orifice 0 030 inch 0 76 mm Platform rotate circuit 2 2 position 3 way valve AC isis Platform rotate select 8 10 ft lbs 11 14 Nm How to Check the Resistance of a Valve Coil 1 Turn the key switch to the orr position and disconnect the wires from the valve coil to be tested 2 Connectthe leads from an ohmmeter to the valve coil terminals Valve coil specification 2 position 3 way solenoid valve 50 schematic item AC PartNo 52856 Genie Z 60 34 7 17 Section 7 Repair Procedures Service Manual Second Edition
239. nges in coolant level that might indicate cooling system problems 1 Check the fluid level in the coolant recovery tank Add fluid as needed Result The fluid level should be at the FULL mark Bodily injury hazard Fluids in the AWARNING radiator are under pressure and extremely hot Use caution when removing cap and adding fluids A 6 Check for Fuel Leaks Failure to detect and correct fuel leaks will result in an unsafe condition An explosion or fuel fire may cause death or serious injury Explosion and fire hazard Engine fuels are combustible Inspectthe machine in an open well ventilated area away from heaters sparks flames and lighted tobacco Always have an approved fire extinguisher within easy reach 1 Open the shutoff valve on the liquid petroleum gas LPG tank by turning it counterclockwise PartNo 52856 Genie Z 60 34 Section 4 Scheduled Maintenance P rocedures Service Manual Second Edition TABLE A PROCEDURES 2 Perform a visual inspection around the following areas An LPG detector may be necessary to locate LPG leaks Gasoline LPG models LPG tank hoses and fittings solenoid shutoff valve LPG regulator and throttle body Gasoline tank manual shutoff valve fuel pump fuel filters fuel rail and fuel injectors hoses and fittings and throttle body Deutz Diesel models Fueltank shutoff valve hoses and fittings fuel pump fuel filter fuel injection pumps and
240. noperative Oscillating Models Be sure all other functions operate normally With key switch in platform position and both Emergency Stop buttons pulled out to the ON position activate footswitch and steer rocker switch on drive controller DP1 in right direction and check voltage on TB37 12V or more With key switch in platform position and both Emergency Stop buttons pulled out to the ON position activate footswitch and steer rocker switch on drive controller DP1 in right direction and check voltage on blu blk 437 wire on steer directional valve coil item 11 Disconnect wires to steer right directional valve coil item and test the resistance of the valve coil Continued on the next page 12V or more 4 5 to 5 3 ohms With key switch in platform position and both Emergency Stop buttons pulled out to the ON position activate footswitch and steer rocker switch on drive controller DP1 in right direction and check voltage at the controller terminal with the blu blk wire attached Repair or replace steer microswitch on drive controller Consult Genie Industries Service Department Repair open in blu blk 37 wire circuit that runs from TB37 to steer right directional valve coil Replace steer right directional valve coil item Il OR repair open in brown ground wire to steer right valve coil Chart 32 Repair open in blu blk 37 wire circuit from driv
241. nsor and check condition of sensor for contamination OR check for poor terminal connections or shorted wires from the HO sensor to the ECM to ground OR replace HO sensor Check engine coolant level OR check for shorted wires or poor terminal connections from the ECT sensor to the ECM OR replace the ECT sensor The IAT sensor shares the same ground wire as the ECT and MAP sensors Check for shorted wires or poor terminal connections from the IAT sensor to the ECT and MAP sensors to the ECM OR replace the IAT sensor Check engine oil level OR check for shorted wires or poor terminal connections from the oil pressure switch to the ECM OR replace the oil pressure switch Genie Z 60 34 Part No 52856 Service Manual Second Edition Section 5 Troubleshooting Flow Charts FAULT CODES Fault rotiem cause solon Crankshaft Position CKP sensor senses extra or missing pulses Camshaft Position CMP sensor senses unknown pattern ECM Fault Illegal ECM Illegal Interuption ECM Computer Operating Properly COP failure System voltage low System voltage high UT The CKP and CMP sensors work together if one is bad the other one won t work correctly and causes the ECM to detect a fault The ECM uses the signal pulses from the CKP and CMP sensors to initiate sequential fuel injection The CMP and CKP sensors work together if one is bad the other one won t work
242. nterbalance valves and activate jib boom down function Replace defective counterbalance valve function inoperative Consult Genie Industries Service Department 5 66 Genie 2 60 34 Part No 52856 Service Manual Second Edition Section 5 Troubleshooting Flow Charts Steer Left Function Inoperative Non Oscillating Models Be sure all other functions operate normally With key switch in platform position and both Emergency Stop buttons pulled out to the ON position activate footswitch and steer rocker switch on drive controller DP1 in left direction and check voltage on TB36 12V or more With key switch in platform position and both Emergency Stop buttons pulled out to the ON position activate footswitch and steer rocker switch on drive controller DP1 in left direction and check voltage on blu 36 wire on steer directional valve coil item FF Disconnect wires to steer left directional valve coil item FF and test the resistance of the valve coil Continued on the next page 12V or more 2 5 to 3 5 ohms With key switch in platform position and both Emergency Stop buttons pulled out to the ON position activate footswitch and steer rocker switch on drive controller DP1 in left direction and check voltage at the controller terminal with the blu wire attached Repair or replace steer microswitch on drive controller Consult Genie Industries S
243. ntinuity 14 wire at terminal 85 of CR9 no continuity Check voltage at the blk 12V 9 wire on the oscillate solenoid valve item HH Rotate the turntable until less the boom is in between than the non steer tires and 2400 turn the engine off psi Install a 0 to 3000 psi 207 bar gauge to the test port on the function manifold then place a block between the rod end wedge on the oscillate cylinder and the wedge stop on the axle to prevent the cylinder from extending Start the engine and rotate the turntable until the boom is past one of the non steer tires Check the pressure on the gauge 2400 psi Adjust the oscillate relief valve item GG to 250 psi 17 bar OR check to make sure LS4 is not being activated OR replace LS4 contact Remove the block and check for mechanical restrictions keeping oscillate cylinder from retracting OR replace oscillate cylinder Replace MS1 microswitch located inside of the electrical rotary coupler OR replace the electrical rotary coupler Replace CR9 Adjust system relief valve item W to 2400 psi 165 bar Remove the block and check for mechanical restrictions keeping oscillate cylinder from extending OR replace oscillate cylinder 5 78 Genie Z 60 34 Part No 52856 Service Manual Second Edition previous page Continued from the Rotate the turntable until the boom is in between the non steer t
244. o 7 14 3 2 Jib Boom Lit Cylinder i ee 7 15 3 3 J ib Boom P latform Rotate Manifold 7 17 Primary Boom Components 451 Cable Track ede et ee Rate ag le Aad ein 7 18 4 24 Priman BOOM nine i 7 19 4 3 Primary Boom Lift Cylinder ooo eee ete 7 22 4 4 Primary Boom Extension 7 23 4 5 Platform Leveling Master 7 24 Secondary Boom Components 5 1 Secondary BOOMs iei a ea re a er eer 7 25 5 2 Secondary Boom Lift Cylinder emen 7 29 Turntable Covers 6elc TumtableCOoV6Ts ore et ees tete D node ee eee eee 7 31 Deutz Engine F4L 1011F 7 1 RPM Adj strmrient n de ie endi ee SED dana 7 32 722 Elex Plate nii RR ERHEBEN dt 7 32 7 3 Oil Temperature and Oil Pressure Gauges 7 33 Ford LRG 425 EFI Engine 8 1 Timing Adjustment oot o e RE BRE EU REM En 7 34 9 2 RPM Adjustment putet e en RE AeA RR 7 34 SEEMS PEL LE 7 34 8 4 Water Temperature and Oil Pressure 7 35 x Genie Z 60 34 Part No 52856 Service Manual Second Edition EIC C c E EE 1 TABLE OF CONTENTS Section Seven Repair Procedures continued Ground Controls 9 1
245. o Hyaraulic Hose and Fitting Torque Specifications 1 Remove the drive chassis cover from the steer end of the machine 7 72 Genie Z 60 34 Part No 52856 Service Manual Second Edition Section 7 Repair Procedures Non steering Axle Components 17 1 Drive Motor How to Remove a Drive Motor CAUTION Component damage hazard Repairs to the motor should only be performed by an authorized Sundstrand S auer dealer 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 CAUTION 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 Referto Section Two Hyaraulic Hose and Fitting Torque Specifications 1 Remove the non steer axle cover fasteners then remove the covers to access the drive motors 2 Tag disconnectand plug the hydraulic hoses from the drive motor Cap the fittings on the drive motor Bodily injury hazard S praying AWARNING 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 drive motor mounting fasteners 4 Guide the drive motor shaft out of the brake and then remove the drive m
246. o Remove the Turntable Rotation Brake or Torque Hub sea FTO a0 1 Secure the turntable from rotating with the turntable rotation lock 3 Remove the torque hub mounting bolts and then use an appropriate lifting device to remove the torque hub from the machine Crushing hazard The turntable AWARNING rotate torque hub may become unbalanced and fall when itis removed from the machine if it is not properly supported 4 Remove the plug from the side of the torque unlocked locked hub Then drain the oil from the hub 5 Install the torque hub Torque the hub mounting bolts to 180 foot pounds 244 Newton meters 6 Install the brake and motor onto the torque hub PartNo 52856 Genie Z 60 34 7 65 Section 7 Repair Procedures Service Manual Second Edition M TURNTABLE ROTATION COMPONENTS 7 Fill the hub with oil from the side hole until the oil level is even with the bottom of the hole Apply pipe thread sealantto the plugs and then install the plugs Turntable rotate torque hub Capacity 8 fluid ounces 0 24 liters Type SAE 90 multipurpose hypoid gear oil API service classification GL5 7 66 Genie Z 60 34 Part No 52856 Service Manual Second Edition Section 7 Repair Procedures 2WD Steering Axle Components 14 1 Yoke and Hub How to Remove the Yoke and Hub 1 Remove the pin retaining fasteners from the steering cylinder and the tie rod pivot pins xe HE
247. off after 2 to 3 seconds Start the engine from the platform controls Do not press down on the footswitch Attemptto activate each machine function o o Result All machine functions should not operate 9 Press down on the footswitch and activate each machine function Result All machine functions should operate through a full cycle TABLE A PROCEDURES A 12 Test the Auxiliary Power Operation Detection of auxiliary power system malfunctions is essential for safe machine operation An unsafe working condition exists if the auxiliary powered functions do not operate in the event of a main power loss When operating the machine on engine power selecting auxiliary power will stop the engine immediately Auxiliary power is designed for short term use only and excessive use will result in battery drain and component damage 1 Tum the key switch to ground control and pull out the Emergency Stop button to the position at the ground controls 2 Liftthe red auxiliary power switch cover 3 Simultaneously hold the auxiliary power switch and activate each boom function toggle switch To conserve battery power test each function through a partial cycle Result All boom functions should operate 4 Turn the key switch to platform control 5 Pull out the Emergency Stop button to the on position at the platform controls then press down the foot switch 6 red auxiliary
