Service Manual - Genie

1 ServiceManualTechnicalPublicationsSecond Edition, First Printing (Rev A1)Part No. 52856 May 2007Z-60 34 (from serial number 1090 to 4000) Genie Z-60/34 Part No. 52856 Service Manual - Second EditioniiIntroductionImportantRead, understand and obey the safety rules andoperating instructions in the Genie Z-60/34 Operator s Manual before attempting anymaintenance or repair Service Manual covers the Genie Z-60/342WD and 4WD models introduced in Manual provides detailed scheduledmaintenance information for the machine ownerand user. It also provides troubleshooting andrepair procedures for qualified mechanical, hydraulic and electrical skillsare required to perform most , several procedures require specializedskills, tools, lifting equipment and a suitableworkshop. In these instances, we stronglyrecommend that maintenance and repair beperformed at a Genie dealer Service Industries has endeavored to deliver thehighest degree of accuracy possible.

2 However,continuous improvement of our products is a Geniepolicy. Therefore product specifications are subjectto change without are encouraged to notify Genie of errorsand send in suggestions for improvement. Allcommunications will be carefully considered forfuture printings of this and other manuals. Pleasewrite or fax to the Technical Publications team: Genie IndustriesPO Box 97030 Redmond WA 98073-97030, USAFax Number: (425) 895-6333 Please visit the Genie Industries Web Site at: Publications Department you have any questions, please call GenieIndustries. Copyright 1999 by Genie IndustriesSecond Edition:First Printing March, 1999" Genie " and "Z" are Registered Trademarksof Genie Industries in the USA and many machines comply withANSI/SIA Printed on recycled paperPrinted in Genie North AmericaTelephone (425) 881-1800 Toll Free 800 536-1800 in Free 800 426-8089 in CanadaFax (425) 556-8649 Genie EuropeOffice Telephone (44) 01636-605030 Office FaxFax (44) 01636-611090 Parts Telephone (44) 01636-605002 Parts Fax (44) 01636-611091 Part No.

3 52856 Genie Z-60/34 Service Manual - Second Edition iiiSafety RulesSection 1 - Safety RulesDangerFailure to obey the instructions and safety rulesin this Manual and the Genie Z-60/34 Operator sManual will cause death or serious of the hazards identified in theoperator s Manual are also safety hazardswhen maintenance and repair proceduresare 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- applicable governmental regulationsYou have the appropriate tools, liftingequipment and a suitable Z-60/34 Part No. 52856 Service Manual - Second EditionSAFETY RULESivSection 1 - Safety RulesPersonal 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.

4 Thismanual and the decals on the machineuse signal words to identify the following:Safety alert symbol used to alertpersonnel to potential personalinjury hazards. Obey all safetymessages that follow this symbolto avoid possible injury or used to indicate thepresence of an imminentlyhazardous situation which, if notavoided, will result in death orserious used to indicate thepresence of a potentiallyhazardous situation which, if notavoided, could result in death orserious with safety alert symbol used to indicate the presence of apotentially hazardous situationwhich, if not avoided, may causeminor or moderate without safety alertsymbol used to indicate thepresense of a potentiallyhazardous situation which, if notavoided, may result in used to indicate operationor maintenance 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.

5 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. Keep work surfaces clean and free ofdebris that could get into machine components andcause sure that your workshop or work areais properly ventilated and well 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.

6 Use an approved be environmentally No. 52856 Genie Z-60/34 Service Manual - Second EditionTable of ContentsvIntroductionImportant Information ..iiSection OneSafety RulesGeneral Safety Rules ..iiiSection TwoSpecificationsMachine Specifications .. 2 - 1 Performance Specifications .. 2 - 2 Hydraulic Specifications .. 2 - 3 Ford Engine LRG-425 EFI Specifications .. 2 - 4 Deutz Engine F4L 1011F Specifications .. 2 - 5 Hydraulic Hose and Fitting Torque Specifications .. 2 - 6 Section ThreeScheduled Maintenance InspectionsIntroduction .. 3 - 1 Table A .. 3 - 2 Table B .. 3 - 3 Table C .. 3 - 5 Table D .. 3 - 6 Maintenance Inspection Report .. 3 - 7 Section FourScheduled Maintenance ProceduresIntroduction .. 4 - 1A-1 Inspect the Operator s and Safety Manuals .. 4 - 2A-2 Inspect the Decals and Placards .. 4 - 2A-3 Inspect for Damage, Loose or Missing Parts.

