Service

Manual
Technical
Publications
First Edition (Rev A1)
Part No. 30105
May 2007
Z-60 34
(before serial number 1090)
Genie Z-60/34 Part No. 30105
Service Manual - First Edition
ii
Important
Read, understand and obey the safety rules and
operating instructions in the Genie Z-60/34
Operator's Manual before attempting any
maintenance or repair procedure.
This service manual covers the Genie Z-60/34
2WD and 4WD models introduced in 1993.
This manual provides detailed scheduled
maintenance information for the machine owner
and user. It also 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.
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 other manuals. Please
write to the technical publications team in care of
Genie Industries, PO Box 69, Redmond WA
98073-0069 USA.
If you have any questions, call Genie Industries.
Genie North America
Telephone (206) 881-1800
Toll Free 800 536-1800 in U.S.A.
Toll Free 800 426-8089 in Canada
Fax (206) 883-3475
Genie Europe
Telephone (44) 0636-813943
Fax (44) 0636-815270
Introduction
Copyright 1993 by Genie Industries
First Edition April 1993
Genie is a registered trademark
of Genie Industries
Registered 2009987
Printed on recycled paper
Printed in U.S.A.

Genie Z-60/34 Part No. 30105

Service Manual - First Edition (May 2007)
TABLE OF CONTENTS
vi
Section Four Scheduled Maintenance Procedures, continued
A-10 Test the Platform and Ground Controls............................................................ 4 - 5
A-11 Test the Auxiliary Power Operation ................................................................. 4 - 6
A-12 Test the Tilt Sensor ......................................................................................... 4 - 7
A-13 Test the Limit Switches ................................................................................... 4 - 7
A-14 Check the Air Filter Condition Indicator - Deutz Diesel Models ...................... 4 - 10
A-15 Replace the Engine Oil and Filter - Gasoline/LPG Models ............................. 4 - 10
A-16 Replace the Engine Air Filter ......................................................................... 4 - 12
B-1 Check the Engine Belt(s) ............................................................................... 4 - 13
B-2 Check the Radiator - Gasoline/LPG Models................................................... 4 - 13
B-3 Check the Oil Cooler and Cooling Fins - Deutz Diesel Models ....................... 4 - 13
B-4 Check the Exhaust System........................................................................... 4 - 14
B-5 Check the Battery ......................................................................................... 4 - 15
B-6 Check the Hydraulic Tank Filter Condition Indicator ....................................... 4 - 15
B-7 Inspect the Electrical Wiring .......................................................................... 4 - 16
B-8 Inspect the Tires and Wheels (including lug nut torque) ................................. 4 - 16
B-9 Confirm the Proper Brake Configuration ......................................................... 4 - 17
B-10 Check the Torque Hub Oil Level and Fastener Torque (REV B) ..................... 4 - 17
B-11 Check and Adjust the Engine Idle Mixture - Gasoline/LPG Models ................ 4 - 18
B-12 Check and Adjust the Engine RPM ............................................................... 4 - 18
B-13 Test the Key Switch ...................................................................................... 4 - 20
B-14 Test the Emergency Stop Buttons................................................................. 4 - 21
B-15 Test the Ground Control Override .................................................................. 4 - 21
B-16 Test the Oscillate Lock-out (oscillating axle-equipped models) ...................... 4 - 22
B-17 Test the Platform Self-leveling ...................................................................... 4 - 22
B-18 Test the Service Horn.................................................................................... 4 - 22
B-19 Test the Foot Switch ..................................................................................... 4 - 23
B-20 Test the Engine Idle Select ........................................................................... 4 - 23
B-21 Test the Fuel Select Operation - Gasoline/LPG Models................................. 4 - 24
Part No. 30105 Genie Z-60/34 3 - 3