248. oints 5 Deutz Diesel models Swing the engine back to its original position and install the 2 engine pivot plate retaining bolts PartNo 52856 Genie Z 60 34 4 17 Section 4 Scheduled Maintenance P rocedures Service Manual Second Edition TABLE B PROCEDURES B 5 Check the Battery 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 Electrocution hazard Contact with AWARNING hot or live circuits could result in death or serious injury Remove all rings watches and other jewelry Bodily injury hazard Batteries AWARNING contain acid Avoid spilling or contacting battery acid Neutralize battery acid spills with baking soda and water 1 Remove the 2 engine pivot plate retaining bolts Then swing the engine out away from the machine to access the battery a engine pivot plate b pivot plate retaining bolts 1 Puton protective clothing and eye wear 2 Besurethatthe battery cable connections are free of corrosion 3 Be sure that battery hold downs and cable connections are tight 4 Remove the battery vent caps and check the specific gravity with a hydrometer 5 Check the battery acid level If needed replenish with distilled water to the battery fill tube Do not overfill 6 Install the vent caps Adding terminal protectors and a
249. ols 2 Push down the Emergency Stop button to the orFr position Result The engine should shut off and no machine functions should operate Deutz Diesel models All functions should stop immediately The engine will shut off after 2 to 3 seconds 3 Startthe engine from the platform controls 4 Push down the Emergency Stop button to the orFr position Result The engine should shut off and no machine functions should operate The ground Emergency Stop button will stop all machine operation even if the key switch is switched to platform control PartNo 52856 Genie Z 60 34 4 23 Section 4 Scheduled Maintenance P rocedures Service Manual Second Edition TABLE B PROCEDURES B 14 Test the Ground Control Override A properly functioning ground control override is essential to safe machine operation The ground control override function is intended to allow ground personnel to operate the machine from the ground controls whether or notthe Emergency Stop button on the platform controls is in the or orr position This function is particularly useful if the operator at the platform controls cannot return the boom to the stowed position 1 Pushin the platform Emergency Stop button to the orr position 2 Startthe engine from the ground controls 3 Atthe ground controls operate each boom function through a partial cycle Result All boom functions should operate B 15 Test the Platform Self
250. on Bodily injury hazard An over AWARNING inflated tire can explode and may cause death or serious injury AWARNING over hazard Do notuse temporary flattire repair products 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 PartNo 52856 Genie Z 60 34 4 19 Section 4 Scheduled Maintenance P rocedures Service Manual Second Edition TABLE B PROCEDURES 4 Checkthe pressure in each air filled tire 2 sure the free wheel valve on the drive pump is closed clockwise Tires and Rough wheels Industrial terrain Tire size 32x12 15 NHS 15 19 5NHS 300 15NHS Tire ply rating 20 12 Tire pressure 110 psi 60 psi 7 58 bar 4 14 bar Wheel lugs 9 5 8 18 9 5 8 18 Lug nut torque dry 125 ftlbs 125 ftlbs 169 5 Nm 169 5 Nm Lug nut torque lubricated 94 ft lbs 94 ft lbs 127 4 Nm 127 4 Nm B 9 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 torque hub disconnect cap to be sure it is the engaged position ho brake disengage position aorg HN u brake engage position The free wheel val
251. on PRIMARY BOOM COMPONENTS 4 3 Primary Boom Lift Cylinder How to Remove the Primary 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 and tools could cause 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 Two Hydraulic Hose and Fitting Torque Specifications 1 Raise the primary boom enough to access the primary boom lift cylinder rod end pivot pin 2 Attach a 5 ton 4 536 kg overhead crane to the primary boom for support Do not lift the boom 3 Place a 24 inch 61 cm long block of wood across the lower secondary boom leveling links to support the primary boom lift cylinder when the rod end pivot pin is removed 4 Supportthe rod end ofthe primary boom lift cylinder with an appropriate lifting device 5 Remove the pin retaining fasteners from the primary boom lift cylinder rod end pivot pin Then use a soft metal drift to remove the pin 6 Lowerthe rod end of the cylinder onto the block that was placed on the lower secondary boom leveling links Then lower the primary boom onto the boom rest 7 Raise the secondary boom enough to access the primary boom l
252. on enable switch to either side and hold the boom extend toggle switch at the ground controls in the extend direction Manually override the directional valve by pushing in on the end of the valve spool Install a 0 to 5000 PSI 345 bar pressure gauge at the quick disconnect coupling on the function manifold and start the engine Move the function enable switch to either 2 5 to 3 5 ohms function inoperative Section 5 Troubleshooting Flow Charts M Replace boom extend directional valve coil item H Replace defective directional valve Check for mechanical restrictions keeping boom from extending OR repair cylinder or cylinder counterbalance valves OR consult Genie Industries Service Department CHART 18 side and hold the boom extend toggle switch at the ground controls in the extend direction and check the pressure less than 1000 PSI function Exchange boom extend operates retract and turntable rotate left right flow regulator valve item O with a like valve item J Check boom extend function Replace defective flow regulator valve function inoperative Repair cylinder or cylinder counterbalance valve OR function manifold could have an internal defect Consult Genie Industries Service Department Part No 52856 Genie Z 60 34 5 41 Section 5 Troubleshooting Flow Charts Service Manual Second Edition Chart 19 P
253. on systems operate ata very high pressure Fuel may be expelled under pressure if the hoses are removed too quickly Loosen the fuel lines very slowly to allow the fuel pressure to dissipate gradually Wrap a cloth around fuel hoses to absorb leaking fuel before disconnecting them ventilated area away from heaters b sparks flames and lighted tobacco Always have an approved fire extinguisher within easy reach Component damage hazard Be CAUTION sure the fuel hoses are routed the same way the original hoses were Perform this procedure with the engine off and the keyswitch in the orr position 1 Remove the 2 engine pivot plate retaining bolts and swing the engine out away from the machine 2 Place a suitable container under the engine pivot plate 3 Gasoline LPG Models At the fuel pressure regulator filter disconnect the fuel hose to the fuel tank and drain the fuel tank into the container Diesel Models At the fuel pump disconnect the fuel hose to the fuel tank and drain the fuel tank into the container Diesel models 4 Remove and replace all of the fuel line hoses and clamps according to the following illustration i EIE GE lg G 3 4 E KY e AS LU gt AS P SS CA a E TN 6 5 Deutz Diesel models a hose from the injector to the fuel tank b hoses connecting injectors C hose
254. ons and the Emergency Stop buttons for malfunctions is essential for safe machine operation An unsafe working condition exists if any function fails to operate properly or either Emergency Stop button fails to stop all the machine functions and shut off the engine Each function should activate operate smoothly and be free of hesitation jerking and unusual noise 1 Pullout Emergency Stop button at the ground controls to the on position 2 Startthe engine from the ground controls 3 Do nothold the function enable switch to either side Attempt to activate each boom and platform function toggle switch Result All boom and platform functions should not operate 4 6 Genie Z 60 34 Part No 52856 Service Manual Second Edition Section 4 Scheduled Maintenance Procedures 4 Hold the function enable switch to either side and activate each boom and platform function toggle switch Result All boom and platform functions should operate through a full cycle Descent alarm if equipped should sound while the boom is lowering 5 Push in the Emergency Stop button to the orr position O Result No function should operate the engine should stop Machines equipped with Platform Level Control Disable Function The platform level function will not operate when the boom is raised or extended past the drive speed limit switches Deut Diesel models All functions should stop immediately The engine will shut
255. ontinuity Check continuity from Repair open in brown ground wire circuit to CR2 ground to terminal 85 on CR2 good Crank engine and check gy Crank engine and check oy Repair or replace voltage at terminal 2 on voltage at org blk 41 alternator OR contact ignition start module wire on alternator Genie Industries Service Department Repair open in org blk 41 wire circuit from alternator to TB41 to terminal 2 on ignition start module Continued on the next page 5 12 Genie Z 60 34 Part No 52856 Service Manual Second Edition Continued from the previous page While cranking engine for 15 seconds check continuity to ground on yes terminal 10 on ignition start module Is continuity maintained no Check voltage at 12V terminal 4 on ignition start module oV Replace ignition start module OR consult Genie Industries Service Department Section 5 Troubleshooting Flow Charts Disconnect wht 24 wire from oil pressure sender and check continuity to yes ground on signal post of sender while cranking the engine Is continuity maintained Disconnect wht 24 wire from engine temperature sender and check continuity to ground on signal post of sender while cranking the engine Is continuity maintained yes no Repair short to ground in wht 24 wire from sending units to TB24 to terminal 10 on ignition start module D
256. ontrol Box Wiring Diagram N st o co WHT 23 2 5 5 BLK 22 als an 5 15 BLK 26 E 2 BLK RED 35 2 m WHT 1 H P L I BRN 2 Zaz zc c BLU BLK 37 GRZ
257. ontrols 54 6883 1 1 CB2 Circuit breaker 24018 ETA zai PER 45 700 IG 1 P 10 2 CR1 2 3 5 8 CR9 10 11 15 Gas LPG Relay SPDT 12V DC 34052 Potter Brumfield VF4 15F11 CO5 9 CR 1through 5 CR8 9 10 11 Diesel Relay SPDT 12V DC 34052 Potter Brumfield VF4 15F11 CO5 9 CR13 and 14 Relay SPDT 12V DC 19274 Potter Brumfield VF4 15F11 CO5 2 Diode Diode 6 amp 200 PIV 45782 Motorola MOTMR752 28 DPA iuo J oystick controller Drive 20424 OEM Controls MCH1159AD1386 1 Flashing beacon 20189 ECCO Electronic Controls 6400A GEN 1 FS1 eee 22 22 4 13482 Linemaster S witch Corp 032 S 1 Alarm Warble 19270 Floyd Bell Inc MW 09 616 Q 1 Horn 12V DC 130 GB 19145 Sparton Engineered Prod 7431 24823 5 1 H3 Alarm intermittent 18963
258. ontrols and both 12V Emergency Stop buttons pulled out to theon position activate the footswitch and check the voltage at terminal 2 on the drive joystick DP1 12V or more With the keyswitch rd turned to platform 12V controls and both Emergency Stop buttons pulled out to theon position activate the footswitch and check the voltage at terminal 1 on the horsepower limiter circuit board 12V or more Start the engine then activate the footswitch and hold the drive joystick in the full forward position and check the voltage at terminal 10 on the horsepower limiter board 9to 12V Continued on the next page Check continuity of Repair open in power brown ground wire from continuity supply circuit from TP24 terminal 3 on DP1 to to terminal 2 on drive ground joystick DP1 no continuity Repair open in brown ground wire circuit from ground to DP1 Check continuity of brown ground wire from terminal 42 on the horsepower limiter circuit board to ground Repair open in power supply circuit from TP24 continuit to terminal 1 on the horsepower limiter circuit board no continuity Repair open in brown ground wire circuit from ground to terminal 2 on the horsepower limiter circuit board Activate the footswitch 7 to 8V Replace horsepower and check the voltage at limiter board terminal 3 on the horsepower limiter board Activate the footswitch an
