Terex Genie Z-62 Installations- und Betriebsanleitung

Service and Repair Manual

Serial Number Range

Z®-62/40

from Z6215A-101

to Z6216N-

2999

from Z6216D-

101

to Z6216D-149

This manual includes:

Repair procedures

Fault Codes

Electrical and

Hydraulic Schematics

from Z6216M-101

To Z6216M-

399

from Z62D-150

from Z62H-

3000

from Z62M-400

For detailed maintenance

procedures, refer to the

appropriate Maintenance

Manual for your machine.

Original Instructions

Part No. 1268555GT

Rev B1

June 2022

Service and Repair Manual June 2022

Introduction

ii Z®-62/40 Part No. 1268555GT

Intro ductio n Intro ductio n

Importan t Inf or matio 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.

1268555GT Rev B1, June 2022

First Edition, Second Printing

Genie and "Z" are registered trademarks of Terex South

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

"TraX" is a trademark of Terex South Dakota, Inc.

June 2022 Service and Repair Manual

Introduction

Part No. 1268555GT Z®-62/40 iii

RevisionHistory

Revision History

Revision Date Section Procedure / Page / Description

A 9/2015

Initial Release

A1 9/2016 Introduction Serial Number Legend

A2 11/2017 Specifications Machine Specifications

A3 2/2020 Specifications Hydraulic Component Specifications

B 5/2020 All Sections Add Deutz TD 2.2 L3 Engine

Fault Codes Control System Fault Codes

B1 6/2022 Repair 5-1

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 June 2022

Introduction

iv Z®-62/40 Part No. 1268555GT

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)

June 2022 Service and Repair Manual

Safety Rules

Part No. 1268555GT Z®-62/40 v

Sec ti on 1 Safety Rul es

Gene ralS af ety 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 modify or alter a MEWP without prior

written permission from the manufacturer.

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 June 2022

Safety Rules

vi Z®-62/40 Part No. 1268555GT

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 sym

bol—used to

alert personnel to potential

personal 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 injur

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 sur

e 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

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 reuse

d. 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.

June 2022

Table of Contents

Part No. 1268555GT Z®-62/40 vii

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

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

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

Revision History ................................................................................................ iii

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

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

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

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

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

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

Hydraulic Oil Specifications ................................................................................2

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

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

Ford MSG-425 EFI Engine Specifications ...........................................................7

Deutz D2011 L03i Engine Specifications.............................................................8

Deutz TD2011 L04i Engine Specifications ..........................................................9

Deutz TD 2.2 L3 Engine Specifications.............................................................10

Deutz D 2.9 L4 Engine Specifications ...............................................................11

Perkins 404D-22 Engine Specifications ............................................................12

Perkins 404F-22 Engine Specifications.............................................................13

Machine Torque Specifications .........................................................................14

TRAX Torque Specifications.............................................................................14

Hydraulic Hose and Fitting Torque Specifications .............................................15

Torque Procedure ............................................................................................16

SAE and Metric Fasteners Torque Charts.........................................................18

June 2022

Table of Contents

viii Z®-62/40 Part No. 1268555GT

Section 3 Repair Procedures ......................................................................................... 19

Introduction...................................................................................................... 19

Platform Controls........................................................................................... 21

1-1 ALC-500 Circuit Board ............................................................................... 21

1-2 Joysticks.................................................................................................... 22

How to Adjust the Joystick Threshold Setting .............................................. 22

How to Adjust the Joystick Max-out Setting ................................................. 23

How to Adjust the Joystick Ramp Rate Setting ............................................ 24

Platform Components.................................................................................... 26

2-1 Platform Leveling Slave Cylinder ................................................................ 26

2-2 Platform Rotator......................................................................................... 28

2-3 Platform Overload System.......................................................................... 30

Jib Boom Components.................................................................................. 32

3-1 Jib Boom.................................................................................................... 32

3-2 Jib Boom Lift Cylinder ................................................................................ 33

Primary Boom Components .......................................................................... 34

4-1 Cable Track ............................................................................................... 34

How to Remove the Cable Track................................................................. 34

How to Repair the Cable Track.................................................................... 35

4-2 Primary Boom ............................................................................................ 35

How to Disassemble the Primary Boom....................................................... 36

4-3 Primary Boom Lift Cylinder......................................................................... 37

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

4-5 Platform Leveling Master Cylinder.............................................................. 39

