Terex Genie Z-60/37 DC Installations- und Betriebsanleitung

Service and Repair Manual

Serial Number Range

Z®-60/37 DC

from Z6016N-101 to

Z6016N-

599

from Z60N-

600

This manual includes:

Repair procedures

Fault Codes

Electrical and

Hydraulic Schematics

Z®-60/37 FE

For detailed maintenance

procedures, refer to the

appropriate Maintenance

Manual for your machine.

Part No. 1271125GT

Rev A6

December 2018

Service and Repair Manual December 2018

Introduction

ii Z®-60/37 DC • Z®-60/37 FE Part No. 1271125GT

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.

1271125GT Rev A, April 2016

First Edition, First Printing

Genie and “Z” are registered trademarks of Terex South Dakota,

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

December 2018 Service and Repair Manual

Introduction

Part No. 1271125GT Z®-60/37 DC • Z®-60/37 FE iii

Revision History

Revision

Date

Section

Procedure / Page / Description

A 3/2016

Initial Release

A1 6/2016 Repair Procedures How to Adjust Proportional Relief Valve and Hydraulic

Pressure Sensor / Updated

A2 9/2016 Introduction Serial number Legend

A3 12/2016 Schematic Power Cable Wiring Diagram

A4 11/2017 Specifications Machine Specifications

A5 5/2018 Schematic Corrected Options Schematic

A6 12/2018 Specifications Rotate hub torque value

Reference Examples:

Electronic Version

Click on any content o

r 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 December 2018

Introduction

iv Z®-60/37 DC • Z®-60/37 FE Part No. 1271125GT

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)

December 2018 Service and Repair Manual

Safety Rules

Part No. 1271125GT Z®-60/37 DC • Z®-60/37 FE 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:

RYou are trained and qualified to perform

maintenance on this machine.

RYou read, understand and obey:

•manufacturer's instructions and safety rules

•employer's safety rules and worksite

regulations

•applicable governmental regulations

RYou have the appropriate tools, lifting

equipment and a suitable workshop.

Service and Repair Manual December 2018

Safety Rules

vi Z®-60/37 DC • Z®-60/37 FE Part No. 1271125GT

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 per

sonal

injury hazards. Obey all safety

messages that follow this symbol

to avoid possible injury or death.

Indicates a imminently hazardous

situation which, if not avoided, will

result in death or serious injury.

Indicates a potentially hazardous

situ

ation 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. Alw

ays 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

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 t

o 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.

December 2018

Table of Contents

Part No. 1271125GT Z®-60/37 DC • Z®-60/37 FE 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 2 Specifications.......................................................................................................1

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

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

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

Hydraulic Component Specifications......................................................................5

Manifold Component Specifications.......................................................................6

Kubota D1105 Engine Specifications.....................................................................7

Machine Torque Specifications..............................................................................8

Machine Component Weights................................................................................8

Hydraulic Hose and Fitting Torque Specifications .................................................9

Torque Procedure ................................................................................................10

December 2018

Table of Contents

viii Z®-60/37 DC • Z®-60/37 FE Part No. 1271125GT

Section 3 Repair Procedures.............................................................................................12

Introduction ..........................................................................................................12

Cailbration Process Steps....................................................................................14

Platform Controls...............................................................................................15

1-1 Platform Controls...........................................................................................15

How to Adjust the Joystick Threshold Setting ................................................16

How to Adjust the Joystick Max-out Setting ...................................................17

How to Adjust the Joystick Ramp Rate Setting ..............................................20

1-2 How to Calibrate Booms Angle Sensors .......................................................21

1-3 How to Clear the Fault History.......................................................................22

Platform Components .......................................................................................22

2-1 Platform Leveling Slave Cylinder...................................................................22

2-2 Platform Rotator.............................................................................................24

2-3 Platform Overload System.............................................................................25

2-4 How to Reset Overload Recovery Message..................................................27

Jib Boom Components......................................................................................28

3-1 Jib Boom........................................................................................................28

