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Genie Z-80/60 Service Manual 88619 – PDF DOWNLOAD
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Description
Genie Z-80/60 Service Manual 88619 – PDF DOWNLOAD
Language : English
Pages : 324
Downloadable : Yes
File Type : PDF
Table of Contents:
Genie Z-80/60 Service Manual 88619 – PDF DOWNLOAD
Front Cover...................................................................................................... 1 Safety Rules..................................................................................................... 5 Table of Contents................................................................................................ 7 Specifications................................................................................................... 15 Machine Specifications....................................................................................... 15 Performance Specifications................................................................................... 16 Hydraulic Oil Specifications................................................................................. 17 Hydraulic Component Specifications........................................................................... 18 Valve Coil Resistance Specifications......................................................................... 19 GM 3.0L EFI Engine........................................................................................... 20 Ford LRG-425 EFI Engine...................................................................................... 21 Continental TME27 Engine..................................................................................... 23 Deutz F4L- 913 Engine........................................................................................ 24 Deutz BF4L-2011 Engine....................................................................................... 25 Deutz TD2011L04i Engine...................................................................................... 27 Perkins 704-30 Engine........................................................................................ 29 Perkins 804C-33 and 804D-33 Engine........................................................................... 30 Machine Torque Specifications................................................................................ 31 Hydraulic Hose and FittingTorque Specifications.............................................................. 32 SAE FASTENER TORQUE CHART.................................................................................... 33 METRIC FASTENER TORQUE CHART................................................................................. 33 Scheduled Maintenance Procedures................................................................................. 35 Pre-Delivery Preparation..................................................................................... 38 Maintenance Inspection Report................................................................................ 39 Checklist A Procedures....................................................................................... 41 A-1Inspect the Manuals and Decals........................................................................ 41 A-2Perform Pre-operation Inspection...................................................................... 42 A-3Perform Function Tests................................................................................ 42 A-4Perform Engine Maintenance............................................................................ 42 A-5Check the Hydraulic FilterCondition Indicators........................................................ 44 A-6Perform 30 Day Service................................................................................ 45 A-7Perform Engine Maintenance - Continental Models....................................................... 45 A-8Perform Engine Maintenance - Perkins and Continental Models........................................... 46 A-9 Perform Engine Maintenance........................................................................... 47 A-10Grease the Turntable RotationBearing and Rotate Gear................................................. 48 A-11Inspect the Fuel Filter/WaterSeparator - Diesel Models............................................... 48 A-12Replace the Drive Hub Oil............................................................................ 50 A-13Perform Engine Maintenance -GM and Ford Models....................................................... 52 Checklist B Procedures....................................................................................... 52 B-1Inspect the Batteries................................................................................. 53 B-2Inspect the Electrical Wiring......................................................................... 54 B-3Test the Key Switch................................................................................... 56 B-4Check the Exhaust System.............................................................................. 56 B-5Inspect the Engine Air Filter......................................................................... 57 B-6Perform Engine Maintenance -Deutz F4L913, Perkins and Continental Models.............................. 58 B-7Check the Tires, Wheelsand Lug Nut Torque............................................................. 59 B-8Confirm the ProperBrake Configuration................................................................. 59 B-9Check the Drive Hub Oil Level and Fastener Torque..................................................... 60 B-10Test the Ground Control Override..................................................................... 61 B-11Test the Platform Self-leveling...................................................................... 62 B-12Test the Engine Idle SelectOperation................................................................. 63 B-13Test the Fuel Select Operation -Gasoline/LPG Models.................................................. 64 B-14Test the Drive Brakes................................................................................ 65 B-15Test the Drive Speed -Stowed Position................................................................ 65 B-16Test the Drive Speed -Raised or Extended Position.................................................... 66 B-17Test the Alarm and OptionalFlashing Beacon........................................................... 67 B-18Perform Hydraulic Oil Analysis....................................................................... 67 B-19Check and Adjust theEngine RPM....................................................................... 68 B-20Test the Safety Envelope andCircuits................................................................. 71 B-21Test the Primary BoomSelf-leveling................................................................... 74 B-22Test the Primary Boom AngleSensor.................................................................... 75 B-23Inspect the Fuel and HydraulicTank Cap Venting Systems............................................... 