259. op buttons are pulled out to the position Be sure engine is not running when using auxiliary power Note Operating auxiliary power with the engine running should immediately kill the engine Lift the red auxiliary motor pump switch cover hold operates auxiliary switch and listen for sound of auxiliary pump motor operating motor does not operate With the keyswitch turned to ground control and both Emergency Stop buttons pulled out lo the ON position activate the auxiliary pump toggle switch and check the voltage on the red cable on the auxiliary power unit 12V Continued on the next page Install a 0 to 5000 psi 0 to 345 bar pressure gauge into the pressure port of the auxiliary 2400 psi pump and hold the auxiliary power toggle switch and note the pressure less than 2400 psi Check for a positive connection between good electric motor and the pump by removing the pump from the motor but leave all the hoses connected Visually check coupling connection bad Replace the auxiliary power unit Activate the auxiliary 12V or pump toggle switch and more check the voltage at TB27 Activate the auxiliary pump toggle switch and check the voltage at the center terminal of TS11 Reconnect pressure line and check battery condition There is possibly not enough battery capacity to operate both aux pump and function valves Repair or rep
260. or the secondary boom to fully raise Adjust the max out trimpot to achieve a 40 to 50 second cycle time Turn the hi range trimpot adjustment screw clockwise to increase the speed or counterclockwise to decrease the speed 11 Start a timer and record how long it takes for the secondary boom to fully lower Adjust the dual range trimpot to achieve an 30 to 40 second cycle time Turn the hi range trimpot adjustment screw clockwise to increase the speed or counterclockwise to decrease the speed If the function cycle time is not achievable check the relief valve pressure See 11 2 Valve Adjustments Function Manifold 12 Turn the engine off 13 Pull outthe Emergency Stop button to the on position 14 Press down the foot switch and then move the control handle all the way to the up position Record the maximum voltage reading 15 Startthe engine 16 Starta timer and simultaneously move the control handle all the way to the up position Note how long ittakes to reach the maximum voltage recorded in step 14 This is the ramp rate 7 4 Genie Z 60 34 Part No 52856 Service Manual Second Edition Section 7 Repair Procedures 17 Setthe ramp rate turn the trimpot to obtain a 2 to 3 second ramp speed Turn the trimpot clockwise to increase the time or counterclockwise to decrease the time Secondary boom up down specifications Threshold 4 3V DC 8 5V DC 40 to 50 seconds Secondary boom up hi range
261. orque hub 0 24 liters Continuous improvement of our products is a Genie policy Product specifications are subject to change without notice PartNo 52856 Genie Z 60 34 Section 2 Specifications Service Manual Second Edition E PERFORMANCE SPECIFICATIONS Performance Specifications Drive speeds maximum 2WD 4WD Boom stowed high range 3 5 mph 4 5 mph Gasoline LP G models 5 6 km h 7 2 km h 40 7 8 sec 40 ft 6 1 sec 12 2m 7 8 sec 12 2m 6 1 sec Boom stowed high range 3 0 mph 3 9 mph Deutz diesel models 4 8 km h 6 3 km h 40 ft 9 1 sec 40 ft 7 sec 12 2m 9 1 12 2 7 sec Boom raised or extended 0 6 mph 0 6 mph All models 1 km h 1 km h 40 40 40 ft 40 sec 12 2m 40 sec 12 2m 40 sec Gradeability stowed 2WD 4WD Industrial 30 NA Rough terrain 20 35 Boom function speeds maximum from platform controls Jib boom up 15 to 25 seconds Jib boom down 15 to 25 seconds Primary boom up 35 to 45 seconds Primary boom down 50 to 60 seconds Primary boom extend 20 to 30 seconds Primary boom retract 15 to 25 seconds Secondary boom up 40 to 50 seconds Secondary boom down 30 to 40 seconds Turntable rotate 360 130 to 140 seconds Platform rotate 180 7 to 10 seconds Platform level up 30 to 40 seconds Platform level down 15 to 25 seconds 2 2 Genie Z 60 34 Part 52856 Service Manual Second Edition Section 2 Specifications H
262. ot Bodily injury hazard S praying AWARNING 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 35 Remove the hose and cable covers from both of the lower secondary boom leveling links 36 Tag disconnect and plug the master cylinder hydraulic hoses Cap the fittings on the cylinder Bodily injury hazard S praying AWARNING 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 37 Attach a lifting strap from an overhead crane to the lug on the rod end of the master cylinder 38 Remove the pin retaining fasteners from the master cylinder barrel end pivot pin Use a soft metal drift to remove the pin Then remove the master cylinder from the machine Crushing hazard The master AWARNING cylinder may become unbalanced and fall when itis removed from the machine if itis not properly supported by the overhead crane 39 Attach a lifting strap from an overhead crane to the upper mid pivot then remove the securing strap from the upper mid pivot 40 Pull all ofthe hoses and cables out of the upper mid pivot Component damage hazard 41 Remove the secondary boom drive limit switch mounting fasteners from the lower secondary boom Do not disconnectthe wiring 42 Pull all of the hoses and c
263. otor from the machine 17 2 Torque Hub How to Remove a Drive Torque Hub When removing a hose assembly or fitting the O ring on the fitting and or hose end must be replaced and then torqued to specification during installation Refer to Section Two Hyaraulic Hose and Fitting Torque Specifications 1 Remove the drive motor See 17 1 How to Remove a Drive Motor 2 Tag disconnectand plug the hydraulic hose from the brake Then remove the hydraulic fitting and the bleed valve Bodily injury hazard S praying AWARNING 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 Loosen the wheel lug nuts Do not remove them 4 Blockthe steering wheels then center a lifting jack under the non steering axle Raise the machine and place blocks under the chassis for support 5 Remove the wheel lug nuts then the tire and wheel assembly 6 Place a second lifting jack under the torque hub for support and secure the torque hub to the lifting jack 7 Remove the torque hub mounting bolts that attach the torque hub to the non steer axle PartNo 52856 Genie Z 60 34 7 13 Section 7 Repair Procedures Service Manual Second Edition NON STEERING AXLE COMPONENTS 8 Remove the torque hub from the non steer axle Crushing hazard The torque ACAUTION hub may become unbalanced and fall if itis not pro
264. perly supported and secured to the lifting jack Torque specifications Lug nut dry 125 ft lbs 169 5 Nm lubricated 94 ft Ibs 127 4 Nm Torque hub mounting bolts dry 120 ftlbs 163 Nm lubricated 90 ft Ibs 122Nm Drive motor mounting bolts dry 75 ftlbs 102 Nm lubricated 56 ft lbs 76 Nm 7 74 Genie Z 60 34 Part No 52856 Distributed Genie North America Phone 425 881 1800 Toll Free in USA 800 536 1800 Toll Free in Canada 800 426 8089 Fax 425 883 3475 Genie UK Limited Phone 44 1636 605030 Fax 44 1636 611090 Genie China Phone 86 21 62483040 Fax 86 21 62488180 Genie Japan Phone 813 3453 6082 Fax 81 3 3453 6083 Genie Australia Pty Ltd Phone 61 7 3375 1660 Fax 61 7 3375 1002 Genie France Phone 33237 260 999 Fax 33 237 260 998 Genie Holland Phone 31 7051 78836 Fax 31 7051 13993 Genie Latin America Phone 561 994 0380 Fax 561 997 5877
265. plosion and fire hazard If a fuel leak is discovered keep any additional personnel from entering the area and do notoperate the machine Repair the leak immediately D 4 Check the Engine Valve Clearance Gasoline LPG Models Complete information to perform this procedure is available in the Ford LRG 425 EFI 2 5 Liter Industrial Engine Service Manual Ford number FPP 194 303 Genie partnumber 52695 D 5 Check the Engine Cylinder Compression Gasoline LPG Models Complete information to perform this procedure is available in the Ford LRG 425 EFI 2 5 Liter Industrial Engine Service Manual Ford number FPP 194 303 Genie partnumber 52695 PartNo 52856 Genie Z 60 34 4 43 Section 4 Scheduled Maintenance P rocedures Service Manual Second Edition TABLE D PROCEDURES D 6 Clean the PCV Hose and Fittings Gasoline LPG Models Maintaining P CV hoses is essential to good engine performance Improperly functioning P CV hoses will fail to ventilate the crankcase and continued use of neglected hoses could result in component damage Perform this procedure with the engine off 1 Open the engine side turntable cover 2 Remove the 2 engine pivot plate retaining bolts and swing the engine out away from the machine to access the PCV valve 3 Locate the PCV valve and hose under the intake manifold a PCV valve b PCV valve hose 4 Disconnect the hose from the PCV valve then disconnect the hose from t
266. power switch cover PartNo 52856 Genie Z 60 34 4 7 Section 4 Scheduled Maintenance P rocedures Service Manual Second Edition TABLE A PROCEDURES 7 Simultaneously hold the auxiliary power switch and activate each function control handle or toggle switch To conserve battery power test each function through a partial cycle Result All boom and steer functions should operate Drive functions should not operate with auxiliary power A 13 Test the Tilt Sensor The tilt sensor sounds an alarm located in the platform when the incline of the turntable exceeds the rating on the serial plate Selecta level test area The tilt alarm should not be sounding prior to the test 1 Open the ground controls side turntable cover 2 Turn the keyswitch to platform controls and pull out the red Emergency Stop buttons outto the ON position at both the ground and platform controls 3 Locate the tilt sensor next to the ground control box 4 Press down on one side of the tilt sensor Result The alarm located in the platform should sound Tip over hazard The alarm should AWARNING be heard at the ground controls If you can t hear the alarm atthe ground controls replace the alarm in the platform 4 8 Genie Z 60 34 Part No 52856 Service Manual Second Edition Section 4 Scheduled Maintenance Procedures A 14 Test the Limit Switches Drive Limit Switches The drive limit switc
267. r fitting the O ring on the fitting and or hose end must be replaced and then torqued to specification during installation Refer to Section Two Hyaraulic Hose and Fitting Torque Specifications 1 Disconnect the electrical connection at the electronic displacement controller EDC located on the drive pump PartNo 52856 Genie Z 60 34 7 39 Section 7 Repair Procedures HYDRAULIC PUMPS 2 Close the two hydraulic tank valves located at the hydraulic tank open closed CAUTION Component damage hazard The engine must not be started with the hydraulic tank shutoff valves in the cLosep 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 3 Tagand disconnect and plug the hydraulic hoses from the drive and lift steer pumps Cap the fittings on the pumps AWARNING Bodily injury hazard S praying hydraulic oil can penetrate and burn skin Loosen hydraulic connections very slowly to allow the oil pressure to dissipate gradually Do not allow oil to squirt or spray 4 Supportthe pump with a 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 from the machine CAUTION CAUTION Component damage hazard The hydraulic pump may become unbalanced and fall if itis not