7 4 - 2A-4 Check the Engine Oil Level .. 4 - 3A-5 Check the Engine Coolant Level - Gasoline/LPG Models .. 4 - 3A-6 Check for Fuel Leaks .. 4 - 3A-7 Check the Hydraulic Oil Level .. 4 - 4A-8 Check for Hydraulic Leaks .. 4 - 5A-9 Check the Tire Pressure .. 4 - 5A-10 Test the Oscillate Axle Lockout (oscillating axle equipped models) .. 4 - 6 Genie Z-60/34 Part No. 52856 Service Manual - Second Edition (May 2007)TABLE OF CONTENTSviSection FourScheduled Maintenance Procedures, continuedA-11 Test the Platform and Ground Controls .. 4 - 6A-12 Test the Auxiliary Power Operation .. 4 - 7A-13 Test the Tilt Sensor .. 4 - 8A-14 Test the Limit 4 - 9A-15 Replace the Engine Oil and Filter - Gasoline/LPG Models .. 4 - 12A-16 Replace the Engine Air 4 - 13B-1 Check the Engine Belt .. 4 - 15B-2 Check the Radiator - Gasoline/LPG 4 - 16B-3 Check the Oil Cooler and Cooling Fins - Deutz Diesel 4 - 16B-4 Check the Exhaust 4 - 17B-5 Check the Battery.

8 4 - 18B-6 Chech the Hydraulic Return Filter Condition 4 - 18B-7 Inspect the Electrical 4 - 19B-8 Inspect the Tires and Wheels (including lug nut torque) .. 4 - 19B-9 Confirm the Proper Brake 4 - 20B-10 Check the Torque Hub Oil Level and Fastener Torque (REV B) .. 4 - 21B-11 Check and Adjust the Engine RPM ..4 - 22B-12 Test the Key Switch .. 4 - 23B-13 Test the Emergency Stop 4 - 23B-14 Test the Ground Control 4 - 24B-15 Test the Platform 4 - 24B-16 Test the Horn ..4 - 24B-17 Test the Foot Switch .. 4 - 24B-18 Test the Engine Idle Select ..4 - 25B-19 Test the Fuel Select Operation - Gasoline/LPG 4 - 26B-20 Test the Drive Enable System ..4 - 26B-21 Test the Drive 4 - 27B-22 Test the Drive Speed - Stowed Position ..4 - 27B-23 Test the Alarm Package - Optional Equipment .. 4 - 28B-24 Perform Hydraulic Oil Analysis .. 4 - 28B-25 Replace the Engine Oil and Filter - Deutz Diesel 4 - 29 Part No.

9 52856 Genie Z-60/34 Service Manual - Second EditionTABLE OF CONTENTSviiSection FourScheduled Maintenance Procedures, continuedC-1 Check the Primary Boom Wear Pads .. 4 - 30C-2 Check the Turntable Rotation Bearing Bolts .. 4 - 30C-3 Check the Free-wheel Configuration .. 4 - 31C-4 Grease the Turntable Rotation Bearing and Rotate Gear .. 4 - 32C-5 Replace the Torque Hub Oil .. 4 - 32C-6 Replace the Hydraulic Tank Return Filter .. 4 - 34C-7 Replace the Drive Loop Hydraulic Filter .. 4 - 34C-8 Replace the Diesel Fuel Filter/Water Separator - Deutz Diesel Models .. 4 - 35C-9 Replace the Gasoline Fuel Filters - Gasoline/LPG Models .. 4 - 36C-10 Replace the PCV Valve - Gasoline/LPG Models .. 4 - 37C-11 Replace the Spark Plugs - Gasoline/LPG Models .. 4 - 37C-12 Check and Adjust the Air/LPG Mixture - Gasoline/LPG Models.

10 4 - 38C-13 Check the Engine Valve Clearances - Deutz Diesel Models .. 4 - 38D-1 Test or Replace the Hydraulic Oil .. 4 - 39D-2 Change or Recondition the Engine Coolant - Gasoline/LPG Models .. 4 - 41D-3 Change the Fuel Hoses .. 4 - 42D-4 Check the Engine Valve Clearance - Gasoline/LPG Models .. 4 - 43D-5 Check the Engine Cylinder Compression - Gasoline/LPG Models .. 4 - 43D-6 Clean the PCV Hoses and Fittings - Gasoline/LPG Models .. 4 - 44D-7 Check the Fuel Injection Pumps and Injectors - Deutz Diesel Models .. 4 - 44D-8 Check the Toothed Belt - Deutz Diesel Models .. 4 - 44D-9 Replace the Timing Belt - Gasoline/LPG Models .. 4 - 44D-10 Grease the Steer Axle Wheel Bearings, 2WD Models .. 4 - 45 Section FiveTroubleshooting Flow ChartsIntroduction .. 5 - 1 Fault Codes .. 5 - 31 Engine Will Not Crank Over .. 5 - 62 Engine Cranks Over But Will Not Start - Gasoline/LPG Models.