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

5-1 Secondary Boom Lift Cylinder .................................................................... 41

June 2022

Table of Contents

Part No. 1268555GT Z®-62/40 ix

Engines...........................................................................................................43

6-1 RPM adjustment - Deutz Models.................................................................43

6-2 RPM adjustment - Perkins Models ..............................................................43

6-3 Flex Plate ...................................................................................................43

How to Install the Flex Plate ........................................................................44

How to install the Pump and Bell Housing Assembly....................................46

6-4 Ford MSG-425 Engine Fault Codes ............................................................47

6-5 Engine Fault Codes - Deutz TD 2.2 L3 Models ...........................................48

6-6 Engine Fault Codes - Deutz D 2.9 L4 and Perkins 404F-22 Models ............48

6-7 Diesel Particle Filter Regeneration - Deutz TD 2.2 L3 .................................49

Hydraulic Pumps ............................................................................................50

7-1 Function Pump ...........................................................................................50

7-2 Drive Pump ................................................................................................51

Manifolds ........................................................................................................54

8-1 Function Manifold Components ..................................................................54

8-2 Valve Adjustments - Function Manifold .......................................................60

How to Adjust the System Relief Valve ........................................................60

How to Adjust the Platform Level Up Relief Valve ........................................60

How to Adjust the Platform Level Down Relief Valve....................................61

8-3 Jib Boom / Platform Rotate Manifold Components ......................................62

8-4 Brake / Two Speed Manifold Components ..................................................63

8-5 Brake / Two Speed / Steer Mode Manifold Components .............................64

8-6 Steer Select Manifold Components.............................................................65

8-7 Turntable Rotation Manifold Components ...................................................66

8-8 Oscillate Directional Valve Manifold Components .......................................67

8-9 How to Set Up the Oscillate Directional Valve .............................................68

8-10 Valve Adjustment - Oscillate Relief Valve..................................................69

8-11 Drive Oil Diverter Manifold Components (welder option) ...........................70

8-12 Traction Manifold Components, 2WD........................................................72

8-13 Traction Manifold Components, 4WD........................................................74

8-14 Valve Adjustments, Traction Manifold .......................................................76

8-15 Hydraulic Generator Manifold Components, 3kW......................................77

8-16 Valve Coils ...............................................................................................78

How to Test a Coil Diode .............................................................................79

June 2022

Table of Contents

x Z®-62/40 Part No. 1268555GT

Turntable Rotation Components................................................................... 80

9-1 Turntable Rotation Assembly ..................................................................... 80

Axle Components........................................................................................... 82

10-1 Oscillating Axle Cylinders......................................................................... 82

Track Components......................................................................................... 83

11-1 Track Assembly ....................................................................................... 83

Generators...................................................................................................... 87

12-1 Hydraulic Generator ................................................................................. 87

Section 4 Fault Codes .................................................................................................... 88

Introduction...................................................................................................... 88

Control System Fault Codes.......................................................................... 89

How to Retrieve Control System Fault Codes.............................................. 89

Control System Fault Codes........................................................................ 90

Fault Code Display - Deutz and Perkins Models........................................... 93

How to Retrieve Active Engine Fault Codes

Deutz D 2.9 L4 and Perkins 404F-22 Models ....................................... 93

How to Retrieve Active Engine Fault Codes - Deutz TD 2.2 L3 Models ........ 94

Fault Code Display - Flashing and Solid LED's -

Deutz D 2.9 L4 and Perkins 404F-22 Models ....................................... 95

Soft Key Functions and Icons -

Deutz D 2.9 L4 and Perkins 404F-22 Models ....................................... 96

Soft Key Functions and Icons - Deutz TD 2.2 L3 Models ............................. 97

Main Menu Structure - Deutz D 2.9 L4 Models ............................................ 98

Main Menu Structure - Deutz TD 2.2 L3 Models .......................................... 99

Main Menu Structure - Perkins 404F-22 Models ........................................ 100

Deutz TD 2.2 L3 Engine Fault Codes........................................................... 101

Deutz D 2.9 L4 Engine Fault Codes............................................................. 111

Perkins 404F-E22T Engine Fault Codes...................................................... 122

Ford MSG-425 Engine Fault Codes ............................................................. 124

How to Retrieve Ford MSG-425 Engine Fault Codes ................................. 124

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