268. r 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 Locate the fuel pre filter behind the ground control box 2 Turn manual shutoff valve located at the fuel tank to the cLosep position 3 Atthe pre filter disconnect the fuel hose that goes to the fuel tank 4 Disconnect and plug the fuel hose from the fuel pre filter to the fuel pump then remove the pre filter 5 Install the new fuel pre filter Genie part no 52179 and connect the fuel hoses to the filter 6 Clean up any fuel that may have spilled during the installation procedure 7 Remove the 2 engine pivot plate retaining bolts Then swing the engine out and away from the machine to access the fuel pressure regulator filter 8 Locate the fuel pressure regulator filter installed on the engine mounting leg 9 Disconnectthe hoses from the fuel pressure regulator filter Explosion and fire hazard Electronic Fuel Injection EFI systems operate at a very high pressure Fuel may be expelled under pressure if the hoses are removed too quickly Loosen the fuel lines very slowly to allow the fuel pressure to dissipate gradually Wrap a cloth around fuel hoses to absorb leaking fuel before disconnecting them 10 Remove the fuel pressure regulator filter mounting fasteners Then remove the regulator filter fro
269. r in forward direction and check voltage at terminal 2 on drive controller DP1 12V or more Repair open from terminal 4 on DP1 to center terminal on TS10 OR refer to Chart 34 OR consult Genie Industries Service Department Hold the drive enable switch TS10 to either side and activate the footswitch and drive forward function Will unit drive Repair open in blu wht wire from drive enable toggle switch TS10 to TP12 to TB12 OR replace drive enable toggle switch TS10 Rotate the boom so it is between the non steer end tires to check for proper activation of microswitch located inside of the electrical rotary coupler Check continuity from TB30 to TB12 no continuity Please begin troubleshooting from beginning of chart OR consult Genie Industries Service Department yes continuit consult Chart 39 Repair open in power supply circuit from TP24 The machine is operating correctly If machine does not operate gore enie Industries Service Department Replace drive enable microswitch MS2 inside of the electrical rotary coupler OR replace the electrical rotary coupler Part No 52856 Genie Z 60 34 5 87 Section 5 Troubleshooting Flow Charts Service Manual Second Edition Chart 40 Auxiliary Functions Inoperative Be sure all other functions operate normally Be sure key switch is in the appropriate position and both Emergency St
270. radually Do not allow oil to squirt or spray 26 Attach a lifting strap from an overhead crane to the lug on the rod end of the secondary boom lift cylinder 27 Remove the pin retaining fasteners from the secondary boom lift cylinder pivot pins Use a slide hammer to remove the pins then remove the secondary boom lift cylinder from the machine Crushing hazard The secondary AWARNING boom lift cylinder may become unbalanced and fall when it is removed from the machine if it is not properly supported by the overhead crane 28 Attach a securing strap from the lower mid pivot to the lower secondary boom to secure the lower mid pivot from moving 29 Number each electrical cable and its entry location at the platform control box 30 Open the platform control box 31 Label and disconnect each wire of the cables that enter the platform control box Electrocution hazard Contact with AWARNING electrically charged circuits could result in death or serious injury Remove all rings watches and other jewelry 32 Pull all of the cables out of the platform control box 33 Pull all of the electrical cables out of the cable track Do not pull out the hydraulic hoses PartNo 52856 Genie Z 60 34 7 27 Section 7 Repair Procedures Service Manual Second Edition SECONDARY BOOM COMPONENTS 34 Tag disconnect and plug the platform rotator and slave cylinder hydraulic hoses atthe union located near the upper mid piv
271. raulic Tank Filter Condition Indicator B 7 Inspect the Electrical Wiring B 8 Inspect the Tires and Wheels including lug nut torque B 9 Confirm the Proper Brake Configuration B 10 Check the Torque Hub Oil Level and Fastener Torque B 11 Check and Adjust the Engine RPM Ea Pa Pa Va Pa B 12 Test the Key Switch Part No 52856 Genie Z 60 34 Section 3 Scheduled Maintenance Inspections Service Manual Second Edition MAINTENANCE TABLES Table B continued Warm Cold Dealer Tools are New parts engine engine service required required required required suggested B 13 Testthe Emergency Stop Buttons B 14 Testthe Ground Control Override B 15 Platform Self leveling B 16 Testthe Horn B 17 Testthe Foot Switch B 18 Testthe Engine Idle Select B 19 Testthe Fuel Select Operation Gasoline LP G Models B 20 Test the Drive Enable System B 21 Test the Drive Brakes B 22 Testthe Drive Speed Stowed Position B 23 Testthe Alarm Package Optional Equipment B 24 Perform Hydraulic Oil Anaysis See D 1 Test or Replace the Hydraulic Oil Every 500 hours perform the following engine maintenance procedure B 25 Replace the Engine Oil and Filter Deutz Diesel Models 2 3 4 Genie 7 60 34 Part 52856 Service Manual Second Edition Section 3 Scheduled Maintenance Inspections
272. re gauge at the quick disconnect coupling on the boom function manifold and start the engine Move the function enable switch in the high rpm position and hold the turntable rotate right toggle switch at the ground controls in the right direction and check the pressure Continued on the next page 2 5 to 3 5 ohms less than 2400 PSI Replace turntable rotate right directional valve coil item E Exchange flow regulator function valve item O with a like operates valve item J Check turntable rotate right function Replace defective flow regulator valve function inoperative Repair or replace the turntable rotation motor OR function manifold could have an internal defect Consult Genie Industries Service Department 5 50 Genie 2 60 34 Part No 52856 Service Manual Second Edition Section 5 Troubleshooting Flow Charts CHART 21 Plumb a 0 to 5000 psi Turntable rotation 0 to 345 bar pressure lessthan manifold could have an gauge into the hose 250 psi internal defect OR the from the turntable 0 030 orifice may be rotation manifold to the plugged OR consult turntable rotation brake Genie Industries Service Move the function Department enable switch to either side and activate the turntable rotate right function Continued from the previous page 250 psi or more Exchange turntable rotate left and right function counterbalance valves op
273. re more often if dusty 1 With the engine off and the boom in the stowed conditions exist or the machine is position visually inspect the lift interlock limit subjected to extended low idle switch for the following operation Broken or missing actuator arm Periodic replacement of the engine oil and filter is essential to good engine performance Operating the machine with an improper oil level or Loose wiring neglecting periodic oil and filter changes can damage engine components A daily check of machine hours againstthe hours noted on the oil filter will allow the inspector to anticipate and perform oil and filter changes atthe 100 hour interval Missing fasteners Perform this procedure after warming the engine to normal operating temperature Bodily injury hazard Beware of ACAUTION hot engine parts and oil Contact with hot engine oil and or engine parts may cause severe burns 1 Remove the oil filler cap located on the valve cover a lift interlock switch hidden from view 2 Pullthe oil drain hose out from underneath the b primary boom engine C cable track d drive limit switch 3 Openthe valve on the oil pan and allow all of the oil from the engine to drain into a suitable 2 Using auxiliary power raise the primary boom vius 9 ry p y container See capacity specifications past the lift interlock limit switch Result When the primary boom passes the 4 Close the valve on the oil pan lif
274. re that the solenoid valve item oscillate cylinder is HH clean and clear of all debris Retract the boom and less turn the engine off than gine 2400 0 to 3000 p el et system relief 207 bar gauge to the valve item W to 2400 test port on the function manifold then place a block between the rod end wedge on the oscillate cylinder and the wedge stop on the axle to prevent the cylinder from extending Start the engine and extend the boom 2 feet 0 6 m Check the pressure on the gauge psi 165 bar yes 2400 psi Remove the block and check for mechanical restrictions keeping oscillate cylinder from extending OR replace oscillate cylinder Continued on the next page Part No 52856 Genie Z 60 34 5 75 Section 5 Troubleshooting Flow Charts CHART 33 Continued from the previous page Fully retract the primary boom Does the oscillate cylinder fully retract yes Start the engine from the ground controls and raise the primary boom approximately 2 feet 0 6 m Does the oscillate cylinder fully extend yes Continued on the next page Service Manual Second Edition Turn the engine off and less place a block between than the rod end wedge and 250 psi the cylinder barrel to prevent the cylinder from retracting Install a 0 to 1500 psi 103 bar pressure gauge at the quick disconnect coupling on the function manifold
275. resistor being tested 4 Compare the ohmmeter reading with the resistance rating printed on the resistor 9 5 Engine Fault Codes Gasoline LPG Models How to Retrieve Engine Fault Codes When a 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 ground and platform controls Use the following procedure to retrieve the engine fault code to determine the engine malfunction Perform this procedure with the keyswitch in the orr position 1 Open the ground controls side turntable cover 2 Open the ground control box and locate the run test toggle switch inside of the ground control box PartNo 52856 Genie Z 60 34 7 37 Section 7 Repair Procedures GROUND CONTROLS 3 Pull outthe ground controls red Emergency Stop button to the on position 4 Hold the run test toggle switch to the test position and turn the keyswitch to the ground controls position Result The check engine light should turn on The check engine light should begin to blink 5 Continue to hold the run test toggle switch in the test position and countthe blinks Fault codes are two digits The check engine light will blink the first digit of a two digit code then will pause for 1 2 seconds and then blink the second digit For example the check engine light blinks 5 consecutive times then pauses for 1 2 seconds and then blinks 1
276. ressure gauge during boom up Do not allow the pressure to exceed 2500 PSI Repair or replace the master cylinder 2000 PSI or more Repair or replace the slave cylinder 5 52 Genie 2 60 34 Part No 52856 Service Manual Second Edition Section 5 Troubleshooting Flow Charts Platform Level Up Function Inoperative Be sure all other functions operate normally With the keyswitch turned to ground controls and both Emergency Stop buttons pulled out to theon position move the function enable switch to either side and activate the platform level toggle switch TS17 in the up direction and check the voltage at org wire on platform level up function directional valve item C Continued on the next page 12V or more With the keyswitch turned to ground controls and both Emergency Stop buttons pulled out to the on position move the function enable switch to either side and activate the platform level toggle switch TS17 in the up direction and check the voltage at TB14 With the keyswitch turned to platform controls and both Emergency Stop buttons pulled out to the ON position activate the footswitch and the platform level toggle switch TS7 in the up direction and check the voltage at TB14 Troubleshoot platform level toggle switch TS17 on ground control panel OR repair open in red power wire circuit to TS17 OR repair open in org wire circuit from TS17 to TB14 OR
