Genie Z-60/34 Boom Lift Service Manual – Part No. 75861 Rev E

Description

Genie Z-60/34 Service Manual – Part No. 75861 Rev E

This Genie Z-60/34 service manual (Part No. 75861, Revision E, September 2013 printing) is the factory-issued repair and maintenance reference covering Z-60/34 boom lifts from serial number Z60-4001 onward. It’s the same Z-60/34 service manual technicians and dealer shops use to maintain and troubleshoot this articulating boom lift, delivered here as a searchable PDF you can keep on the shop laptop or print as needed.

• Manual type: Service Manual
• Brand / Model: Genie Z-60/34
• Serial number range: from Z60-4001
• Language: English
• Page count: 345 pages
• File format: PDF
• Document number: 75861
• Revision: Rev E
• Publication date: September 2013

Chapters Covered

• Section 1 – Safety Rules
• Section 2 – Specifications
  • Machine Specifications
  • Performance Specifications
  • Hydraulic Oil Specifications
  • Hydraulic Component Specifications
  • Manifold Component Specifications
  • Valve Coil Resistance Specifications
  • Ford LRG-425 EFI Engine Specifications
  • Ford DSG-423 EFI Engine Specifications
  • Ford MSG-425 EFI Engine Specifications
  • Deutz F4L-1011F Engine Specifications
  • Deutz F3L-1011F Engine Specifications
  • Deutz F3L-2011 / Deutz D2011L03i Engine Specifications
  • Perkins 404C-22 Engine Specifications
  • Machine Torque Specifications
  • Hydraulic Hose and Fitting Torque Specifications
  • SAE and Metric Fasteners Torque Charts
  Complete PDF Bookmark Tree

  Complete Bookmarks

  The complete bookmarks in the “Genie Z-60/34 Boom Lift Service Manual – Part No. 75861 Rev E” are as follows:

