Genie Z-80/60 Bedienungsanleitung

Service Manual

Part No. 88619

Rev F3

February 2015

Z-80/60

Serial Number Range

from Z80-101 to Z8013-4591

Z-80/60 Part No. 88619

February 2015

Important

Read, understand and obey the safety rules and

operating instructions in the

Genie Z-80/60

Operator's Manual

before attempting any

maintenance or repair procedure.

This manual provides detailed scheduled

maintenance information for the machine owner

and user. It also provides troubleshooting fault

codes 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 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 all other manuals.

http://www.genieindustries.com

e-mail: [email protected]

88619 Rev F June 2011

First Edition, Seventh Printing

"Genie" and "Z" are registered trademarks of

Genie Industries in the USA and many other

countries.

Printed on recycled paper

Printed in U.S.A.

Introduction

Part No. 88619 Z-80/60

February 2015

iii

Serial Number Legend

Z80 06 - 12345

Model

Model year

Sequence

number

PN - 77055

Country of manufacture: USA

This machine complies with:

Genie Industries

18340 NE 76th Street

Redmond, WA 98052

USA

ANSI A92.5-

CAN B.354.4-

Model: Z-80/60

Serial number: Z8006-12345

Electrical schematic number: ES0188

Machine unladen weight:

Rated work load (including occupants): 500 lb / 227 kg

Maximum allowable inclination of the chassis:

0 deg

Gradeability: N/A

Maximum allowable side force : 150 lb / 670 N

Maximum number of platfrm occupants: 2

Model year: Manufacture date: 01/05/06

2006

Maximum wind speed : 28 mph/ 12.5 m/s

Maximum platform height : 86 ft/ 26.38 m

Maximum platform reach : 60 ft/ 18.28 m

Serial number

(stamped on chassis)

Serial label

(located under cover)

INTRODUCTION

Z-80/60 Part No. 88619

February 2015

This page intentionally left blank.

Part No. 88619 Z-80/60

February 2015

Safety Rules

Danger

Failure to obey the instructions and safety rules in

this manual, and the Operator's Manual 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.

Section 1 • Safety Rules

Z-80/60 Part No. 88619

July 2013

SAFETY RULES

Section 1 • Safety Rules

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 injury or death.

Used to indicate the presence of

an imminently hazardous situation

which, if not avoided, will result in

death or serious injury.

Used to indicate the presence of a

potentially hazardous situation

which, if not avoided, could result

in death or serious injury.

With safety alert symbol—used to

indicate the presence of a

potentially hazardous situation

which, if not avoided, may result in

minor or moderate injury.

Used to indicate the presence of 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

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 components 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.

Be 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.

Part No. 88619 Z-80/60

July 2013

Table of Contents

vii

Introduction

Important Information ...................................................................................................

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

iii

Section 1 Safety Rules

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

Section 2 Rev Specifications

G Machine Specifications .......................................................................................... 2 - 1

Performance Specifications ................................................................................... 2 - 2

Function Speeds Specifications ............................................................................. 2 - 2

Hydraulic Oil Specifications ................................................................................... 2 - 3

Hydraulic Component Specifications ...................................................................... 2 - 4

Manifold Component Specifications ....................................................................... 2 - 5

Valve Coil Resistance Specifications ..................................................................... 2 - 5

GM 3.0L EFI Engine .............................................................................................. 2 - 6

Ford LRG-425 Engine ............................................................................................. 2 - 7

Continental TME27 Engine .................................................................................... 2 - 9

Deutz F4L-913 Engine (before serial number 339) ................................................ 2 - 10

Deutz BF4L-2011 (from serial number 339 to 2177).............................................. 2 - 11

Deutz TD2011L04i Engine (from serial number 2178) ........................................... 2 - 13

Perkins 704-30 Engine ......................................................................................... 2 - 15

Perkins 804C-33 / 804D-33 Engine ...................................................................... 2 - 16

Machine Torque Specifications ............................................................................ 2 - 17

Hydraulic Hose and Fitting Torque Specifications ................................................ 2 - 18

SAE and Metric Fasteners Torque Charts ............................................................ 2 - 19

Section 3 Rev Scheduled Maintenance Procedures

Introduction ............................................................................................................ 3 - 1

Pre-Delivery Preparation ........................................................................................ 3 - 3

Maintenance Inspection Report .............................................................................. 3 - 5

Z-80/60 Part No. 88619

July 2013

TABLE OF CONTENTS

viii

Section 3 Rev Scheduled Maintenance Procedures, continued

EChecklist A Procedures

A-1 Inspect the Manuals and Decals .................................................................. 3 - 7

A-2 Perform Pre-operation Inspection ................................................................ 3 - 8

A-3 Perform Function Tests ............................................................................... 3 - 8

A-4 Perform Engine Maintenance ....................................................................... 3 - 8

A-5 Check the Hydraulic Filter Condition Indicators .......................................... 3 - 10

A-6 Perform 30 Day Service ............................................................................. 3 - 11

A-7 Perform Engine Maintenance - Continental Models .................................... 3 - 11

A-8 Perform Engine Maintenance - Perkins and Continental Models ................. 3 - 12

A-9 Perform Engine Maintenance ..................................................................... 3 - 13

A-10 Grease the Turntable Rotation Bearing and Rotate Gear ............................ 3 - 14

A-11 Inspect the Fuel Filter/Water Separator - Diesel Models ............................. 3 - 14