277. rictions keeping gauge at the quick platform level up disconnect coupling on function from operating the function manifold OR replace slave and activate the platform cylinder OR replace level up function slave cylinder counterbalance valves OR consult Genie Industries Service less than 2000 psi Department Replace flow regulator valve item R OR test master cylinder see Chart 22 OR repair or replace slave cylinder or slave cylinder counterbalance valves OR function manifold may have an internal defect Consult Genie Industries Service Department 5 54 Genie 2 60 34 Part No 52856 Service Manual Second Edition Section 5 Troubleshooting Flow Charts Platform Level Down Function Inoperative Be sure all other functions operate normally With the keyswitch turned to ground controls and both Emergency Stop buttons pulled out to theon position move the function enable switch to either side and activate the platform level toggle switch TS17 in the down direction and check the voltage at org blk wire on platform level down function directional valve item C Continued on the next page 12V or more With the keyswitch turned to ground controls and both Emergency Stop buttons pulled out to the on position move the function enable switch to either side and activate the platform level toggle switch TS17 in the down direction and check the voltage at TB15 With the keyswitch turned to pla
278. rimary Boom Retract Function Inoperative Be sure all other functions operate normally With key switch in ground position and both Emergency Stop buttons pulled out to the ON position move the function enable switch to either side and hold the boom retract toggle switch TS21 on ground panel in the retract direction and check voltage on wht red wire on boom extend retract and turntable rotate left right proportional valve coil item Q 12V or more Continued on the next page Move the function enable switch to either side and hold the boom retract toggle switch 9 to 10V TS21 on ground panel in the retract direction and check voltage at TB6 With keyswitch in 9 to 10V platform position and both Emergency Stop buttons pulled out to the on position activate footswitch and boom extend retract toggle switch TS8 on platform control panel in the retract direction and check voltage at TP6 oV Activate footswitch and check voltage at center terminal of TS8 12V or more Test toggle switch see bad Repair Section good Repair open in blk red wire circuit from TS8 to TP6 good If boom retract function is still inoperative replace CR15 and begin troubleshooting from beginning of chart OR consult Genie Industries Service Department Repair open in wht red wire circuit from TB6 to boom extend retract and turntable rotate left right proportional valve coil
279. roduction Important Information wees ot le db t deed rdc a ii Section One Safety Rules General Safety Rules encre e eod bd ale a eda bete be id lii Section Two Specifications Machine 5 0 2 1 Performance Specifications 2 2 2 eb ep 2 3 Ford Engine LRG 425 EFI Specifications 2 4 Deutz Engine F4L 1011F mes 2 5 Hydraulic Hose and Fitting Torque 5 e 2 6 Section Three Scheduled Maintenance Inspections Nto TUETION 3 1 3 2 Tia DIO Be E 3 3 Urt E 3 5 3 6 Maintenance Inspection 2 3 7 Section Four Scheduled Maintenance Procedures WTO 4 1 1 Inspect the Operator s and Safety Manuals 4 2 2 Inspectthe Decals and Placards sss emm 4 2 A 3 Inspectfor Damage Loose or Missing Parts 4 2 A 4 Check the Engine 4 3
280. rom TP6 to TB6 both Emergency Stop buttons pulled out to the on position activate footswitch and turntable rotate left right proportional controller 1 on platform control panel in the right direction and check voltage at TP6 oV Activate footswitch and check voltage at terminal on BP1 Repair open in power supply circuit from TP24 to BP1 OR repair open in brown ground wire circuit from ground to 12V or more 1 Re adjust controller see Repair Section OR replace controller BP1 OR consult Genie Industries Service Department 5 48 Genie 2 60 34 Part No 52856 Service Manual Second Edition Continued from the previous page With key switch in ground position and both Emergency Stop buttons pulled out to the ON position move the function enable switch to either side and hold the turntable rotate left right toggle switch TS20 on ground panel in the right direction and check voltage on wht wire on boom function directional valve coil item E 12V Continued on the next page Section 5 Troubleshooting Flow Charts NE Move the function enable switch to either side and hold the add turntable rotate left right toggle switch TS20 on ground panel in the right direction and check voltage at TB4 With key switch in platform position and both Emergency Stop 12V or buttons pulled out to More ON position activate footswitch and turntab
281. ry power to extend the extension cylinder until the rod end clears the end of the extension tube Tag disconnect and plug the extension cylinder hydraulic hoses Cap the fittings on the cylinder AWARNING 894i 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 9 Place blocks under the barrel end of the extension cylinder for support 10 Remove the cotter pin from the extension cylinder barrel end pivot pin Use a soft metal drift to remove the pin 11 Support and slide the extension cylinder out of the extension boom from the platform end AWARNING Crushing hazard The extension cylinder may become unbalanced and fall when itis removed from the extension boom if it is not properly supported Component damage hazard Be CAUTION careful notto damage the counterbalance valves on the primary boom extension cylinder when removing the cylinder from the primary boom PartNo 52856 Genie Z 60 34 7 23 Section 7 Repair Procedures Service Manual Second Edition gt PRIMARY BOOM COMPONENTS 4 5 3 Attach the lifting strap from an overhead crane to the platform end of the lower secondary Platform Leveling Master boom arm for support Do not lift Cylinder The master cylinder acts as a pump forthe slave cylinder It is part of the closed
282. s then remove the flex plate from the engine fly wheel How to Install the Flex Plate 1 Install the flex plate onto the engine flywheel with the raised spline towards the pump Torque the flex plate mounting bolts to 34 ft lbs 46 Nm 2 Install the pump coupler onto the pump shaft with the setscrew towards the pump Leave a 1 6 inch 1 5 mm gap between the pump coupler and pump end plate 3 Apply Loctite9 removable thread sealantto the pump coupler set screw Torque the set screw to 45 ft lbs 61 Nm Component damage hazard Do CAUTION not force the drive pump during installation or the flex plate teeth may become damaged 4 Install the pump and torque the pump mounting plate fasteners to 34 ft lbs 46 Nm Genie Z 60 34 Part No 52856 Service Manual Second Edition Section 7 Repair Procedures 8 4 Water Temperature and Oil Pressure Gauges The water temperature gauge is an electrical gauge The sending unit has limit contacts that are factory set The contacts will close at approximately 230 F 110 C When the contacts close the engine will shut off to prevent damage and will not start until the temperature drops below the contact point Temperature will be indicated when the keyswitch is and the Emergency Stop button is pulled outto the ow position CAUTION Component damage hazard Do not crank the engine with the over temperature light on The oil pressure gauge is an electrical gaug
283. si 17 2 bar Charge pressure circuit 2 Flow divider combiner valve KK Controls flow to drive motors 3 Orifice 0 070 in 1 78 mm LE Drive circuit 4 Shuttle valve 3 position 3 way MM Charge pressure circuit that motor shift 5 Diagnostic fitting NN Testing Plug Torque Specifications SAE No 8 5 16 50 ft lbs 68 Nm SAE No 10 9 36 55 ftlbs 75 Nm SAE No 12 5 8 75 ft lbs 102 Nm 10 12 ft lbs 14 16 Nm 25 30 ft lbs 34 41 Nm 15 18 ft lbs 20 24 Nm 7 54 Genie Z 60 34 Part No 52856 Section 7 Repair Procedures Service Manual Second Edition MANIFOLDS 11 8 Valve Adjustments 2WD Drive Manifold How to Adjust the Charge Pressure Relief Valve 1 Connecta 0 600 psi 0 to 41 bar pressure gauge to the test port item 5 located on the drive manifold 2 Startthe engine from the platform controls 3 Drive the machine slowly in either direction and observe the pressure reading on the pressure gauge 4 Turnthe engine off Hold the charge pressure relief valve and remove the cap item 1 5 Adjustthe internal hex socket Turn it clockwise to increase the pressure or counterclockwise to decrease the pressure Then install the valve cap 6 Restartthe engine Drive the machine in either direction and recheck the valve pres
284. side of the electrical rotary coupler The switch signals the oscillate cylinder to extend the lock out wedges when the primary boom is rotated past either of the non steering wheels An improperly functioning rotation oscillate lock out switch will allow the machine to operate in an unsafe position 1 Startthe engine from the platform controls Then rotate the turntable to the left until the primary boom is past the left non steering wheel a steer axle b oscillating lock out wedge c lock out wedge stop O Result The oscillate cylinder should fully extend the lock out wedges against the wedge stops 2 Rotate the turntable to the right until the primary boom is past right non steering wheel O Result The oscillate cylinder should fully extend the lock out wedges against the wedge stops PartNo 52856 Genie Z 60 34 Section 4 Scheduled Maintenance P rocedures Service Manual Second Edition M 4 23 TABLE A PROCEDURES Lift Interlock Limit Switch A 15 On oscillating axle equipped machines the lift Replace the Engine Oil and interlock switch stops the primary boom from being Filter Gasoline LPG Models raised if the oscillate lock out wedges are not fully extended An improperly functioning lift interlock Ford engine specifications require switch will allow the machine to operate in an thatthis procedure be performed unsafe position every 100 hours Perform this procedu
285. sitve lead from a voltmeter to terminal 5 on the joystick and with the footswitch activated and the drive joystick in the full forward position hold the negative lead of the voltmeter onto the center terminal of the drive enable toggle switch TS10 and check the voltage 2V Replace drive enable toggle switch TS10 Repair open in wht wire from terminal 4 on drive joystick to TS10 to TP30 to TB30 OR repair open in red wire circuit from TB30 to rotator microswitch and from rotator microswitch to TB12 Repair open in blu wht wire from TS10 to TP12 to TB12 Repair open in wire from terminal 4 from drive joystick DP1 to drive enable toggle switch TS10 OR replace drive joystick controller OR consult Genie Industries Service Department 5 82 Genie Z 60 34 Part No 52856 Service Manual Second Edition Section 5 Troubleshooting Flow Charts Chart 35 Drive Forward Disconnect Mus voltage readings different Meer Pf wire connector from the rive controller drive pump start H engine move the drive Fu nction controller to full forward inoperative position and note the voltage across the wht 12 and the wht blk 31 Be all other wire terminals on the functions operate EDC Reverse the volt i i meter leads and move Ho including the drive controller to full drive in opposite reverse position and direction of note the voltage malfunction voltage
