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Genie Z-80/60 Service & Repair Manual 1268556 – PDF DOWNLOAD
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Genie Z-80/60 Service & Repair Manual 1268556 – PDF DOWNLOAD
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Description
Genie Z-80/60 Service & Repair Manual 1268556 – PDF DOWNLOAD
Language : English
Pages : 241
Downloadable : Yes
File Type : PDF
Table of Contents:
Genie Z-80/60 Service & Repair Manual 1268556 – PDF DOWNLOAD
Front Cover....................................................................................... 1 Important Information............................................................................. 2 Find a Manual for this Model...................................................................... 2 Revision History.................................................................................. 3 Serial Number Legend.............................................................................. 4 General Safety Rules.............................................................................. 5 Table of Contents................................................................................. 7 Specifications.................................................................................... 13 Machine Specifications........................................................................ 13 Performance Specifications.................................................................... 14 Hydraulic Oil Specifications.................................................................. 14 Hydraulic Component Specifications............................................................ 17 Continental TME27 Engine Specifications....................................................... 19 GM 3.0L Engine Specifications................................................................. 20 Deutz TD2011L04i Engine Specifications........................................................ 21 Deutz TCD 2.2 L3 Engine Specifications........................................................ 22 Deutz TD 2.9 Engine Specifications............................................................ 23 Perkins 404D-22T Engine Specifications........................................................ 24 Perkins 404F-22T Engine Specifications........................................................ 25 Perkins 804D-33 Engine Specifications......................................................... 26 Machine Torque Specifications................................................................. 27 Hydraulic Hose and Fitting Torque Specifications.............................................. 28 Torque Procedure.............................................................................. 29 Repair Procedures................................................................................. 31 Introduction.................................................................................. 31 Platform Controls............................................................................. 33 Platform Controls......................................................................... 33 1-1 Platform Circuit Board................................................................ 34 How to Remove the LED Circuit Board................................................... 35 1-2 Joysticks - How to Calibrate a Joystick............................................... 36 How to Reset a Proportional Valve Coil Default........................................ 39 How to Set the Function Thresholds and Default Functions Speeds....................... 40 How to Adjust the Function Speeds..................................................... 42 How to Adjust the Function Ramp Rate Setting.......................................... 43 Platform Components........................................................................... 45 2-1 Platform.............................................................................. 45 2-2 Platform Leveling Cylinder............................................................ 45 How to Remove the Platform Leveling Cylinder.......................................... 45 How to Bleed the Platform Leveling Cylinder........................................... 46 2-3 Platform Rotator...................................................................... 47 How to Bleed the Platform Rotator..................................................... 48 2-4 Platform Overload System (if equipped)................................................ 49 2-5 Platform Overload Recovery Message.................................................... 52 Jib Boom Components........................................................................... 53 3-1 Jib Boom.............................................................................. 53 3-2 Jib Boom Lift Cylinder................................................................ 55 Boom Components............................................................................... 56 4-1 Primary Boom Cable Track.............................................................. 57 How to Repair the Primary Boom Cable Track............................................ 59 4-2 Primary Boom.......................................................................... 60 How to Shim the Primary Boom.......................................................... 60 How to Disassemble the Primary Boom................................................... 62 4-3 Primary Boom Lift Cylinder............................................................ 63 4-4 Primary Boom Extension Cylinder....................................................... 64 4-5 Primary Boom Angle Sensor............................................................. 66 How to Replace the Primary Boom Angle Sensor.......................................... 66 How to Calibrate the Primary Boom Angle Sensor........................................ 67 4-6 Secondary Boom Cable Track............................................................ 69 How to Remove the Secondary Boom Cable Track.......................................... 69 How to Repair the Secondary Boom Cable Track.......................................... 69 4-7 Secondary Boom........................................................................ 70 4-8 Secondary Boom Lift Cylinder.......................................................... 71 4-9 Secondary Boom Extension Cylinder..................................................... 73 Engines....................................................................................... 75 5-1 RPM Adjustment........................................................................ 75 5-2 Flex Plate............................................................................ 75 How to Remove the Flex Plate.......................................................... 75 How to Install the Flex Plate......................................................... 78 How to install the Pump and Bell Housing Assembly..................................... 79 5-3 How to Access Perkins 404F Engine Regeneration Service................................ 80 _5-4 Diesel Particle Filter Regeneration - Deutz TCD 2.2 L3............................... 81 Ground Controls............................................................................... 82 6-1 Bypass/Recovery Key Switch............................................................ 82 How to Use the Recovery Mode.......................................................... 84 6-2 Circuit Boards........................................................................ 85 6-3 Membrane Decal........................................................................ 86 Display Module................................................................................ 87 Hydraulic Pumps............................................................................... 