Genie Z-80/60 Installations- und Betriebsanleitung

Service and Repair Manual

Serial Number Range

Z-80/60

from Z80134592 to

Z8016H-

6399

from Z80H-

6400

This manual includes:

Repair

procedures

Fault Codes

Electrical and

Hydraulic Schematics

For detailed maintenance

procedures, refer to the

appropriate Maintenance

Manual for your machine.

Part No. 1268556

Rev A3

January 2017

Service and Repair Manual January 2017

Introduction

ii Part No. 1268556

Intr oduct io n Intr oduct io n

Important

Read, understand and obey the safety rules and

operating instructions in the appropriate Operator's

Manual on your machine before attempting any

procedure.

This manual 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 at an

authorized Genie dealer service center.

Compliance

Machine Classification

Group B/Type 3 as defined by ISO 16368

Machine Design Life

Unrestricted with proper operation, inspection and

scheduled maintenance.

Technical Publications

Genie has endeavored to deliver the highest

degree of accuracy possible. However, continuous

improvement of our products is a Genie policy.

Therefore, product specifications are subject to

change without notice.

Readers are encouraged to notify Genie of errors

and send in suggestions for improvement. All

communications will be carefully considered for

future printings of this and all other manuals.

Internet: www.genielift.com

E-mail: awp.techpub@terex.com

Find a Manual for this Model

Go to http://www.genielift.com

Use the links to locate Service Manuals,

Maintenance Manuals, Service and Repair

Manuals, Parts Manuals and Operator's Manuals.

1268556 Rev A, September 2015

First Edition, First Printing

Genie is a registered trademark of Terex South Dakota, Inc. in

the U.S.A. and many other countries.

“Z” is a trademark of Terex South Dakota, Inc..

January 2017 Service and Repair Manual

Introduction

Part No. 1268556 iii

Revision History

Revision

Date

Section

Procedure / Page / Description

A 9/2015

Initial Release

A1 11/2015 Schematics Added new serial number (from Z8013-4592)

Added Electrical Schematic

(from Z8013-4592 to Z8015-5653)

A2 9/2016 Introduction Serial Number Legend

Specifications GM 3.0L engine

Fault Codes GM 3.0L engine

Schematics GM 3.0L engine; Hydraulic Schematics

1/2017

Repair

Calibrate Steer Sensors

Reference Examples:

Electronic Version

Click on any content or procedure in the Table of Contents to view

the update.

Section – Repair Procedure, 4-2

Section – Fault Codes, All charts

Section – Schematics, Legends and schematics

Service and Repair Manual September 2016

Introduction

iv Part No. 1268556

Serial Number Legend

To August 31, 2016

1 Model

2 Model year

3 Facility code

4 Sequence number

5 Serial number (stamped on chassis)

6 Serial label (located under cover)

From September 1, 2016

1 Model

2 Facility code

3 Sequence number

4 Serial number (stamped on chassis)

5 Serial label (located under cover)

September 2016 Service and Repair Manual

Safety Rules

Part No. 1268556 v

Section 1 Safet y Rul es

Danger

Failure to obey the instructions and safety rules in

this manual and the appropriate Operator's Manual

on your machine will result in death or serious

injury.

Many of the hazards identified in the operator's

manual are also safety hazards when maintenance

and repair procedures are performed.

Do Not Perform Maintenance

Unless:

You are trained and qualified to perform

maintenance on this machine.

You read, understand and obey:

•manufacturer's instructions and safety rules

•employer's safety rules and worksite

regulations

•applicable governmental regulations

You have the appropriate tools, lifting

equipment and a suitable workshop.

Service and Repair Manual September 2016

Safety Rules

vi Part No. 1268556

Personal Safety

Any person working on or around a machine must

be aware of all known safety hazards. Personal

safety and the continued safe operation of the

machine should be your top priority.

Read each procedure

thoroughly. This

manual and the decals on the machine,

use signal words to identify the following:

Safety alert symbol

—

used to alert

personnel to potential personal

injury hazards. Obey all safety

messages that follow this symbol

to avoid possible injur

y or death.

Indicates a imminently hazardous

situation which, if not avoided, will

result in death or serious injury.

Indicates a potentially hazardous

situation which, if not avoided,

could result in death or serious

injury.

Indicates a

potentially hazardous

situation which, if not avoided,

may cause minor or moderate

injury.

Indicates a potentially hazardous

situation which, if not avoided,

may result in property damage.

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

Any person working on or around a machine must

be aware of all known safety hazards. Personal

safety and the continued safe operation of the

machine should be your top priority.

Be sure to keep sparks, flames and

lighted tobacco away from flammable and

combustible materials like

battery gases

and engine fuels. Always have an

approved fire extinguisher within easy

reach.

Be sure that all tools and working areas

are properly maintained and ready for

use. Keep work surfaces clean and free of

debris that could get into machine

com

ponents and cause damage.

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.

e sure that fasteners intended for one

time use (i.e., cotter pins and self

-locking

nuts) are not reused. These components

may fail if they are used a second time.

Be sure to properly dispose of old oil or

other fluids. Use an approved container.

Please

be environmentally safe.

Be sure that your workshop or work area

is properly ventilated and well lit.