286. stries Service Department circuit from key switch to TB22 OR Replace the platform controls contact at the key switch Repair open in blk 2 wire circuit from TB22 TP22 Repair open in blk wire from TP22 to Emergency Stop button P2 Check if Emergency Stop button internal cam yes is activating the contact no Replace the platform Emergency Stop button Repair open in red wire with diode from Emergency Stop button to TP23 Replace contact on Emergency Stop button P2 Part No 52856 Genie Z 60 34 5 25 Section 5 Troubleshooting Flow Charts Service Manual Second Edition Chart 14 Primary Boom Up Function Inoperative Be sure all other functions operate normally Be sure LS2 limit switch is being activated when the primary boom is in the stowed position If primary boom raises approximately 2 feet 0 6 m and stops refer to Chart 33 With the key switch turned to ground controls and both Emergency Stop buttons pulled out to the ON position move the function enable switch to either side and hold the primary boom up toggle Switch TS19 at the ground controls in the up direction and check voltage on red wht wire on primary boom up down proportional valve coil item N 12V or more Continued on the next page Move the function enable switch to either side and hold the primary boom up toggle Switch TS19 at the ground controls in th
287. sure 7 Turn the engine off then remove the pressure gauge Charge Pressure Relief valve specifications Pressure 250 psi 17 2 bar 7 56 Genie Z 60 34 Part 52856 Service Manual Second Edition Section 7 Repair Procedures Eu H MM J MANIFOLDS This page intentionally left blank PartNo 52856 Genie Z 60 34 7 5 Section 7 Repair Procedures Service Manual Second Edition MANIFOLDS 11 9 4WD Drive Manifold Components The drive manifold is mounted inside the drive chassis atthe non steer end Index Schematic No Description Item Function Torque 1 Directional valve 2 position 2 way OO High speed divider bypass N C Pilot to 25 30 ft lbs 34 41 Nm 2 Flow divider combiner valve PP Controls flow to flow divider combiner valves 6 and 7 25 30 ft lbs 34 41 Nm 3 Relief valve 250 psi 17 2 bar QQ Charge pressure circuit 10 12 ft lbs 14 16 Nm 4 Check valve pilot to close RR Works in conjunction with Index no 12 in the high speed divider bypass circuit 10 12 ft lbs 14 16 Nm 5 Orifice plug 0 052 inch 1 32 mm SS Front drive motor circuit 6 Flow divider combiner valve Controls flow to steer end driv
288. t interlock limit switch the primary boom should stop and not be able to continue to raise because the auxiliary power will not extend the oscillating lock out wedges 4 12 Genie Z 60 34 Part No 52856 Service Manual Second Edition Section 4 Scheduled Maintenance Procedures 5 Remove the 2 engine pivot plate retaining bolts Then swing the engine out away from the machine to access the oil filter a engine pivot plate b pivot plate retaining bolts drain hose 6 Place a container under the oil filter 7 Usean oil filter wrench and remove the filter 8 Apply a thin layer of oil to the new oil filter gasket Genie part no 52581 Then install the filter and tighten it securely by hand 9 Use a permanent ink marker to write the date and number of hours from the hour meter on the oil filter 10 Fill the engine with new oil per specifications and install the filler cap See capacity specifications 11 Startthe engine from the ground controls Allow the engine to run for 30 seconds then turn the engine off 12 Check the oil filter oil pan drain hose and drain valve for leaks 13 Swing the engine pivot plate back to its original position and install the 2 engine pivot plate retaining bolts TABLE A PROCEDURES 14 Check the engine oil level dipstick Add oil if needed Ford LRG 425 EFI Engine 4 5 quarts Cil capacity including filter 4 3 liters Ford LRG 425 EFI Engine Oil viscosit
289. t is not properly attached to the overhead crane 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 Referto Section Two Hyaraulic Hose and Fitting Torque Specifications JIB BOOM COMPONENTS 1 Raise the jib boom slightly and place blocks under the platform mounting weldment for support Then lower the jib boom until the platform is resting on the blocks Do not rest the entire weight of the boom on the blocks LT i ei M 2 Remove the pin retaining fasteners from the jib boom lift cylinder rod end pivot pin Do not remove the pin 3 Remove the pin retaining fasteners from the platform leveling slave cylinder barrel end pivot pin Do not remove the pin 4 Remove both ofthe jib boom leveling links from the machine 5 Tag disconnect and plug the jib boom lift cylinder hydraulic hoses Cap the fittings on the cylinder Bodily injury hazard S praying AWARNING 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 6 Attach a lifting strap from an overhead crane to the lug on the rod end of the jib boom lift cylinder 7 Remove the pin retaini
290. t to the controller in the stowed the engine to stall position potentiometer adjustmentis a compromise between engine stability surging and engine b potentiometer maximum voltage output to the drive controller in the boom raised position rpm droop C potentiometer reaction rate or 12 Disconnect the volt meter how fast the voltage output reacts to the change in engine rpm 13 Raise the primary boom above horizontal 4 Startthe engine from the platform controls 14 Drive the machine for 40 feet 12 m and record the elapsed time Repeat this step in the opposite drive direction PartNo 52856 Genie Z 60 34 7 7 Section 7 Repair Procedures Service Manual Second Edition PLATFORM CONTROLS 15 Adjustthe B potentiometer to obtain the correct raised drive speed of 1 foot per second 0 31 m per second Turn the B potentiometer counterclockwise to increase voltage or clockwise to decrease voltage 16 Close the platform control box lid and install the fasteners Drive speed stowed position high range 2WD 4wWD 40 ft 7 8 sec 12 2m 7 8 sec Gasoline LPG models 40 ft 6 1 sec 12 2m 6 1 sec Deutz Diesel models 40 ft 9 1 sec 40 ft 7 sec 12 2 9 1 12 2m 7 sec Booms raised or extended 40 ft 40 sec all models 12 2m 40 sec 1 3 Foot Switch How to Test the Foot Switch Perform this procedure with the keyswitch in the orr position 1 Turnthe keyswit
291. te left and right function counterbalance valves Operates items DD and CC at the turntable rotation motor counterbalance valve manifold Activate turntable rotate left function Replace defective counterbalance valve function inoperative Check for mechanical restrictions keeping turntable rotate left function from operating OR replace shuttle valve item BB OR consult Genie Industries Service Department CHART 20 Part No 52856 Genie Z 60 34 Section 5 Troubleshooting Flow Charts Service Manual Second Edition Chart 21 Turntable With key switch in Rotate Right Both Emergency Stop Function TE Inoperative NEL turntable rotate toggle switch TS20 on ground panel in the right direction and check Be sure all other functions operate normally voltage on wht red wire on turntable rotate left right and boom extend retract proportional valve coil item Q 12V Continued on the next page Move the function Repair open in wht red enable switch to either wire circuit from TB6 to side and hold the 10 to turntable rotate left right turntable rotate toggle 12V and boom extend retract switch TS20 on ground panel in the right direction and check voltage at TB6 proportional valve coil item Q OR repair open in brown ground wire circuit to valve coil oV 10 to With keyswitch in 12V Repair open in wht red platform position and wire f
292. tend retract and turntable rotate left right flow regulator valve item O with a like valve item J Check boom retract function Replace defective flow regulator valve function inoperative Re adjust system relief valve item W OR repair cylinder or cylinder counterbalance valve OR function manifold could have an internal defect Consult Genie Industries Service Department CHART 19 Part No 52856 Genie Z 60 34 Section 5 Troubleshooting Flow Charts Service Manual Second Edition Chart 20 Turntable Rotate Left Function Inoperative Be sure all other functions operate normally With key switch in ground position and both Emergency Stop ON position move the function enable switch to either side and hold the turntable rotate toggle switch TS20 on ground panel in the left direction and check voltage on wht red wire on turntable rotate left right and boom extend retract proportional valve coil 12V Continued on the next page buttons pulled out to the 0V Move the function enable switch to either side and hold the turntable rotate toggle switch TS20 on ground panel in the left direction and check voltage at TB6 oV With keyswitch in platform position and both Emergency Stop buttons pulled out to the on position activate footswitch and turntable rotate left right proportional controller 1 on platform control panel in
293. tform controls and both Emergency Stop buttons pulled out to the ON position activate the footswitch and the platform level toggle Switch TS7 in the down direction and check the voltage at TB15 Troubleshoot platform level toggle switch TS17 on ground control panel OR repair open in red power wire circuit to TS17 OR repair open in org blk wire circuit from TS17 to TB15 OR consult Genie Industries Service Department 12V or more Chart 24 Repair open in org blk wire from TB15 to platform level down directional valve coil item C OR repair open in brown ground wire circuit to valve coil Troubleshoot platform level toggle switches TS17 and TS7 on ground and platform control panels OR repair open in red power wire circuit to TS17 and TS7 OR repair open in org blk wire circuit from TS17 and TS7 to TB15 OR consult Genie Industries Service Department Part No 52856 Genie Z 60 34 Section 5 Troubleshooting Flow Charts Service Manual Second Edition S CHART 24 Disconnect the wires 0 or from the platform level infinite down directional valve ohms coil item C and test the resistance of the valve coil Continued from the previous page Replace the platform level down directional valve coil item 2 5 to 3 5 ohms Exchange platform level function up and down directional operates valve coils and activate the platform level down function Repla
294. that attach the lower cable track to the primary boom 20 Remove the cable track from the machine and place it on a structure capable of supporting it Crushing hazard The cable track AWARNING may become unbalanced and fall if itis not properly attached to the overhead crane Component damage hazard Cables and hoses can be damaged if they are kinked or pinched CAUTION Component damage hazard The primary boom cable track can be damaged if itis twisted CAUTION PRIMARY BOOM COMPONENTS How to Repair the Primary Boom Cable Track ACAUTION Component damage hazard The primary boom cable track can be damaged if itis twisted A 7 link repair section of cable track is available through the Genie Industries Service Parts Department Genie part no 58919 a link separation point b lower clip 1 Use a slotted screwdriver to pry down on the lower clip 2 To remove a single link open the lower clip and then use a screw driver to pry the link to the side Repeat steps 1 and 2 for each link 4 2 Primary Boom How to Shim the Primary Boom Measure each wear pad Replace the pad if itis less than 7 16 inch 11 mm thick If the pad is more than 7 16 inch 11 mm thick perform the following procedure 1 Extend the primary boom 10 inches 25 cm 2 Remove the wear pad mounting fasteners PartNo 52856 Genie Z 60 34 7 19 Section 7 Repair Procedures Service Manual Second Edition PRIMAR