A-12 Replace the Drive Hub Oil .......................................................................... 3 - 16

A-13 Perform Engine Maintenance - GM and Ford Models ................................. 3 - 18

GChecklist B Procedures

B-1 Inspect the Batteries .................................................................................. 3 - 19

B-2 Inspect the Electrical Wiring ....................................................................... 3 - 20

B-3 Test the Key Switch ................................................................................... 3 - 22

B-4 Check the Exhaust System ....................................................................... 3 - 22

B-5 Inspect the Engine Air Filter ....................................................................... 3 - 23

B-6 Engine Maintenance - Deutz F4L913 and Continental Models .................... 3 - 24

B-7 Check the Tires, Wheels and Lug Nut Torque ............................................ 3 - 25

B-8 Confirm the Proper Brake Configuration...................................................... 3 - 25

B-9 Check the Drive Hub Oil Level and Fastener Torque .................................. 3 - 26

B-10 Test the Ground Control Override ............................................................... 3 - 27

B-11 Test the Platform Self-leveling ................................................................... 3 - 28

B-12 Test the Engine Idle Select Operation ........................................................ 3 - 29

B-13 Test the Fuel Select Operation - Gasoline/LPG Models ............................. 3 - 30

Part No. 88619 Z-80/60

July 2013

TABLE OF CONTENTS

Section 3 Rev Scheduled Maintenance Procedures, continued

B-14 Test the Drive Brakes ................................................................................ 3 - 31

B-15 Test the Drive Speed - Stowed Position ..................................................... 3 - 31

B-16 Test the Drive Speed - Raised or Extended Position ................................. 3 - 32

B-17 Test the Alarm and Optional Flashing Beacon ........................................... 3 - 33

B-18 Perform Hydraulic Oil Analysis .................................................................. 3 - 33

B-19 Check and Adjust the Engine RPM ............................................................ 3 - 34

B-20 Test the Safety Envelope and Safety Circuits ............................................ 3 - 37

B-21 Test the Primary Boom Self-leveling .......................................................... 3 - 40

B-22 Test the Primary Boom Angle Sensor ........................................................ 3 - 41

B-23 Inspect the Fuel Tank Cap Venting Systems ............................................. 3 - 42

B-24 Perform Engine Maintenance - GM and Ford Models ................................. 3 - 43

DChecklist C Procedures

C-1 Perform Engine Maintenance - Diesel Models ............................................ 3 - 44

C-2 Grease the Platform Overload Mechanism (if equipped) ............................. 3 - 45

C-3 Test the Platform Overload System (if equipped) ....................................... 3 - 45

C-4 Replace the Engine Air Filter ...................................................................... 3 - 47

C-5 Replace the Fuel Filter/Water Separator - Diesel Models ............................ 3 - 48

C-6 Perform Engine Maintenance - GM and Ford Models ................................. 3 - 50

EChecklist D Procedures

D-1 Check the Boom Wear Pads ...................................................................... 3 - 51

D-2 Check the Free-wheel Configuration ........................................................... 3 - 52

D-3 Check the Turntable Rotation Bearing Bolts ............................................... 3 - 53

D-4 Inspect for Turntable Bearing Wear ............................................................ 3 - 54

D-5 Replace the Drive Hub Oil .......................................................................... 3 - 55

D-6 Perform Engine Maintenance ..................................................................... 3 - 56

D-7 Replace the Hydraulic Filter Elements ........................................................ 3 - 57

Z-80/60 Part No. 88619

July 2013

Section 3 Rev Scheduled Maintenance Procedures, continued

DChecklist E Procedures

E-1 Test or Replace the Hydraulic Oil ............................................................... 3 - 61

E-2 Grease the Steer Axle Wheel Bearings, 2WD Models ................................ 3 - 63

E-3 Perform Engine Maintenance ..................................................................... 3 - 64

E-4 Perform Engine Maintenance - Ford Models ............................................... 3 - 65

E-5 Perform Engine Maintenance - Deutz and Perkins Models ......................... 3 - 66

E-6 Perform Engine Maintenance - Deutz BF4L2011 / TD2011L04i Models ...... 3 - 67

E-7 Perform Engine Maintenance - Deutz BF4L2011 / TD2011L04i Models ...... 3 - 68

E-8 Perform Engine Maintenance - Deutz BF4L2011 Models ............................ 3 - 68

Section 4 Rev Repair Procedures

Introduction ............................................................................................................ 4 - 1

E Display Module ...................................................................................................... 4 - 2

FPlatform Controls

1-1 ALC-1000 Circuit Board .............................................................................. 4 - 10

1-2 Membrane Decal ........................................................................................ 4 - 11

1-3 Joysticks ................................................................................................... 4 - 13

CPlatform Components

2-1 Platform ..................................................................................................... 4 - 19

2-2 Platform Leveling Cylinder .......................................................................... 4 - 19

2-3 Platform Rotator ......................................................................................... 4 - 21

2-4 Calibrate the Platform Overload System (if equipped) ................................ 4 - 23

BJib Boom Components

3-1 Jib Boom .................................................................................................... 4 - 26

3-2 Jib Boom Lift Cylinder ................................................................................ 4 - 28

DBoom Components

4-1 Primary Boom Cable Track ........................................................................ 4 - 30

4-2 Primary Boom ............................................................................................ 4 - 33

4-3 Primary Boom Lift Cylinder ......................................................................... 4 - 36

4-4 Primary Boom Extension Cylinder .............................................................. 4 - 38

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