Revision Date Section Procedure / Schematic Page / Description

1 June 2015Z-60/34 Part No. 75861iiIntroductionSerial Number InformationGenie offers the following Service Manuals forthese models:TitlePart Service Manual(before serial number 1090) ..30105Z-60/34 Service Manual(from serial number 1090 to 4000) ..52856 IntroductionCopyright 2011 by Terex Corporation75861 Rev E September 2013 Third Edition, Fifth PrintingGenie and "Z" are registered trademarks ofTerex south dakota , Inc. in the USA and manyother countries. Printed on recycled paperPrinted in , understand and obey the safety rules andoperating instructions in the Genie Z-60/34 Operator's Manual before attempting anymaintenance or repair manual provides detailed scheduledmaintenance information for the machine owner anduser. It also provides troubleshooting fault codesand repair procedures for qualified mechanical, hydraulic and electrical skills arerequired to perform most procedures. However,several procedures require specialized skills, tools,lifting equipment and a suitable workshop.

2 In theseinstances, we strongly recommend thatmaintenance and repair be performed at anauthorized dealer service ClassificationGroup B/Type 3 as defined by ISO 16368 Machine Design LifeUnrestricted with proper operation, inspection andscheduled PublicationsGenie has endeavored to deliver the highest degreeof accuracy possible. However, continuousimprovement of our products is a Genie , product specifications are subject tochange without are encouraged to notify Genie of errorsand send in suggestions for improvement. Allcommunications will be carefully considered forfuture printings of this and all other Us: : 2015 Part No. 75861Z-60/34 RevisionDateSectionProcedure / Schematic Page / DescriptionE9/2013 New PrintingE16/2015 IntroductionTOC, Checklist B ProceduresMaintenanceInspection ReportE26/2015 MaintenanceInspection ReportC-6 and C-7 REFERENCE EXAMPLES:2-1_Section 2_Specifications Page #.3-3_Section 3_Maintenance Procedure Page #.4-48_Section 4_Repair Procedure Page #.

3 Section 5_Fault 6_Schematic Page #.Electronic VersionClick on any Procedure or page numberhighlighted in blue to view the HistoryiiiJune 2015Z-60/34 Part No. 75861 Revision HISTORY, CONTINUEDR evisionDateSectionProcedure / Schematic Page / DescriptionREFERENCE EXAMPLES:2-1_Section 2_Specifications Page #.3-3_Section 3_Maintenance Procedure Page #.4-48_Section 4_Repair Procedure Page #.Fault Codes_Section 6_Schematic Page #.Electronic VersionClick on any Procedure or page numberhighlighted in blue to view the 2015 Part No. 75861Z-60/34Z60 06 - 12345 ModelModel yearSequencenumberPN - 77055 Country of manufacture: USAThis machine complies with:Terex south dakota , NE 76th StreetRedmond, WA 98052 USAANSI :Z-60/34 Serial number:Z6006-12345 Electrical Schematic number:ES0423 Machine unladen weight:Rated work load (including occupants):500 lb / 227 kgMaximum allowable inclination of the chassis:0 degGradeability:N/AMaximum allowable side force :150 lb / 670 NMaximum number of platfrm occupants:2 Model year:Manufacture date:01/05/062006 Maximum wind speed :28 mph/ m/sMaximum platform height :60 ft 4 in/ mMaximum platform reach :34 ft / mSerial number(stamped on chassis)Serial label(located on backof tank sidebulkhead)(located on groundcontrol box)ORvSerial Number LegendINTRODUCTIONS ection 1 Serial Number LegendJune 2015Z-60/34 Part No.

4 75861 Section 1 Safety RulesSafety RulesDangerFailure to obey the instructions and safety rules inthis manual, and the Genie Z-60/34 Operator's Manual will result in death or of the hazards identified in the operator'smanual are also safety hazards when maintenanceand repair procedures are Not Perform MaintenanceUnless:You are trained and qualified to performmaintenance on this read, understand and obey:- manufacturer s instructions and safety rules- employer s safety rules and worksiteregulations- applicable governmental regulationsYou have the appropriate tools, liftingequipment and a suitable 2015 Part No. 75861Z-60/34viiSAFETY RULESP ersonal SafetyAny person working on or around a machine mustbe aware of all known safety hazards. Personalsafety and the continued safe operation of themachine should be your top each Procedure thoroughly. Thismanual and the decals on the machineuse signal words to identify the following:Safety alert symbol used to alertpersonnel to potential personalinjury hazards.