295. the secondary boom toggle switch in the pown position hold fora moment and then release it Result The descent alarm should sound when the switch is held down 4 Turn the key switch to platform control Result The flashing beacon should be on and flashing B 24 Perform Hydraulic Oil Analysis See D 1 Test or Replace the Hydraulic Oil 4 28 Genie Z 60 34 Part No 52856 Service Manual Second Edition Section 4 Scheduled Maintenance Procedures B 25 Replace the Engine Oil and Filter Deutz Diesel Models Engine specifications require thatthis procedure be performed every 500 hours Perform this procedure more often if dusty conditions exist or if the machine is operated in hot climates Periodic replacement of the engine oil and filter is essential to good engine performance Operating the machine with an improper oil level or neglecting periodic oil and filter changes can damage engine components A frequent check of elapsed machine hours againstthe hours noted on the oil filter will allow the inspector to anticipate and perform oil and filter changes at the 500 hour interval Perform this procedure after warming the engine to normal operating temperature Bodily injury hazard Beware of ACAUTION hot engine parts and oil Contact with hot engine oil and or engine parts may cause severe bums 1 Remove the oil filler cap located above the dipstick 2 Remove the oil pan drain plug located o
296. the upper secondary boom 10 Remove the mounting fasteners from the secondary boom lift cylinder rod end pivot pin mounting bracket upper mid pivot to upper secondary boom pivot pins Use a soft metal drift to remove the pins AWARNING Crushing hazard The upper mid pivot may fall when the pins are removed if the upper mid pivot is not properly secured 12 Remove the pin retaining fasteners from the lower mid pivot to upper secondary boom pivot pin 13 Use a soft metal drift to remove the lower mid pivot to upper secondary boom pivot pin then remove the upper secondary boom from the machine AWARNING Crushing hazard The upper secondary boom may become unbalanced and fall when it is removed from the machine if itis not properly supported by the overhead crane 14 Remove both turntable covers See 6 1 How to Remove a Turntable Cover 15 Remove the 2 engine pivot plate retaining bolts Then swing the engine out away from the machine a engine pivot plate b pivot plate retaining bolts 26 Genie Z 60 34 Part No 52856 Service Manual Second Edition Section 7 Repair Procedures 16 Disconnectthe battery cables Electrocution hazard Contact with AWARNING hotor live circuits could result in death or serious injury Remove all rings watches and other jewelry 17 Remove the battery hold down fasteners then remove the battery Bodily injury hazard Batteries AWARNING contain acid
297. time That would indicate code 51 7 Refer to the Troubleshooting Section for definition of engine fault codes Once a fault code has been retrieved and the repair has been completed the ECM memory must be reset to clear the fault code from the ECM See 9 5 How to Clear Engine Fault Codes Service Manual Second Edition How to Clear Engine Fault Codes from the ECM Perform this procedure with the engine off and the keyswitch in the position 1 Openthe engine side turntable cover and locate the battery 2 Disconnectthe negative battery cable from the battery for a minimum of 5 minutes AWARNING Electrocution hazard Contact with electrically charged circuits could cause death or serious injury Remove all rings watches and other jewelry 3 Connectthe negative battery cable to the battery Genie Z 60 34 Part No 52856 Service Manual Second Edition Section 7 Repair Procedures 10 1 Lift Steer Pump How to Remove the Lift Steer Pump When removing a hose assembly or fitting the O ring on the fitting and or hose end must be replaced and then torqued to specification during installation Refer to Section Two Hydraulic Hose and Fitting Torque Specifications 1 Close the two hydraulic tank valves located at the hydraulic tank open closed Component damage hazard The engine must not be started with the hydraulic tank shutoff valves in the cLosep position or component
298. tion 5 Troubleshooting Flow Charts Service Manual Second Edition CHART 27 Activate footswitch and jib boom toggle switch TS6 in the up direction and check voltage on the red and black wires at the jib platform rotate select valves item AC Continued from the previous page Replace CR13 Install a 0 to 5000 psi 0 Exchange jib boom to 345 bar pressure platform rotate select gauge at the quick i valves item AC disconnect coupling on Activate footswitch and the function manifold jib boom up function and activate the jib boom up function function operate Replace defective valve function inoperative Check for mechanical restrictions keeping jib boom up function from Operating OR repair or replace jib boom cylinder OR replace counterbalance valve OR 0 030 orifice item AB may be plugged OR jib boom platform rotate select manifold has an internal defect OR consult Genie Industries Service Department less than 2400 psi function Exchange jib boom operate counterbalance valves and activate jib boom up function Replace defective counterbalance valve function inoperative Consult Genie Industries Service Department 5 64 Genie 2 60 34 Part No 52856 Service Manual Second Edition Section 5 Troubleshooting Flow Charts Jib Boom Down Function Inoperative Be sure all other functions operate normally With the keyswitch turn
299. to ground controls and both Emergency Stop buttons pulled out to the ON position check voltage at terminal 85 on CR3 Continued on the next page Check for poor terminal connections OR check for shorted or damaged wires that go from the ECM to the sensor that is causing the fault OR replace the sensor OR consult Genie Industries Service Department center terminal of the fuel select switch TS13 Replace fuel select switch TS13 Repair open in blu red wire circuit from fuel select switch to TB39 Repair open in red wire circuit from ECM to terminal 85 OR replace ECM Check the voltage at the ov Refer to the fault code chart in this section for a description of the fault and recommended repairs Repair open in power supply circuit to fuel select switch TS13 5 14 Genie Z 60 34 Part No 52856 Service Manual Second Edition Section 5 Troubleshooting Flow Charts S CHART 4 Crank engine for 15 Repair open in dk grn seconds and check for inuity wire from ECM to continuity to ground at terminal 86 on CR3 OR terminal 86 on CR3 replace ECM Continued from the previous page continuity Crank engine for 15 seconds and check for inui continuity to ground at Replace LPG relay CR3 terminal 30 on CR3 continuity oor infinite ohms Check resistance of LPG solenoid Replace LPG solenoid 910 10 ohms Reconnect LPG tan
300. to side and hold the TBI primary boom up toggle Continued from the previous page switch TS19 at the ground controls in the up direction and check voltage at TB1 Repair open in wht wire circuit from TB21 to TB43 OR replace the diode at TB43 Turn the keyswitch to ground controls and start the engine Check voltage at TB43 12V or more With the engine still Repair open in wht wire running check voltage circuit from TB43 to on wht wire at LS2 152 12V or more Check voltage on blk oV Be sure that LS2 is wire at LS2 being activated when the primary boom is in the stowed position OR 12V or replace LS2 contact more 12V Check voltage blk oV Repair open in blk wire wire at CR11 from LS2 to CR10 to CR11 12V or more Continued on page Continued on page Part No 52856 Genie Z 60 34 5 27 Section 5 Troubleshooting Flow Charts Service Manual Second Edition N CHART 14 Disconnect wires to 0 or primary boom up infinite directional valve coil ohms item G and test the resistance of the valve coil See Repair Section Continued from page 5 27 left column Replace primary boom up directional valve coil item G 5 to 7 ohms Install a 0 to 5000 PSI Check for mechanical 345 bar pressure restrictions keeping gauge at the quick primary boom from disconnect coupling on moving OR repair the function manifold cylinder or cylinder item V
301. to 345 bar pressure gauge to the test port item 22 on the function manifold 2 Startthe engine from the ground controls 3 Hold the function enable switch to the HIGH IDLE position and activate and hold the primary boom down switch with the primary boom fully lowered Observe the pressure reading on the pressure gauge Primary boom down relief valve specifications Pressure 1800 psi 124 bar 4 Turn the engine off Use a wrench to hold the relief valve and remove the cap item 12 function manifold 5 Adjustthe internal hex socket Turn it clockwise to increase the pressure or counterclockwise to decrease the pressure Then install the relief valve cap Tip over hazard Do notadjust AWARNING the relief valve higher than specified 6 Repeatsteps 2 through 5 and recheck relief valve pressure 7 46 Genie Z 60 34 Part No 52856 Service Manual Second Edition Section 7 Repair Procedures How to Adjust the Primary Boom Extend Relief Valve Perform this procedure with the boom in the stowed position 1 Connecta 0 to 5000 psi 0 to 345 bar pressure gauge to the test port item 22 on the function manifold 2 Startthe engine from the ground controls 3 Hold the function enable switch to the HIGH IDLE position and activate and hold the primary boom extend switch with the primary boom fully extended Observe the pressure reading on the pressure gauge Primary boom extend relief valve specif
302. turn the trimpot to obtain a 2 to 3 second ramp speed Turn the trimpot clockwise to increase the time or counterclockwise to decrease the time Boom up down specifications Threshold 4 4V DC 6 5V DC 35 to 45 seconds Primary boom up hi range Cycle time 6V DC 50 to 60 seconds Primary boom down lo range Cycle time Ramp rate 2 to 3 seconds Secondary Boom Up Down Controller Adjustments Do not adjust the joystick controllers unless the static battery voltage is above 12V DC and the alternator is operating properly with 13 6 to 14 5V DC output AWARNING Electrocution hazard Contact with electrically charged circuits could result in death or serious injury Remove all rings watches and other jewelry 1 Check the battery condition with a volt meter The reading should be 12V DC or more to accurately adjust the controller 2 Turn the key switch to platform control and pull out the Emergency Stop button to the on position at both the ground and platform controls Do not start the engine PartNo 52856 Genie Z 60 34 7 3 Section 7 Repair Procedures Service Manual Second Edition PLATFORM CONTROLS 3 Openthe platform control box lid and locate the secondary boom up down controller ramp rate adjustable trimpot lo range adjustable trimpot terminal R activates hi range not used terminal X not used terminal ground terminal positive terminal A proport
303. ulic loop with the master cylinder The slave cylinder is equipped with counterbalance valves to prevent movement in the event of a hydraulic line failure How to Remove the Slave Cylinder Before cylinder removal is considered to correcta malfunction bleed the slave cylinder to be sure there is no air in the closed loop hydraulic circuit When removing a hose assembly or fitting the O ring on the fitting and or hose end must be replaced and then torqued to specification during installation Refer to Section Two Hydraulic Hose and Fitting Torque Specifications 1 Adjust the platform to a level position 2 Raise the jib boom slightly and place blocks under the platform mounting weldment Then lower the jib boom until the platform is resting on the blocks just enough to supportthe platform E Genie Z 60 34 Part No 52856 Service Manual Second Edition Section 7 Repair Procedures 3 Supportthe slave cylinder with an appropriate lifting device P rotect the cylinder rod from damage 4 Remove the pin retaining fasteners from both the barrel end and rod end pivot pins Do not remove the pins 5 Use a soft metal drift to remove the barrel end pivot pin 6 Tag and disconnect the hydraulic hoses from the slave cylinder and connect them together with a connector Cap the fittings on the slave cylinder Bodily injury hazard Spraying AWARNING hydraulic oil can penetrate and burn skin Loos