September 2016

Table of Contents

Part No. 1268556 vii

Introduction Introduction ..........................................................................................................ii

Important Information............................................................................................. ii

Find a Manual for this Model.................................................................................. ii

Serial Number Legend .......................................................................................... iv

Section 1 Safety Rules..........................................................................................................v

General Safety Rules.............................................................................................v

Section 2Specifications.......................................................................................................1

Machine Specifications...........................................................................................1

Performance Specifications ...................................................................................1

Hydraulic Specification...........................................................................................2

Hydraulic Component Specifications .....................................................................4

Continental TME27 Engine Specifications.............................................................6

GM 3.0L Engine Specifications..............................................................................7

Deutz TD2011L04i Engine Specifications..............................................................8

Deutz TD 2.9 Engine Specifications.......................................................................9

Perkins 404F-22T Engine Specifications.............................................................10

Perkins 804D-33 Engine Specifications...............................................................11

Machine Torque Specifications............................................................................12

Hydraulic Hose and Fitting Torque Specifications ...............................................13

Torque Procedure ................................................................................................14

SAE and Metric Fasteners Torque Charts...........................................................16

September 2016

Table of Contents

viii Part No. 1268556

Section 3 Repair Procedures.............................................................................................17

Introduction ..........................................................................................................17

Platform Controls...............................................................................................19

Platform Controls .................................................................................................19

1-1 Platform Circuit Board....................................................................................20

How to Remove the LED Circuit Board ..........................................................21

1-2 Joysticks - How to Calibrate a Joystick .........................................................21

How to Reset a Proportional Valve Coil Default.............................................25

How to Set the Function Thresholds and Default Functions Speeds.............25

How to Adjust the Function Speeds ...............................................................27

How to Adjust the Function Ramp Rate Setting .............................................28

Platform Components .......................................................................................28

2-1 Platform..........................................................................................................28

2-2 Platform Leveling Cylinder.............................................................................29

How to Remove the Platform Leveling Cylinder.............................................29

How to Bleed the Platform Leveling Cylinder .................................................30

2-3 Platform Rotator.............................................................................................31

How to Bleed the Platform Rotator.................................................................32

2-4 Platform Overload System (if equipped)........................................................33

2-5 Platform Overload Recovery Message..........................................................36

Jib Boom Components......................................................................................37

3-1 Jib Boom........................................................................................................37

3-2 Jib Boom Lift Cylinder....................................................................................39

September 2016

Table of Contents

Part No. 1268556 ix

Boom Components............................................................................................40

4-1 Primary Boom Cable Track............................................................................41

How to Repair the Primary Boom Cable Track...............................................43

4-2 Primary Boom ................................................................................................44

How to Shim the Primary Boom......................................................................44

How to Disassemble the Primary Boom .........................................................46

4-3 Primary Boom Lift Cylinder ............................................................................47

4-4 Primary Boom Extension Cylinder.................................................................48

4-5 Primary Boom Angle Sensor..........................................................................50

How to Replace the Primary Boom Angle Sensor..........................................50

How to Calibrate the Primary Boom Angle Sensor.........................................51

4-6 Secondary Boom Cable Track.......................................................................53

How to Remove the Secondary Boom Cable Track.......................................53

How to Repair the Secondary Boom Cable Track..........................................53

4-7 Secondary Boom............................................................................................54

4-8 Secondary Boom Lift Cylinder .......................................................................55

4-9 Secondary Boom Extension Cylinder ............................................................57

Engines ...............................................................................................................59

5-1 RPM Adjustment............................................................................................59

5-2 Flex Plate .......................................................................................................59

How to Remove the Flex Plate .......................................................................59

How to Install the Flex Plate ...........................................................................62

How to install the Pump and Bell Housing Assembly.....................................63

5-3 How to Access Perkins 404F Engine Regeneration Service.........................64

Ground Controls.................................................................................................66

6-1 Bypass/Recovery Key Switch ........................................................................66

How to Use the Recovery Mode .....................................................................68

6-2 Circuit Boards.................................................................................................69

6-3 Membrane Decal............................................................................................70

Display Module...................................................................................................71

September 2016

Table of Contents

x Part No. 1268556

Hydraulic Pumps................................................................................................79

7-1 Function Pump...............................................................................................79

7-2 Drive Pump....................................................................................................80

How to Prime the Pump..................................................................................81

Manifolds ............................................................................................................82

8-1 Function Manifold Components - View 1.......................................................82

8-2 Function Manifold Components - View 2.......................................................84

8-3 Valve Adjustments - Function Manifold .........................................................86

How to Adjust the System Relief Valve ..........................................................86

How to Adjust the Primary Boom Down Relief Valve.....................................87

How to Adjust the Primary Boom Extend Relief Valve...................................88

How to Adjust the Secondary Boom Up Relief Valve.....................................89

How to Adjust the Secondary Boom Down Relief Valve ................................90

How to Adjust the Secondary Boom Extend Relief Valve ..............................91

How to Adjust the Platform Manifold Relief Valve..........................................91

8-4 Platform Manifold...........................................................................................92

8-5 Turntable Rotation Manifold...........................................................................94

8-6 Platform Rotate Manifold...............................................................................95

8-7 Two Wheel Steer and Oscillate Manifold.......................................................96

How to Adjust the Oscillate Relief Valve ........................................................98

8-8 Four Wheel Steer and Oscillate Manifold....................................................100

How to Adjust the Oscillate Relief Valve ......................................................104

8-9 Oil Diverter Manifold Components (welder option)......................................105

8-10 Traction Manifold Components, 2WD........................................................106

8-11 Valve Adjustments, 2WD Traction Manifold ..............................................108

8-12 Traction Manifold Components, 4WD........................................................110

8-13 Valve Adjustments, 4WD Traction Manifold ..............................................112

8-14 Valve Coils.................................................................................................113

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