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88619 Z-80/60 Service Manual Rev E

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2. N M L K J D B TURNTABLE PRIMARY LIFT PRIMARY BOOM SECONDARY BOOM LIFT SECONDARY BOOM ROTATE 7 1 5 1 gpm 26 8 19 3 L min EXTEND RETRACT 5 3 6 18 9 13 63 L min EXTEND RETRACT 1 3 gpm 11 4 L min 97 LA LENIN 5 6 1 2 1 gpm 23 7 95 L m
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4. M L K J G F E D C B A TURNTABLE PRIMARY LIFT PRIMARY BOOM SECONDARY BOOM LIFT SECONDARY BOOM ROTATE 7 1 5 1 gpm 26 8 19 3 L min EXTEND RETRACT 5 3 6 gpm 18 9 13 63 L min EXTEND RETRACT 3gpm 1t 4L mn 7 7 9 7 4 4 36 7 16 7 L min 6 1 21 gpm 23 7 95 COUNTERBALANCE VALVE 1 E A RATIO PRESSURE LN A A 3 1 1000 psi 69 bar 1 51 2000 psi 138 bar 9 A 8 1 3800 51 262 bar 0 3 1 _ 2500 51 172 bar CHARGE PTER 144 A 1 3000 psi 207 bar 1 A 1 3300 psi 227 5 bar BER Ji A 1 51 3500 psi 241 8 bar 2 Em m E BERT A 3 1 3500 psi 241 3 bar HIGH PRESSURE FILTERS SS a Se ee be A 1 3800 psi 262 bar FUNCTION poe 1 Its i MANIFOLD 2500 psi 2600 psi PLATFORM LEVEL JIB BOOM Lo y L3 H 172bar 1795 7 PLATFORM ROTATE 1 25gpm 1 00gpm 1 25 gpm 1 00 gpm DENE T t 2
5. 9 ES set 555 28822 System Code Fault Name 5 lt 5 3 Fault Conditions FPP 2122 FPP1 High Voltage Y FPP1 voltage gt 4 8 vdc 2123 FPP1 Low Voltage Y FPP1 voltage lt 0 2 vdc Engine 219 Govern Speed RPM gt 3400 Speed 1111 Rev Fuel Limit RPM gt 3600 1112 Spark Rev Limit Y RPM gt 3800 Oil 524 Oil Pressure Low Y Oil pressure pulled up input with a Pressure threshold voltage of 2 5 vdc and RPM gt 500 and run time gt 30s Adaptive 171 AL High Gasoline Bank 1 AL_BM gt 30 and RPM between 0 9999 Learn and MAP between 0 99 psi 172 AL Low Gasoline Bank 1 AL_BM lt 30 and RPM between 0 9999 and MAP between 0 99 psi 1161 AL High LPG AL_BM gt 30 and RPM between 0 9999 and MAP between 0 99 psi 1162 ALLow LPG AL_BM lt 30 and RPM between 0 9999 and MAP between 0 99 psi Closed 1155 CL High Gasoline Bank 1 CL_BM gt 40 and RPM between 0 9999 Loop and MAP between 0 99 psi 1156 CL Low Gasoline Bank 1 CL_BM lt 40 and RPM between 0 9999 and MAP between 0 99 psi 1151 CL High LPG CL BM gt 35 and RPM between 0 9999 and MAP between 0 99 psi 1152 CL Low LPG CL BM 35 and RPM between 0 9999 and MAP between 0 99 psi Catalyst 420 Gasoline Cat Monitor EGO2 RMS gt 0 005 phi EGO2 Monitor RMS gt EGO1 RMS 50 and EGO2 RMS gt CL waveform R
6. Non adjustable fitting Non adj SAE O ring Boss Port tube fitting installed into Steel SAE Dash size Thread Size Flats SAE Dash size Torque 4 7he 20 2 4 ORFS 37 Adj 15 ft Ibs 20 3 Nm 6 9 16 18 11 4 ORFS Non adj 26 ft lbs 35 3 Nm 8 3 4 16 1 37 Non adj 22 ft lbs 30 Nm 6 ORFS Adj Non adj 35 ft lbs 47 5 N 10 7 8 14 1 2 i 37 Adj Non adj 29 ft lbs 39 3 Nm 1 16 12 1 1 16 12 1 8 ORFS Adj 60 ft lbs 81 3 Nm 16 1 5 16 12 1 37 52 ft lbs 70 5 Nm 20 1 5 12 1 10 ORFS Adj Non adj 100 ft lbs 135 6 Nm 37 Adj Non adj 85 ft lbs 115 3 Nm 24 1 12 1 12 All types 135 ft lbs 183 Nm 16 All types 200 ft lbs 271 2 Nm 20 All types 250 ft lbs 339 Nm 24 All types 305 ft lbs 413 5 Nm 2 16 Z 80 60 Part No 1258748 November 2014 Section 2 Specifications Torque Procedure Seal Lok fittings 1 Replace the O ring The O ring must be replaced anytime the seal has been broken The O ring cannot be re used if the fitting or hose end has been tightened beyond finger tight Note The O rings used in the Parker Seal Lok fittings and hose ends are custom size O rings They are not standard SAE size O rings They are available i