Section 3 - Scheduled Maintenance Inspections Service Manual - First Edition (May 2007)
Tools are
required
New parts
required
Warm
engine
required
Cold
engine
required
Dealer
service
suggested
Table B
B-1 Check the Engine Belt(s)
B-2 Check the Radiator -
Gasoline/LPG Models
B-3 Check the Oil Cooler and Cooling Fins -
Deutz Diesel Models
B-4 Check the Exhaust System
B-5 Check the Battery
B-6 Check the Hydraulic Tank
Filter Condition Indicator
B-7 Inspect the Electrical Wiring
B-8 Inspect the Tires and Wheels
(including lug nut torque)
B-9 Confirm the Proper Brake Configuration
B-10 Check the Torque Hub Oil Level and
Fastener Torque
B-11 Check and Adjust the Engine Idle Mixture -
Gasoline/LPG Models
B-12 Check and Adjust the Engine RPM
B-13 Test the Key Switch
B-14 Test the Emergency Stop Buttons
B-15 Test the Ground Control Override
B-16 Test the Oscillate Lock-out
(oscillating axle equipped models)
B-17 Test the Platform Self-leveling
MAINTENANCE TABLES REV B
Part No. 30105 Genie Z-60/34 4 - 17
Service Manual - First Edition (May 2007) Section 4 - Scheduled Maintenance Procedures
TABLE B PROCEDURES
B-9
Confirm the Proper
Brake Configuration
Proper brake configuration is essential to safe
operation and good machine performance.
Hydrostatic brakes and hydraulically-released,
spring-applied individual wheel brakes can appear
to operate normally when they are actually not
fully operational.
1 Check each torque hub disconnect cap to be
sure it is in the engaged position.
2 On 4WD models, be sure the free-wheel valve
on the drive pump is closed (clockwise).
a drive pump
b free-wheel valve
c screwdriver
d lift pump
On 2WD models, the free-wheel
valve should always remain
closed.
brake disengage position
brake engage position
b a d c
B-10
Check the Torque Hub Oil Level
and Fastener Torque
Failure to maintain proper torque hub oil levels may
cause the machine to perform poorly and continued
use may cause component damage.
Drive Torque Hubs
1 Drive the machine to rotate the hub until the
plugs are located one on top and the other at 90
degrees.
2 Remove the plug located at 90 degrees and
check the oil level.
Result: The oil level should be even with the
bottom of the plug hole.
3 If necessary, remove the top plug and add oil
until the oil level is even with the bottom of the
side plug hole, then re-install the plugs into the
hub.
4 Check the torque hub fasteners. Torque the
fasteners to 160 ft-lbs / 217 Nm.
5 Repeat this procedure for each torque hub.
Drive Torque Hub Oil
Capacity 40 fluid ounces
1.2 liters
Type: SAE 90 multipurpose hypoid gear oil - API
service classification GL5
REV B
4 - 18 Genie Z-60/34 Part No. 30105
Service Manual - First Edition (May 2007) Section 4 - Scheduled Maintenance Procedures
Turntable Rotate Torque Hub
1 Raise the secondary boom until the platform end
of the lower secondary boom arm is 8 feet
(2.4m) off the ground.
2 Attach the lifting strap from an overhead crane
to the platform end of the lower secondary boom
arm for support. Do not lift.
3 Remove the plug located on the side of the hub
and check the oil level.
Result: The oil level should be even with the
bottom of the plug hole.
a eletrical rotary coupler
b plug
c torque hub
4 If necessary, add oil until the oil level is even
with the bottom of the side plug hole, then
re-install the plug into the hub.
TABLE B PROCEDURES
5 Check the turntable rotate torque hub fasteners.
Torque the fasteners to 160 ft-lbs / 217 Nm.
Turntable Rotate Torque Hub Oil
Capacity 8 fluid ounces
0.24 liters
TypeSAE 90 multipurpose hypoid gear oil - API service
classification GL5
B-11
Check and Adjust the Engine Idle
Mixture - Gasoline/LPG Models
Complete information to perform this procedure is
available in the Ford LSG-423 2.3 Liter Industrial
Engine Service Manual (Ford number: 194-216).
Genie part number 29586.
B-12
Check and Adjust the
Engine RPM
Maintaining the engine rpm at the proper setting
for both low and high idle is essential to good
engine performance and service life. The machine
will not operate properly if the rpm is incorrect and
continued use may cause component damage.
Gasoline/LPG Models
Perform this procedure in gasoline
mode with the engine at normal
operating temperature.
1 Disconnect the blue/black wire from the
governor actuator.
a
b
c
b
REV B
U.S.A.
18340 NE 76th Street
P.O. Box 69
Redmond, Washington
98073-0069
Europe
Market Place
Southwell,
Nottinghamshire
NG25 OHE England
Canada
P.O. Box 86754
North Vancouver, B.C.
V7L4L3