5 Obey all safetymessages that follow this symbolto avoid possible injury or to indicate the presence ofan imminently hazardous situationwhich, if not avoided, will result indeath or serious to indicate the presence of apotentially hazardous situationwhich, if not avoided, could resultin death or serious to indicate the presence of apotentially hazardous situationwhich, if not avoided, may result inminor or moderate to indicate the presence of apotentially hazardous situationwhich, if not avoided, may result inproperty sure to wear protective eye wear andother protective clothing if the situationwarrants aware of potential crushing hazardssuch as moving parts, free swinging orunsecured components when lifting orplacing loads. Always wear approved SafetyBe sure to keep sparks, flames andlighted tobacco away from flammable andcombustible materials like battery gasesand engine fuels. Always have an approved fireextinguisher within easy sure that all tools and working areasare properly maintained and ready foruse.

6 Keep work surfaces clean and free ofdebris that could get into machine components andcause sure any forklift, overhead crane orother lifting or supporting device is fullycapable of supporting and stabilizing theweight to be lifted. Use only chains or straps thatare in good condition and of ample sure that fasteners intended for onetime use ( , cotter pins and self-lockingnuts) are not reused. These componentsmay fail if they are used a second sure to properly dispose of old oil orother fluids. Use an approved be environmentally sure that your workshop or work areais properly ventilated and well 1 Safety RulesJune 2015Z-60/34 Part No. 75861 Table of ContentsIntroductionImportant Number 1 Safety RulesGeneral Safety Rules ..viSection 2 SpecificationsMachine 2 - 1 Performance 2 - 2 Hydraulic Oil 2 - 3 Hydraulic Component 2 - 4 Manifold Component 2 - 6 Ford LRG-425 EFI Engine 2 - 7 Ford DSG-423 EFI Engine 2 - 9 Ford MSG-425 EFI Engine Specifications.

7 2 - 10 Deutz F4L-1011F Engine 2 - 12 Deutz F3L-1011F Engine 2 - 13 Deutz F3L-2011/Deutz D2011L03i Engine 2 - 14 Perkins 404C-22 Engine 2 - 16 Machine Torque 2 - 17 Hydraulic Hose and Fitting Torque 2 - 18 SAE and Metric Fasteners Torque 2 - 10viiiJune 2015 Part No. 75861Z-60/34 TABLE OF CONTENTSixSection 3 Scheduled Maintenance 3 - 1 Pre-Delivery 3 - 3 Maintenance Inspection Report .. 3 - 5 Checklist A ProceduresA-1 Inspect the Manuals and 3 - 7A-2 Perform Pre-operation 3 - 8A-3 Perform Function 3 - 8A-4 Perform Engine Maintenance - All Models .. 3 - 9A-5 Perform 30 Day 3 - 10A-6 Check the High Pressure Hydraulic Filter Condition 3 - 10A-7 Perform Engine Maintenance - Deutz and Ford Models .. 3 - 11A-8 Perform Engine Maintenance - Perkins Models .. 3 - 12A-9 Inspect the Fuel Filter/Water Separator - Deutz Models ..3 - 12A-10 Perform Engine Maintenance - Ford Models .. 3 - 13A-11 Grease the Turntable Rotation Bearing and Rotate Gear .. 3 - 14A-12 Perform Engine Maintenance - Deutz 1011 F Models.

