Service Manual - Genie

1 ServiceManualTechnicalPublicationsFirst Edition (Rev A1)Part No. 30105 May 2007Z-60 34 (before serial number 1090) Genie Z-60/34 Part No. 30105 Service Manual - First EditioniiImportantRead, 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 electricalskills are 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 an authorized Genie dealerservice Industries has endeavored to deliver thehighest degree of accuracy possible.

2 However,continuous improvement of our products is aGenie policy. Therefore product specificationsare subject to 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 to the technical publications team in care ofGenie Industries, PO Box 69, Redmond WA98073-0069 you have any questions, call Genie North AmericaTelephone (206) 881-1800 Toll Free 800 536-1800 in Free 800 426-8089 in CanadaFax (206) 883-3475 Genie EuropeTelephone (44) 0636-813943 Fax (44) 0636-815270 IntroductionCopyright 1993 by Genie IndustriesFirst Edition April 1993 Genie is a registered trademarkof Genie IndustriesRegistered 2009987 Printed on recycled paperPrinted in Genie Z-60/34 Part No. 30105 Service Manual - First Edition (May 2007)TABLE OF CONTENTSviSection FourScheduled Maintenance Procedures, continuedA-10 Test the Platform and Ground Controls.

3 4 - 5A-11 Test the Auxiliary Power Operation .. 4 - 6A-12 Test the Tilt Sensor .. 4 - 7A-13 Test the Limit 4 - 7A-14 Check the Air Filter Condition Indicator - Deutz Diesel Models .. 4 - 10A-15 Replace the Engine Oil and Filter - Gasoline/LPG Models .. 4 - 10A-16 Replace the Engine Air 4 - 12B-1 Check the Engine Belt(s) ..4 - 13B-2 Check the Radiator - Gasoline/LPG 4 - 13B-3 Check the Oil Cooler and Cooling Fins - Deutz Diesel 4 - 13B-4 Check the Exhaust 4 - 14B-5 Check the Battery .. 4 - 15B-6 Check the Hydraulic Tank Filter Condition Indicator .. 4 - 15B-7 Inspect the Electrical 4 - 16B-8 Inspect the Tires and Wheels (including lug nut torque) .. 4 - 16B-9 Confirm the Proper Brake 4 - 17B-10 Check the Torque Hub Oil Level and Fastener Torque (REV B) .. 4 - 17B-11 Check and Adjust the Engine Idle Mixture - Gasoline/LPG Models .. 4 - 18B-12 Check and Adjust the Engine RPM.

4 4 - 18B-13 Test the Key Switch .. 4 - 20B-14 Test the Emergency Stop 4 - 21B-15 Test the Ground Control 4 - 21B-16 Test the Oscillate Lock-out (oscillating axle-equipped models) .. 4 - 22B-17 Test the Platform 4 - 22B-18 Test the Service Horn .. 4 - 22B-19 Test the Foot Switch .. 4 - 23B-20 Test the Engine Idle Select ..4 - 23B-21 Test the Fuel Select Operation - Gasoline/LPG 4 - 24 Part No. 30105 Genie Z-60/343 - 3 Section 3 - Scheduled Maintenance InspectionsService Manual - First Edition (May 2007)Tools arerequiredNew partsrequiredWarmenginerequiredColdengin erequiredDealerservicesuggestedTable BB-1 Check the Engine Belt(s)B-2 Check the Radiator -Gasoline/LPG ModelsB-3 Check the Oil Cooler and Cooling Fins -Deutz Diesel ModelsB-4 Check the Exhaust SystemB-5 Check the BatteryB-6 Check the Hydraulic TankFilter Condition IndicatorB-7 Inspect the Electrical WiringB-8 Inspect the Tires and Wheels(including lug nut torque)

5 B-9 Confirm the Proper Brake ConfigurationB-10 Check the Torque Hub Oil Level andFastener TorqueB-11 Check and Adjust the Engine Idle Mixture -Gasoline/LPG ModelsB-12 Check and Adjust the Engine RPMB-13 Test the Key SwitchB-14 Test the Emergency Stop ButtonsB-15 Test the Ground Control OverrideB-16 Test the Oscillate Lock-out(oscillating axle equipped models)B-17 Test the Platform Self-levelingMAINTENANCE TABLESREV BPart No. 30105 Genie Z-60/344 - 17 Service Manual - First Edition (May 2007)Section 4 - Scheduled Maintenance ProceduresTABLE B PROCEDURESB-9 Confirm the ProperBrake ConfigurationProper brake configuration is essential to safeoperation and good machine brakes and hydraulically-released,spring-applied individual wheel brakes can appearto operate normally when they are actually notfully Check each torque hub disconnect cap to besure it is in the engaged On 4WD models, be sure the free-wheel valveon the drive pump is closed (clockwise).

6 Adrive pumpbfree-wheel valvecscrewdriverdlift pumpOn 2WD models, the free-wheelvalve should always disengage positionbrake engage positionbadcB-10 Check the Torque Hub Oil Leveland Fastener TorqueFailure to maintain proper torque hub oil levels maycause the machine to perform poorly and continueduse may cause component Torque Hubs1 Drive the machine to rotate the hub until theplugs are located one on top and the other at Remove the plug located at 90 degrees andcheck the oil : The oil level should be even with thebottom of the plug If necessary, remove the top plug and add oiluntil the oil level is even with the bottom of theside plug hole, then re-install the plugs into Check the torque hub fasteners. Torque thefasteners to 160 ft-lbs / 217 Repeat this procedure for each torque Torque Hub OilCapacity40 fluid litersType: SAE 90 multipurpose hypoid gear oil - APIservice classification GL5 REV B4 - 18 Genie Z-60/34 Part No.

7 30105 Service Manual - First Edition (May 2007)Section 4 - Scheduled Maintenance ProceduresTurntable Rotate Torque Hub1 Raise the secondary boom until the platform endof the lower secondary boom arm is 8 feet( ) off the Attach the lifting strap from an overhead craneto the platform end of the lower secondary boomarm for support. Do not Remove the plug located on the side of the huband check the oil : The oil level should be even with thebottom of the plug rotary couplerbplugctorque hub4 If necessary, add oil until the oil level is evenwith the bottom of the side plug hole, thenre-install the plug into the B PROCEDURES5 Check the turntable rotate torque hub the fasteners to 160 ft-lbs / 217 Rotate Torque Hub OilCapacity8 fluid litersTypeSAE 90 multipurpose hypoid gear oil - API serviceclassification GL5B-11 Check and Adjust the Engine IdleMixture - Gasoline/LPG ModelsComplete information to perform this procedure isavailable in the Ford LSG-423 Liter IndustrialEngine Service Manual (Ford number: 194-216).

8 Genie part number and Adjust theEngine RPMM aintaining the engine rpm at the proper settingfor both low and high idle is essential to goodengine performance and Service life. The machinewill not operate properly if the rpm is incorrect andcontinued use may cause component ModelsPerform this procedure in gasolinemode with the engine at normaloperating Disconnect the blue/black wire from thegovernor NE 76th Box 69 Redmond, Washington98073-0069 EuropeMarket PlaceSouthwell,NottinghamshireNG25 OHE Box 86754 North Vancouver.