95 7-1 Function Pump......................................................................... 95 7-2 Drive Pump............................................................................ 96 How to Prime the Drive Pump........................................................... 97 Manifolds..................................................................................... 98 8-1 Function Manifold Components - View 1................................................. 98 8-2 Function Manifold Components - View 2.................................................100 8-3 Valve Adjustments - Function Manifold.................................................102 How to Adjust the System Relief Valve.................................................102 How to Adjust the Primary Boom Down Relief Valve......................................103 How to Adjust the Primary Boom Extend Relief Valve....................................104 How to Adjust the Secondary Boom Up Relief Valve......................................105 How to Adjust the Secondary Boom Down Relief Valve....................................106 How to Adjust the Secondary Boom Extend Relief Valve..................................107 How to Adjust the Platform Manifold Relief Valve......................................107 8-4 Platform Manifold.....................................................................108 8-5 Turntable Rotation Manifold...........................................................110 8-6 Platform Rotate Manifold..............................................................111 8-7 Two Wheel Steer and Oscillate Manifold................................................112 How to Adjust the Oscillate Relief Valve..............................................114 8-8 Four Wheel Steer and Oscillate Manifold...............................................116 How to Adjust the Oscillate Relief Valve..............................................120 8-9 Oil Diverter Manifold Components (welder option)......................................121 8-10 Traction Manifold Components, 2WD....................................................122 8-11 Valve Adjustments, 2WD Traction Manifold.............................................124 8-12 Traction Manifold Components, 4WD....................................................126 8-13 Valve Adjustments, 4WD Traction Manifold.............................................128 8-14 Valve Coils..........................................................................129 Turntable Rotation Components.................................................................131 9-1 Turntable Rotation Assembly...........................................................131 How to Adjust the Turntable Rotation Gear Backlash....................................132 Axle Components...............................................................................133 10-1 Steer Sensors........................................................................133 How to Measure the Tire Alignment.....................................................133 How to Adjust a Steer Sensor..........................................................134 How to Calibrate the Steer Sensors....................................................135 How to Adjust the Oscillate Limit Switches............................................136 10-2 Oscillating Axle Cylinders...........................................................137 Fault Codes.......................................................................................138 Introduction..................................................................................138 Control System Fault Codes....................................................................139 How to Read Control System Fault Codes....................................................139 How to Clear Secondary Boom Safety Switch Faults..........................................139 Fault Code Source.........................................................................147 Fault Code Display - Deutz and Perkins Models.................................................150 How to Retrieve Active Engine Fault Codes Deutz D 2.9 L4 and Perkins 404F-22 Models.......150 Deutz TD 2.9 L4 Engine Fault Codes............................................................151 Deutz TCD 2.2 L3 Engine Fault Codes...........................................................162 Perkins 404F-E22TA Engine Fault Codes.........................................................172 Continental TME27 Engine Fault Codes..........................................................175 How to Retrieve Continental Engine Fault Codes............................................175 How to Clear Engine Fault Codes from the ECM..............................................175 Continental TME27 Engine Fault Codes......................................................176 GM 3.0L Engine Fault Codes....................................................................181 Schematics........................................................................................186 Introduction..................................................................................186 Wire Circuit Legend...........................................................................187 Wire Color Legend.............................................................................191 Limit Switches and Angle Sensors..............................................................196 Drive Chassis and Platform Controller Pin Legend..............................................198 Turntable Controller Pin Legend...............................................................199 Relay and Fuse Panel Legends..................................................................201 Electrical Symbol Legend......................................................................203 Hydraulic Symbols Legend......................................................................204 Electrical Schematics.........................................................................205 Electrical Schematic - Engine Options, Deutz TD 2.9 L4 Engine.............................206 Electrical Schematic - Engine Options, Deutz TD 2.9 L4 Engine Harness.....................207 Electrical Schematic - Engine Options, Deutz TCD 2.2 L3 Engine............................210 Electrical Schematic - Engine Options, Deutz TCD 2.2 L3 Engine Harness, Tier IV Models....211 Electrical Schematic - Engine Options, Deutz TCD 2.2 L3 Engine Harness, Stage V Models....214 Electrical Schematic - Engine Options, Perkins 404D-22T Engine............................215 Electrical Schematic - Engine Options,Perkins 404F-E22TA Engine...........................218 Electrical Schematic - Engine Options, Perkins 404F-E22TA Engine Harness..................219 Electrical Schematic - Engine Options, Perkins 804D Engine................................222 Electrical Schematic - Engine Options, Continental TME27 Engine...........................223 Electrical Schematic - Engine Options, GM 3.0 Engine......................................226 Electrical Schematic - Safety Circuits....................................................227 Electrical Schematic - Generator Options..................................................230 Electrical Schematic - Welder Generator Option............................................231 Electrical Schematic – (from Z8013-4592 to Z8016H-6187)...................................239 Electrical Schematic – (from Z8016H-6188).................................................240 Hydraulic Schematics..........................................................................233 Hydraulic Schematic - 2 Wheel Drive (2 and 4 Wheel Steer).................................234 Hydraulic Schematic - 4 Wheel Drive (2 and 4 Wheel Steer).................................235 Hydraulic Schematic - Hydraulic Generator Options.........................................238 Back Cover........................................................................................241
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