304. upply and return fuel lines Cap the fuel return fitting on the fuel tank 4 Remove the retaining fasteners from the fuel tank hold down straps Remove the straps from the fuel tank 5 Supportthe fuel tank with 2 lifting straps Place one lifting strap at each end ofthe tank and attach the lifting straps to an overhead crane 6 Remove the fuel tank from the machine Crushing hazard The fuel tank AWARNING may become unbalanced and fall if itis not properly supported and secured to the overhead crane Clean the fuel tank and inspect for rust and corrosion before installing 12 2 Hydraulic Tank The primary functions of the hydraulic tank are to cool clean and deaerate the hydraulic fluid during operation The hydraulic tank has a 45 gallon 170 liters capacity and an oil level gauge with a temperature indicator It utilizes internal suction strainers forthe pump supply suction lines and has an external return line filter with condition indicator How to Remove the Hydraulic Tank 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 When removing a hose assembly or fitting the O ring on the fitting and or hose end must be replaced and then torqued to specification during installation Refer to Section Two Hyaraulic Hose and Fitting Torque Specifications 1 Remove the fuel tank See 12 1
305. ustment screw clockwise to increase the voltage or counterclockwise to decrease the voltage 9 Startthe engine and move the engine idle control switch to foot switch activated high idle rabbit and foot switch symbol Lower the primary boom to the stowed position Engine should be at normal operating temperature 10 Starta timer and record how long it takes for the primary boom to fully raise Adjust the hi range trimpot to achieve a 35 to 45 second cycle time Turn the hi range trimpot adjustment screw clockwise to increase the speed or counterclockwise to decrease the speed 11 Starta timer and record how long it takes for the boom to fully lower Adjust the lo range trimpot to achieve an 50 to 60 second cycle time Turn the lo range trimpot adjustment screw clockwise to increase the speed or counterclockwise to decrease the speed If the function cycle time is not achievable check the relief valve pressure See 11 2 Valve Adjustments Function Manifold 12 Turn the engine orr 13 Pull out the Emergency Stop button to the on position 14 Press down the foot switch and then move the control handle all the way to the up position Record the maximum voltage reading 15 Start the engine PLATFORM CONTROLS 16 Start a timer and simultaneously move the control handle all the way to the up position Note how long it takes to reach the maximum voltage recorded in step 14 This is the ramp rate 17 Set the ramp rate
306. ve is located on the side of the drive pump a drive pump b free wheel valve C screwdriver d liftpump The free wheel valve should always remain closed 4 20 Genie Z 60 34 Part No 52856 Service Manual Second Edition May 2007 Section 4 Scheduled Maintenance Procedures n REV B TABLE B PROCEDURES B 10 Turntable Rotate Torque Hub Check the Torq ue Hub Oil Level 1 Raisethe secondary boom until the platform end and Fastener Torque of the lower secondary boom arm is 8 feet 2 4 m off the ground Failure to maintain proper torque hub oil levels may cause the machine to perform poorly and continued use may cause component damage 2 Attach the lifting strap from an overhead crane to the platform end of the lower secondary boom arm for support Do not lift Drive Torque Hubs 1 Drive the machine to rotate the hub until the plugs are located one on top and the other at 90 degrees 3 Remove the plug located on the side of the hub and check the oil level N Remove the plug located at 90 degrees and Result The oil level should be even with the check the oil level bottom of the plug hole Result The oil level should be even with the bottom of the plug hole If necessary remove the top plug and add until the oil level is even with the bottom of the side plug hole
307. y boom Remove the side panel from the cable track to access the cable track mounting fasteners Place blocks between the lower cable track and the upper cable track tube and secure them together hi AWARNING Crushing hazard If the lower cable track and upper cable track tube are not properly secured together the cable track may become unbalanced and fall when itis removed from the machine 8 Attach a lifting strap from an overhead crane to the cabletrack 9 Remove the cable track guide fasteners from the platform end of the primary boom 10 Remove the cable track mounting fasteners that attach the lower cable track to the primary boom 11 Remove the cable track from the machine and place iton a structure capable of supporting it AWARNING Crushing hazard The cable track may become unbalanced and fall if itis not properly attached to the overhead crane Component damage hazard CAUTION Cables and hoses can be damaged if they are kinked or pinched Component damage hazard CAUTION The primary boom cable track can be damaged if it is twisted 12 Atthe engine side of the upper mid pivot remove the retaining fasteners from the master cylinder rod end pivot pin Use a slide hammer to remove the pin 13 Pull the master cylinder back and secure it from moving 7 20 Genie Z 60 34 Part No 52856 Service Manual Second Edition Section 7 Repair Procedures 14 Tag disconnect and plug
308. y boom drive limit switch is being activated by the cam on the primary boom when the primary boom is raised Be sure secondary boom drive limit switch is being activated by the cam on the compression link when the secondary boom is raised Be sure that the primary boom extend drive limit switch is not being held down or being activated when the primary boom is extended Be sure the wiring to limit switches is intact and show no sign of damage or corrosion Extend the boom approximately 3 feet 0 9 m turn the engine off then turn the keyswitch to the off position Disconnect the org wire from TB40 Check continuity from the org wire to terminal 6 on the horsepower limiter board With the org wire disconnected from 40 check continuity from TB40 to ground Fully retract the boom then raise the primary boom approximately 6 feet 1 8 m Check continuity from TB40 to ground Lower the primary boom to the stowed position n then raise the secondary boom approximately 6 feet 1 8 m Check continuity from TB40 to ground Re adjust the horsepower limiter board see Repair Section OR replace the horsepower limiter board OR consult Genie Industries Service Department Repair open in org wire circuit from TB40 to 40 to terminal 6 on horsepower limiter circuit board Repair open in wht wire from cable 7 from TB40 to primary boom extend drive limit switch LS3 OR repair open
309. y requirements below 60 F 15 5 5W 30 10 F to 90 F 23 C to 32 C 5W 30 above 10 F 23 C 5W 30 above 25 F 4 C 10W 30 Use oils meeting API classification SH or SG Units ship with 10 40 CC SG A 16 Replace the Engine Air Filter Engine specifications require that this procedure be performed every 100 hours 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 F ailure to perform this procedure can lead to poor engine performance and component damage Perform this procedure with the engine off 1 Raise the turntable cover Support and secure the open cover with an overhead crane or forklift Do not lift the cover Crushing hazard Due to its heavy ACAUTION weight do not attempt to support the cover by hand Component damage hazard CAUTION Protect the cover from damage by using carpet or padding on the crane or forklift forks PartNo 52856 Genie Z 60 34 4 13 Section 4 Scheduled Maintenance P rocedures Service Manual Second Edition n 2 9 3 TABLE A PROCEDURES 2 Remove the upper retaining clip from the gas strut atthe cover end 3 Gently pry the strut pivot socket off of the ball stud on the cover Protect the strut cylinder rod from damage 4 Remove the retaining ring from the end cap of the air filter canister 5 Remove the end cap
310. y to the left and then installing the platform mounting weldment all the way in the left 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 Two Hyaraulic Hose and Fitting Torque Specifications PartNo 52856 Genie Z 60 34 7 11 Section 7 Repair Procedures Service Manual Second Edition PLATFORM COMPONENTS 1 Remove the platform See 2 1 How to Remove the Platform 2 Tag disconnectand plug the hydraulic hoses from the V1 and V2 ports on the platform rotator counterbalance valve manifold Cap the fitting on the manifold Bodily injury hazard S praying AWARNING 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 Supportthe platform mounting weldment with an appropriate lifting device but do not apply any lifting pressure 4 Remove the six mounting bolts from the platform mounting weldment then remove the center bolt and slide the platform mounting weldment off of the platform rotator Crushing hazard The platform AWARNING mounting weldment may become unbalanced and fall if itis not properly supported 5 Supportthe platform rotator Do notapply any lifting pressure 6 Supportthe platform leveling slave cylinder Protectthe cylinder rod from damage
311. ydraulic Oil Analysis 4 28 B 25 Replace the Engine Oil and Filter Deutz Diesel Models 4 29 vi Genie Z 60 34 Part No 52856 Service Manual Second Edition EIC C c E EE 1 Section Four Section Five TABLE OF CONTENTS Scheduled Maintenance Procedures continued C 1 Check the Primary Boom WearPads sss eme 4 30 C 2 Check the Turntable Rotation Bearing Bolts 4 30 C 3 Check the Free wheel Configuration meme 4 31 C 4 Grease the Turntable Rotation Bearing and Rotate 4 32 C 5 Replace the Torque Hub Oil meme 4 32 C 6 Replace the Hydraulic Tank Return Filter 4 34 C 7 Replace the Drive Loop Hydraulic Filter s sse 4 34 C 8 Replace the Diesel Fuel Filter W ater Separator Deutz Diesel Models 4 35 C 9 Replace the Gasoline Fuel Filters Gasoline LP G Models 4 36 C 10 Replace the PCV Valve Gasoline LP G Models 4 37 C 11 Replace the Spark Plugs Gasoline LP G 4 37 C 12 Check and Adjust the Air LPG Mixture Gasoline LP G Models 4 38 C 13 Check the Engine Valve Clearances Deutz Diesel Models 4 38 D 1 Testor Replace the Hydraulic 1
312. ydraulic Specifications Hydraulic fluid Dexron equivalent Drive pump Type bi directional variable displacement piston pump Displacement 0 to 31 5 gallons per minute 0 to 119 liters per minute HYDRAULIC SPECIFICATIONS Function pump Type pressure balanced gear 0 98 cu in 16 cc Displacement static Displacement 2600 rpm 10 2 gallons per minute 0 to 38 6 liters per minute Hydraulic tank circuit 10 micron with 25 psi Maximum drive pressure 3500 psi return line filter 1 7 bar bypass 241 3 bar Function manifold Charge pressure 250 psi 17 Function relief 2400 psi valve pressure 165 5 bar Medium pressure filter 10 micron i _ Primary boom down 1800 psi Medium pressure filter 50 psi relief valve pressure 124 bar bypass pressure 3 4 bar f Primary boom extend 1200 psi Drive manifold 82 7 bar Brake relief pressure 290 psi Secondary boom down 1600 psi 20 bar relief valve pressure 110 bar Steer oscillate 3 gallons per minute flow regulator 11 4 liters per minute Steer end drive motors 4WD models Auxiliary pump Displacement per revolution 2 14 cu in 35 1cc Type fixed displacement gear pump Non steer end drive motors Displacement static 0 152 cu in 2 5 cc Displacement per revolution low range 2 8 cu in 45 9 cc Displacement 2600 rpm 1 4 gallons per minute high range 0 16 cu in 2 6 cc 5 3 liters per minute Auxiliary pu

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