  Front Coverp. 1

  Introductionp. 2

  Revision Historyp. 3

  Serial Number Legendp. 5

  Safety Rulesp. 6

  Table of Contentsp. 8

  +Specificationsp. 19

  Machine Specificationsp. 19

  Performance Specificationsp. 20

  Hydraulic Oil Specificationsp. 21

  Hydraulic Component Specificationsp. 22

  Manifold Components Specificationsp. 24

  Ford LRG-425 EFI Enginep. 25

  Ford DSG-423 EFI Enginep. 27

  Ford MSG-425 EFI Enginep. 28

  Deutz F4L 1011F Enginep. 30

  Deutz F3L 1011F Enginep. 31

  Deutz F3L 2011 Engine / Deutz D2011L03ip. 32

  Perkins 404-22 Enginep. 34

  Machine Torque Specificationsp. 35

  Hydraulic Hose & Fittings Torquep. 36

  SAE and Metric Fastener Torque Chartp. 38

  +Scheduled Maintenance Proceduresp. 39

  Pre-Delivery Preparationp. 41

  Maintenance Inspection Reportp. 43

  +Checklist A Proceduresp. 45

  A-1 Inspect the Manuals and Decalsp. 45

  A-2 Perform Pre-operation Inspectionp. 46

  A-3 Perform Function Testsp. 46

  A-4 Perform Engine Maintenance- All Modelsp. 47

  A-5 Perform 30 Day Servicep. 48

  A-6 Check the High Pressure Filter Condition Indicatorp. 48

  A-7 Perform Engine Maintenance- Deutz and Ford Modelsp. 49

  A-8 Perform Engine Maintenance- Perkins Modelsp. 50

  A-9 Inspect the Fuel Filter/Water Separator- Deutz Modelsp. 50

  A-10 Perform Engine Maintenance- Ford Modelsp. 51

  A-11 Grease the Turntable Rotation Bearing and Rotate Gearp. 52

  A-12 Perform Engine Maintenance- Deutz 1011F Modelsp. 52

  A-13 Replace the Drive Hub Oilp. 53

  A-14 Perform Engine Maintenance – Ford Modelsp. 54

  +Checklist B Proceduresp. 55

  B-1 Inspect the Batteryp. 55

  B-2 Inspect the Electrical Wiringp. 56

  B-3 Inspect the Air Filterp. 57

  B-4 Test the Key Switchp. 58

  B-5 Perform Engine Maintenance – Deutz and Perkins Modelsp. 58

  B-6 Check the Exhaust Systemp. 59

  B-7 Check the Oil Cooler and Cooling Fins – Deutz Modelsp. 59

  B-8 Inspect the Tires, Wheels and Lug Nut Torquep. 60

  B-9 Check the Drive Hub Oil Level and Fastener Torquep. 61

  B-10 Confirm the Proper Brake Configurationp. 62

  B-11 Test the Engine Idle Selectp. 63

  B-12 Test the Fuel Select Operation – Ford Modelsp. 63

  B-13 Test the Ground Control Overridep. 64

  B-14 Check the Directional Valve Linkagep. 65

  B-15 Test the Platform Self-levelingp. 65

  B-16 Test the Drive Brakesp. 66

  B-17 Test the Drive Speed – Stowed Positionp. 66

  B-18 Test the Drive Speed – Raised or Extended Positionp. 67

  B-19 Perform Hydraulic Oil Analysisp. 68

  B-20 Test the Alarm Package (if equipped) and the Descent Alarmp. 68

  B-21 Inspect the Fuel and Hydraulic Tank Cap Venting Systemsp. 69

  B-22 Perform Engine Maintenance – Ford Modelsp. 70

  +Checklist C Proceduresp. 71

  C-1 Perform Engine Maintenance – Deutz and Perkins Modelsp. 71

  C-2 Grease the Platform Overload Mechanism (if equipped)p. 72

  C-3 Test the Platform Overload Mechanism (if equipped)p. 72

  C-4 Replace the Engine Air Filter Element- Deutz and Perkins Modelsp. 75

  C-5 Replace the In-line Fuel Strainer- Deutz Modelsp. 75

  C-6 Perform Engine Maintenance- Ford Modelsp. 76

  C-7 Check and Adjust the Engine RPMp. 76

  +Checklist D Proceduresp. 79

  D-1 Check the Boom Wear Padsp. 79

  D-2 Check the Turntable Rotation Bearing Boltsp. 80

  D-3 Check the Free-wheel Configurationp. 81

  D-4 Replace the Drive Hub Oilp. 83

  D-5 Perform Engine Maintenance- Deutz and Perkins Modelsp. 85

  D-6 Replace the Hydraulic Filter Elementsp. 85

  D-7 Inspect for Turntable Bearing Wearp. 86

  +Checklist E Proceduresp. 88

  E-1 Test or Replace the Hydraulic Oilp. 88

  E-2 Grease the Steer Axle Wheel Bearings, 2WD Modelsp. 90

  E-3 Perform Engine Maintenance- Deutz 1011F and Perkins Modelsp. 91

  E-4 Perform Engine Maintenance – Deutz and Perkins Modelsp. 92

  E-5 Perform Engine Maintenance- Ford Modelsp. 93

  E-6 Perform Engine Maintenance- Deutz 2011 Modelsp. 93