3-2 Jib Boom Lift Cylinder....................................................................................29

Primary Boom Components .............................................................................30

4-1 Cable Track....................................................................................................30

How to Repair the Cable Track.......................................................................31

4-2 Primary Boom................................................................................................31

How to Disassemble the Primary Boom.........................................................32

4-3 Primary Boom Lift Cylinder............................................................................33

4-4 Primary Boom Extension Cylinder.................................................................34

4-5 Platform Leveling Master Cylinder.................................................................35

December 2018

Table of Contents

Part No. 1271125GT Z®-60/37 DC • Z®-60/37 FE ix

Secondary Boom Components.........................................................................36

5-1 Secondary Boom Lift Cylinder........................................................................37

Engines................................................................................................................39

6-1 RPM Adjustment ............................................................................................39

How to Replace the Motor Tach Sensor.........................................................39

Hydraulic Pumps................................................................................................40

7-1 Function Pump...............................................................................................40

How to Check the Function Pump Calibration ................................................41

Manifolds.............................................................................................................42

8-1 Function Manifold Components .....................................................................42

8-2 Valve Adjustments - Function Manifold..........................................................47

How to Adjust the Proportional Relief Valve and Hydraulic Pressure Sensor 47

How to Adjust the Platform Level Up Relief Valve..........................................48

How to Adjust the Primary Boom Extend Relief Valve....................................49

8-3 Jib Boom / Platform Rotate Manifold Components........................................50

8-4 Turntable Rotation Manifold Components .....................................................51

8-5 Oscillate Directional Valve Manifold Components.........................................52

8-6 How to Set Up the Oscillate Directional Valve...............................................53

How to Adjust the Oscillate Reducing Valve...................................................53

How to Test a Coil Diode ................................................................................55

Turntable Rotation Components ......................................................................56

9-1 Turntable Rotation Assembly.........................................................................56

9-2 How to Replace the Universal Tilt Sensor .....................................................58

How to Calibrate the Universal Tilt Sensor .....................................................59

Axle Components...............................................................................................60

10-1 Oscillating Axle Cylinders.............................................................................60

10-2 How to Remove the Steer Cylinder..............................................................61

How to Calibrate the Steer Angle Sensor .......................................................61

December 2018

Table of Contents

x Z®-60/37 DC • Z®-60/37 FE Part No. 1271125GT

Section 4 Fault Codes.........................................................................................................63

Introduction ..........................................................................................................63

Control System Fault Codes.............................................................................64

Fault Codes Ground Controls..............................................................................64

How to Retrieve Control System Fault Codes - Platform Controls......................65

Control System Fault Codes................................................................................66

Section 5 Navigation Menus ..............................................................................................81

Faults Navigation Menu .......................................................................................82

Options Navigation Menu.....................................................................................83

Settings Navigation Menu....................................................................................84

Section 6 Schematics.........................................................................................................85

Introduction ..........................................................................................................85

Electrical Symbol Legend ....................................................................................86

Hydraulic Symbols Legend ..................................................................................87

Electrical Component and Wire Color Legends...................................................88

Kubota Engine Fuse and Relay Module ..............................................................91

12V DC Charger Wiring (DC Option)...................................................................92

AC Input Wiring (DC Option)................................................................................93

CAN BUS Wiring Diagram - DC Models..............................................................94

Limit Switch/Angle Sensor Legend......................................................................95

Electrical Schematics – Options ......................................................................97

Wiring Diagram -Options....................................................................................98

Schematics - Options, 4WD, DC, and FE Models ...............................................99

Power Cable Wiring Diagram.............................................................................102

Hydraulic Schematics......................................................................................103

Hydraulic Schematic - DC and FE Models ........................................................104

Electrical Schematics...................................................................................... 105

Electrical Schematics, DC/FE Models ...............................................................106

Ground Control Box Terminal Strip Wiring Diagram..........................................112

Platform Control Box Wiring Diagram................................................................113

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