76 B-24Perform Engine Maintenance - GM and Ford Models...................................................... 77 Checklist C Procedures....................................................................................... 77 C-1Perform Engine Maintenance ........................................................................... 78 C-2Grease the Platform OverloadMechanism (if equipped)................................................... 79 C-3Test the Platform OverloadSystem (if equipped)........................................................ 79 C-4Replace the Engine Air Filter......................................................................... 81 C-5Replace the Fuel/WaterSeparator - Diesel Models....................................................... 82 C-6Perform Engine Maintenance -GM and Ford Models........................................................ 84 Checklist D Procedures....................................................................................... 85 D-1Check the Boom Wear Pads.............................................................................. 85 D-2Check the Free-wheelConfiguration..................................................................... 86 D-3Check the Turntable Rotation Bearing Bolts............................................................ 87 D-4Inspect for Turntable Bearing Wear.................................................................... 89 D-5Replace the Drive Hub Oil............................................................................. 90 D-6Perform Engine Maintenance............................................................................ 92 D-7Replace the Hydraulic FilterElements.................................................................. 93 Checklist E Procedures....................................................................................... 94 E-1Test or Replace the Hydraulic Oil..................................................................... 95 E-2Grease the Steer Axle Wheel Bearings, 2WD Models...................................................... 97 E-3Perform Engine Maintenance............................................................................ 98 E-4Perform Engine Maintenance -Ford Models............................................................... 99 E-5Perform Engine Maintenance -Deutz and Perkins Models..................................................100 E-6Perform Engine Maintenance -Deutz BF4L2011 Models.....................................................101 E-7Perform Engine Maintenance -Deutz BF4L2011 Models.....................................................102 E-8Perform Engine Maintenance -Deutz BF4L2011 Models.....................................................102 Repair Procedures................................................................................................103 Display Module...............................................................................................104 Platform Controls............................................................................................111 1-1ALC-1000 Circuit Board................................................................................112 1-2Membrane Decal........................................................................................113 1-3Joysticks.............................................................................................114 Platform Components..........................................................................................121 2-1Platform..............................................................................................121 2-2Platform Leveling Cylinder............................................................................121 2-3Platform Rotator......................................................................................123 2-4Platform Overload System..............................................................................125 Jib Boom Components..........................................................................................128 3-1Jib Boom..............................................................................................128 3-2Jib Boom Lift Cylinder................................................................................130 Boom Components..............................................................................................131 4-1Primary Boom Cable Track..............................................................................132 4-2Primary Boom..........................................................................................135 4-3Primary Boom Lift Cylinder............................................................................138 4-4Primary Boom ExtensionCylinder........................................................................140 4-5Primary Boom Angle Sensor.............................................................................141 4-6Secondary Boom Cable Track............................................................................144 4-7Secondary Boom........................................................................................145 4-8Secondary Boom Lift Cylinder..........................................................................147 4-9Secondary Boom Extension Cylinder.....................................................................149 Engines......................................................................................................151 5-1RPM Adjustment........................................................................................151 5-2Flex Plate............................................................................................151 5-3Engine Fault Codes -Gasoline/LPG Models...............................................................158 Ground Controls..............................................................................................159 6-1Service Bypass/Recovery Key Switch....................................................................159 6-2Circuit Boards........................................................................................161 6-3Membrane Decal........................................................................................162 Hydraulic Pumps..............................................................................................163 7-1Function Pump.........................................................................................163 7-2Drive Pump............................................................................................164 Manifolds....................................................................................................166 8-1Function Manifold - View 1............................................................................166 8-2Function Manifold - View 2............................................................................168 8-3Valve Adjustments -Function Manifold..................................................................170 8-4Platform Manifold.....................................................................................176 8-5Turntable Rotation Manifold...........................................................................178 8-6Platform Rotate