  E-7 Perform Engine Maintenance- Deutz 2011 Modelsp. 94

  E-8 Perform Engine Maintenance- Deutz 2011 Modelsp. 94

  +Repair Proceduresp. 96

  Introductionp. 96

  +Platform Controlsp. 97

  1-1 ALC-500 Circuit Boardp. 97

  1-2 Joysticksp. 98

  +Platform Componentsp. 102

  2-1 Platformp. 110

  2-2 Platform Leveling Slave Cylinderp. 103

  2-3 Platform Rotatorp. 104

  2-4 Platform Overload Systemp. 105

  +Jib Boom Componentsp. 109

  3-1 Jib Boomp. 109

  3-2 Jib Boom Lift Cylinderp. 110

  +Primary Boom Componentsp. 112

  4-1 Cable Trackp. 112

  4-2 Primary Boomp. 114

  4-3 Primary Boom Lift Cylinderp. 117

  4-4 Primary Boom Extension Cylinderp. 118

  4-5 Platform Leveling Master Cylinderp. 121

  +Secondary Boom Componentsp. 122

  5-1 Secondary Boomp. 122

  5-2 Secondary Boom Lift Cylindersp. 127

  +Enginesp. 128

  6-1 RPM Adjustmentp. 128

  6-2 Flex Platep. 128

  6-3 Engine Fault Codes – Ford Modelsp. 132

  +Hydraulic Pumpsp. 133

  7-1 Function Pumpp. 133

  7-2 Drive Pumpp. 134

  +Manifoldsp. 137

  8-1 Function Manifold – View 1 (before serial number 4461)p. 137

  8-2 Function Manifold – View 2 (before serial number 4461)p. 139

  8-3 Function Manifold (from serial number 4461)p. 141

  8-4 Valve Adjustments – Function Manifoldp. 145

  8-5 Jib Boom/Platform Rotate Manifold Components (before serial number 4461)p. 147

  8-6 Jib Boom/Platform Rotate Manifold Components (from serial number 4461 to serial number 10425)p. 148

  8-7 Jib Boom/Platform Rotate Manifold (from serial number 10426 to serial number 11003 )p. 149

  8-8 Jib Boom/Platform Rotate Manifold (from serial number 11004 to serial number 11477)p. 150

  8-9 Jib Boom/Platform Rotate Manifold (from serial number 11478)p. 151

  8-10 Brake/Two Speed Manifold (before serial number 4461)p. 153

  8-11 Brake/Two-Speed Manifold (from serial number 4461 )p. 154

  8-12 2WD Traction Manifold (before serial number 4551)p. 155

  8-13 2WD Traction Manifold (from serial number 4551)p. 157

  8-14 4WD Traction Manifold (before serial number 10154)p. 159

  8-15 4WD Traction Manifold (from serial number 10154)p. 161

  8-16 Valve Adjustments, Traction Manifoldsp. 163

  8-17 Directional Valve Manifold Componentsp. 164

  8-18 Directional Valve Linkage- How to Set Up the Oscillate Directional Valvep. 165

  8-19 Valve Adjustments- Oscillate Directional Valvep. 166

  8-20 Turntable Rotation Manifoldp. 167

  8-21 Drive Oil Diverter Manifold Components (welder option)p. 168

  8-22 Valve Coilsp. 169

  +Turntable Rotation Componentsp. 171

  9-1 Turntable Rotation Assemblyp. 171

  +Axle Componentsp. 172

  10-1 Hub and Bearings, 2WD Modelsp. 172

  10-2 Oscillate Axle Cylindersp. 173

  +Generatorsp. 174

  11-1 Valve Adjustments- Hydraulic Generatorp. 174

  +Fault Codesp. 176

  Introductionp. 176

  5-1 Fault Codes – Control Systemp. 177

  Fault Codes – Ford LRG-425 EFI Enginep. 181

  Fault Codes – Ford DSG-423 EFI Enginep. 187

  Fault Codes – Ford MSG-425 EFI Enginep. 191

  +Schematicsp. 198

  Introductionp. 198

  Wire Connector Legendp. 199

  Electrical Symbols Legendp. 200

  Hydraulic Symbols Legendp. 201

  Electrical Abbreviations Legendp. 202

  Ford DSG-423 Engine Relay Layoutp. 205

  Ford MSG-425 Engine Relay Layoutp. 205

  Diesel Electrical Schematic (before serial number 4496)p. 207

  Diesel Electrical Schematic (from serial number 4496 to 5325)p. 211

  Diesel Electrical Schematic (from serial number 5326 to 9798)p. 215

  Diesel Electrical Schematic (from serial number 9799 to 10387)p. 219

  Diesel Electrical Schematic, ANSI / CSA (from serial number 10388)p. 223

  Diesel Electrical Schematic, CE (from serial number 9799 to 10387)p. 227

  Diesel Electrical Schematic, CE (from serial number 10388)p. 231

  Diesel Ground Control Box Wiring Diagram (before serial number 5716)p. 235

  Diesel Ground Control Box Wiring Diagram (from serial number 5716 to 9798 )p. 236