8 3 - 14A-13 Replace the Drive Hub 3 - 15A-14 Perform Engine Maintenance - Ford Models .. 3 - 16 Checklist B ProceduresB-1 Inspect the 3 - 17B-2 Inspect the Electrical 3 - 18B-3 Inspect the Air 3 - 19B-4 Test the Key 3 - 20B-5 Perform Engine Maintenance - Deutz and Perkins Models .. 3 - 20B-6 Check the Exhaust 3 - 21 June 2015Z-60/34 Part No. 75861 TABLE OF CONTENTSS ection 3 Scheduled Maintenance Procedures, continuedB-7 Check the Oil Cooler and Cooling Fins - Deutz 3 - 21B-8 Inspect the Tires, Wheels and Lug Nut Torque ..3 - 22B-9 Check the Drive Hub Oil Level and Fastener 3 - 23B-10 Confirm the Proper Brake 3 - 24B-11 Test the Engine Idle Select .. 3 - 25B-12 Test the Fuel Select Operation - Ford Models ..3 - 25B-13 Test the Ground Control 3 - 26B-14 Check the Directional Valve 3 - 27B-15 Test the Platform 3 - 27B-16 Test the Drive 3 - 28B-17 Test the Drive Speed - Stowed Position ..3 - 28B-18 Test the Drive Speed - Raised or Extended 3 - 29B-19 Perform Hydraulic Oil 3 - 30B-20 Test the Alarm Package (if equipped) and the Descent Alarm.

9 3 - 30B-21 Inspect the Fuel and Hydraulic Tank Cap Venting 3 - 31B-22 Perform Engine Maintenance - Ford Models .. 3 - 32 Checklist C ProceduresC-1 Perform Engine Maintenance - Deutz and Perkins Models .. 3 - 33C-2 Grease the Platform Overload Mechanism (if equipped) ..3 - 34C-3 Test the Platform Overload Mechanism (if equipped) ..3 - 34C-4 Replace the Air Filter Element - Deutz and Perkins 3 - 37C-5 Replace the Fuel Inline Strainer- Deutz 3 - 37C-6 Check and Adjust the Engine RPM .. 3 - 38C-7 Perform Engine Maintenance - Ford Models .. 3 - 39xJune 2015 Part No. 75861Z-60/34 Section 3 Scheduled Maintenance Procedures, continuedChecklist D ProceduresD-1 Check the Boom Wear Pads .. 3 - 41D-2 Check the Turntable Rotation Bearing Bolts .. 3 - 42D-3 Check the Free-wheel 3 - 43D-4 Replace the Drive Hub Oil .. 3 - 44D-5 Perform Engine Maintenance - Deutz and Perkins Models .. 3 - 46D-6 Replace the Hydraulic Filter Elements .. 3 - 47D-7 Inspect for Turntable Bearing 3 - 48 Checklist E ProceduresE-1 Test or Replace the Hydraulic Oil.

10 3 - 50E-2 Grease the Steer Axle Wheel Bearings, 2WD Models ..3 - 52E-3 Perform Engine Maintenance - Deutz 1011F and Perkins 3 - 53E-4 Perform Engine Maintenance - Deutz and Perkins Models .. 3 - 54E-5 Perform Engine Maintenance - Ford Models .. 3 - 55E-6 Perform Engine Maintenance - Deutz 2011 3 - 55E-7 Perform Engine Maintenance - Deutz 2011 3 - 56E-8 Perform Engine Maintenance - Deutz 2011 3 - 56 Section 4 Repair 4 - 1 Platform Controls1-1 ALC-500 Circuit 4 - 4 - 3 Platform Components2-1 How to Remove the Platform .. 4 - 72-2 Platform Leveling Slave Cylinder .. 4 - 82-3 Platform 4 - 92-4 Platform Overload 4 - 10xiTABLE OF CONTENTSJune 2015Z-60/34 Part No. 75861 TABLE OF CONTENTSxiiSection 4 Repair Procedures, continuedJib Boom Components3-1 Jib Boom .. 4 - 143-2 Jib Boom Lift 4 - 15 Primary Boom Components4-1 Cable 4 - 174-2 Primary Boom ..4 - 194-3 Primary Boom Lift 4 - 214-4 Primary Boom Extension 4 - 224-5 Platform Leveling Master 4 - 25 Secondary Boom Components5-1 Secondary 4 - 265-2 Secondary Boom Lift Cylinders.