Manifold..............................................................................179 8-7Two Wheel Steer and Oscillate Manifold (before serial number 1291)....................................180 8-8Two Wheel Steer and Oscillate Manifold (after serial number 1290).....................................184 8-9Four Wheel Steer and Oscillate Manifold (before serial number 1301)...................................190 8-10Four Wheel Steer and Oscillate Manifold (after serial number 1300)...................................196 8-11Oil Diverter Manifold Components (welder option).....................................................201 8-12Traction Manifold, 2WD...............................................................................202 8-13Valve Adjustments, 2WDTraction Manifold..............................................................204 8-14Traction Manifold, 4WD...............................................................................206 8-15Valve Adjustments, 4WDTraction Manifold..............................................................208 8-16Valve Coils..........................................................................................209 Turntable Rotation Components................................................................................211 9-1Turntable Rotation Assembly...........................................................................211 Axle Components..............................................................................................213 10-1Steer Sensors........................................................................................213 10-2Hub and Bearings, 2WD................................................................................216 Fault Codes......................................................................................................219 Control System Fault Codes...................................................................................220 Engine Fault Codes - Ford and Continental Models.............................................................229 Ford Engine ECM Fault Code Chart.............................................................................230 Continental Engine ECM Fault Code Chart......................................................................235 Schematics.......................................................................................................239 Wire Circuit Legend..........................................................................................240 Limit Switches and Angle Sensors.............................................................................246 Drive Chassis and Platform Controller Pin Legend.............................................................248 Engine Relay and Fuse Panel Legend...........................................................................249 Turntable Controller Pin Legend..............................................................................252 Electrical Symbols Legend....................................................................................253 Hydraulic Symbols Legend.....................................................................................254 Electrical Schematic Large Format (from serial number 2511)..................................................323 Electrical Schematic Legend (before S/N 2511)................................................................255 Electrical Schematic - View 1 Drive Chassis Controller (DCON) (before S/N 2511).............................258 Electrical Schematic - View 2 Platform Controls (PCON) (before S/N 1167).....................................259 Electrical Schematic - View 2 Platform Controls (PCON) (from S/N 1166 to 2510) ............................261 Electrical Schematic - View 3 Ground Controls (TCON) (before S/N 2511) ......................................264 Electrical Schematic - View 4 (before S/N 2511) .............................................................265 Electrical Schematic - View 5 (before S/N 2511) .............................................................268 Electrical Schematic - View 6 Ground Controls (TCON) (before S/N 2511) ......................................269 Electrical Schematic - View 7 (before S/N 2511)..............................................................272 Electrical Schematic - View 8 (before S/N 2511) .............................................................273 Electrical Schematic - View 9 (before S/N 2511) .............................................................276 Electrical Schematic - View 10 Limit Switches (before S/N 2511) .............................................277 Electrical Schematic - View 11 Deutz F4L-913 Engine (before S/N 339) .......................................280 Electrical Schematic - View 11 Deutz BF4L-2011 Engine (from S/N 339 to 2316) ................................281 Electrical Schematic - View 11 Deutz BF4L-2011 Engine (from S/N 2317 to 2510) ..............................284 Electrical Schematic - View 12 (before S/N 2511) ............................................................286 Electrical Schematic - Perkins 704-30 Engine (before serial number 329)......................................288 Electrical Schematic - Perkins 804C-33 & 804D-33 Engine (from serial number 329 to 2316 ) ...................289 Electrical Schematic - Perkins 804D-33 Engine (from serial number 2317 to 2510) .............................292 Electrical Schematic - Perkins 804D-33 Engine (from serial number 2511) .....................................293 Electrical Schematic - Continental TME27 Engine (before serial number 2511) .................................296 Electrical Schematic - Continental TME27 Engine (from serial number 2511) ...................................297 Electrical Schematic - Ford LRG 425 Engine...................................................................300 Electrical Schematic - GM 3.0L Engine........................................................................301 Electrical Schematic - Safety Circuits ......................................................................303 Electrical Schematic - Generator Options.....................................................................306 Electrical Schematic - Welder Generator Option ..............................................................307 Hydraulic Schematic 2 Wheel Drive (2 and 4 Wheel Steer) (before serial number 990) ..........................310 Hydraulic Schematic 2 Wheel Drive (2 and 4 Wheel Steer) (from serial number 990 to 2674).....................312 Hydraulic Schematic 2 Wheel Drive (2 and 4 Wheel Steer) (serial number 1543 and from 2675)...................313 Hydraulic Schematic 4 Wheel Drive (2 and 4 Wheel Steer) (before serial number 990)...........................316 Hydraulic Schematic 4 Wheel Drive (2 and 4 Wheel Steer) (from serial number 990 to 2674) ....................318 Hydraulic Schematic 4 Wheel Drive (2 and 4 Wheel Steer) (serial number 1543 and after serial number 2675)....319 Hydraulic Schematic - Hydraulic Generator Options............................................................321 Back Page........................................................................................................324
S.S 05/24