  Diesel Ground Control Box Wiring Diagram (from serial number 9799)p. 239

  Diesel Platform Countrol Box Wiring Diagram (before serial number 7227)p. 241

  Diesel Platform Countrol Box Wiring Diagram (from serial number 7227 to 9065 )p. 242

  Diesel Platform Countrol Box Wiring Diagram (from serial number 9066 to 9696 )p. 245

  Diesel Platform Countrol Box Wiring Diagram (from serial number 9697)p. 246

  Ford Electrical Schematic (before serial number 4546)p. 249

  Ford Electrical Schematic (from serial number 4546 to 5715)p. 253

  Ford Electrical Schematic (from serial number 5716 to 6315 )p. 257

  Ford Electrical Schematic (from serial number 6316 to 7226 )p. 261

  Ford Electrical Schematic (from serial number 7227 to 10387 )p. 265

  Ford Electrical Schematic, ANSI / CSA (from serial number 10388 to 11788 )p. 269

  Ford Electrical Schematic, ANSI / CSA (from serial number 11789)p. 273

  Ford Electrical Schematic, CE (from serial number 10388 to 11788 )p. 277

  Ford Electrical Schematic, CE (from serial number 11789)p. 281

  Ford Ground Control Box Wiring Diagram (before serial number 4545)p. 285

  Ford Ground Control Box Wiring Diagram (from serial number 4546 to 5715)p. 286

  Ford Ground Control Box Wiring Diagram (from serial number 5716 to 7226 )p. 289

  Ford Ground Control Box Wiring Diagram (from serial number 7227 to 9798 )p. 290

  Ford Ground Control Box Wiring Diagram (from serial number 9799)p. 293

  Ford Platform Control Box Wiring Diagram (before serial number 7227)p. 294

  Ford Platform Control Box Wiring Diagram (from serial number 7227 to 9065 )p. 297

  Ford Platform Control Box Wiring Diagram (from serial number 9066 to 9798 )p. 298

  Ford Platform Control Box Wiring Diagram (from serial number 9799 to 11788 )p. 310

  Ford Platform Control Box Wiring Diagram (from serial number 11789)p. 302

  Engine Wire Harness, Ford LRG-425 EFI Modelsp. 305

  Engine Wire Harness, Ford DSG-423 EFI Models (before serial number 6810)p. 306

  Engine Wire Harness, Ford DSG-423 EFI Models (from serial number 6810)p. 309

  Engine Wire Harness, Ford MSG-425 EFI Models (from serial number 11789p. 310

  Electrical Schematic- CTE Option (before serial number 9697)p. 313

  Electrical Schematic – CTE Option (from serial number 9697)p. 314

  Joystick Connector Diagramp. 317

  Hydraulic Generator Options (from serial number 10283)p. 318

  Electrical Schematic – Welder Optionp. 321

  Hydraulic Schematic- Welder Optionp. 322

  Hydraulic Schematic – 2WD Models (before serial number 4461)p. 325

  Hydraulic Schematic – 2WD Models (from serial number 4461 to 10282)p. 326

  Hydraulic Schematic – 2WD Models (from serial number 10283 to serial number 11003 )p. 329

  Hydraulic Schematic – 2WD Models (from serial number 11004 to 11477 )p. 330

  Hydraulic Schematic – 2WD Models (from serial number 11478)p. 332

  Hydraulic Schematic – 4WD Models (before serial number 4461)p. 335

  Hydraulic Schematic – 4WD Models (from serial number 4461 to 10282)p. 336

  Hydraulic Schematic – 4WD Models (from serial number 10283 to serial number 11003 )p. 339

  Hydraulic Schematic – 4WD Models (from serial number 11004 to 11478 )p. 340

  Hydraulic Schematic – 4WD Models (from serial number 11478 )p. 342

  Back Coverp. 344

  Spine

• Section 3 – Scheduled Maintenance Procedures
  • Pre-Delivery Preparation
  • Maintenance Inspection Report
  • Checklist A through E Procedures (30-day, 3-month, 6-month, annual and 2-year service intervals)
• Section 4 – Repair Procedures
  • Platform Controls (ALC-500 circuit board, joysticks)
  • Platform Components (platform removal, leveling slave cylinder, rotator, overload system)
  • Jib Boom Components
  • Primary and Secondary Boom Components
  • Engines (RPM adjustment, flex plate, Ford fault codes)
  • Hydraulic Pumps (function pump, drive pump)
  • Manifolds (function, jib boom/platform rotate, brake/two-speed, 2WD and 4WD traction, directional valve, turntable rotation, drive oil diverter, valve coils)
  • Turntable Rotation Components
  • Axle Components (hub and bearings, oscillate axle)
  • Generators (hydraulic generator adjustments)
• Section 5 – Fault Codes
  • Control System Fault Code Chart
  • Ford LRG-425 EFI Engine Fault Code Chart
  • Ford DSG-423 EFI Engine Fault Code Chart
  • Ford MSG-425 EFI Engine Fault Code Chart
• Section 6 – Schematics
  • Wire Connector, Electrical Symbols and Hydraulic Symbols Legends
  • Diesel Electrical Schematics (multiple serial number ranges, ANSI/CSA and CE variants)
  • Diesel Ground Control and Platform Control Box Wiring Diagrams
  • Ford Electrical Schematics (multiple serial number ranges, ANSI/CSA and CE variants)
  • Ford Ground Control and Platform Control Box Wiring Diagrams
  • Engine Wire Harness diagrams for Ford LRG-425, DSG-423 and MSG-425
  • Hydraulic Schematics, 2WD and 4WD models across serial number breaks

Taken together, this Genie Z-60/34 service manual walks a technician from daily inspection checklists through full component teardown, giving the specific torque values, hydraulic pressures, fluid capacities and wiring paths needed to service the machine correctly rather than by guesswork.

IMAGES PREVIEW

Multiple Powertrain Coverage

Because the Z-60/34 was built with several engine options over its production run, this service manual documents specifications separately for the Ford LRG-425 EFI, Ford DSG-423 EFI, Ford MSG-425 EFI, Deutz F4L-1011F, Deutz F3L-1011F, Deutz F3L-2011/D2011L03i, and Perkins 404C-22 engines, including displacement, compression ratios, valve clearances, oil capacities, ignition data and starter/alternator specifications for each.

Serial-Number-Specific Repair Detail

Many of the repair procedures, manifold diagrams and electrical schematics in this Z-60/34 service manual are broken out by serial number range – before and after serial number 4461, 4551, 9799, 10154, 10388 and other production breaks – so the procedure or schematic you pull up matches the actual hardware on the machine in front of you rather than a generic average.

What This Manual Lets You Do

With this Genie Z-60/34 service manual on hand, a technician can perform every scheduled maintenance checklist (A through E) at the correct interval, diagnose control-system and engine fault codes with the manufacturer’s own chart, rebuild boom cylinders and hydraulic manifolds to factory torque specs, and trace electrical or hydraulic faults using the exact wiring diagram for the unit’s serial number. Working from the correct specifications and procedures reduces comebacks, protects warranty compliance, and keeps the boom lift’s safety systems performing the way Genie designed them. This Z-60/34 service manual downloads instantly as a PDF after purchase – no shipping wait, no physical binder to lose – and it opens on a shop laptop, tablet or phone, or prints out for the bay.