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8. J JP DEUTZ TD 2 9L4 ENGINE FAULT CODES November 2014 SPN Suspect Parameter Number FMI Failure Mode Identifier KWP Keyword Protocol SPN FMI KWP Description SPN FMI KWP Description 190 8 422 Sensor crankshaft speed 412 3 1007 Sensorerror EGR cooler disturbed signal downstreamtemperature signal range check high 190 11 390 Enginespeed above warning threshold FOC Level 2 412 4 1008 Sensor error EGR cooler downstream temperature 190 12 420 b camshaft speed no signal range check low signa 520 9 306 TimeoutErrorof CAN Receive 190 12 423 Sensorcrankshaft speed no Frame TSC1TR Setpoint signal 597 2 49 Break lever mainswitch and 190 14 391 Enginespeed above warning break lever redundancyswitch 190 14 1222 Camshaft and Crankshaft 624 3 971 SVS lamp short circuit to batt speed sensor signal not available on CAN 624 4 972 SVS lamp short circuit to grd 411 0 791 Physical range check high for 624 5 969 SVSlamp open load differential pressure Venturiunit EGR 624 12 970 SVS lamp powerstage overtemperature 411 1 792 Physical range check low for Venturiunit EGR memory delete 411 3 795 Sensorerrordifferential 630 12 377 Access error EEPROM pressure Venturiunit EGR memory read signalrange chee high 630 12 378 Access error EEPROM 411 4 381 Physical range check
9. n PLATFORM CONTROLS Ramp Rate Specifications Ramp rate factory settings Turntable rotate accelerate 4 seconds decelerate 1 0 second Primary boom up down accelerate 3 seconds decelerate 0 25 second Primary boom extend retract accelerate 3 seconds decelerate 0 75 second Secondary boom up down accelerate 7 seconds decelerate 0 75 second Secondary boom extend retract accelerate 7 seconds decelerate 0 75 second Drive accelerate 1 5 seconds decelerate to neutral 0 5 second decelerate change of direction 0 5 second decelerate coasting 0 75 second decelerate braking 2 seconds decelerate shift from low to high speed 1 second decelerate shift from high to low speed 4 seconds 4 17 Z 80 60 Section 4 Repair Procedures November 2014 Platform Components 2 1 Platform How to Remove the Platform 1 Separate the foot switch quick disconnect plug 2 Support the platform with an appropriate lifting device 3 Locate the cables that connect to the bottom of the control box Number each cable and its location at the platform control box 4 Disconnect the cables from the bottom of the platform control box 5 Remove the platform control box mounting fasteners Remove the platform control box and set it aside 6 Remove the air line to platform bracket retaining fasteners if equipped 7 Remove the weld cables fr
10. SPN FMI KWP Description SPN FMI KWP Description 1237 2 747 Override switch 2798 4 1338 Injector diagnostics timeout plausibility error error of short circuit to ground m measurement Bank 1 1322 12 610 Toomany recognized misfires in more than one cylinder 2798 4 1339 Injector diagnostics short Em circuit to ground monitoring 1323 12 604 Toomany recognized misfires Test in Cyl Bank 0 in cylinder 1 in firing order 2798 4 1340 Injector diagnostics short 1324 12 605 Toomany recognized misfires circuit to ground monitoring in cylinder 2 in firing order Test in Cyl Bank 1 1325 12 606 Too many recognized misfires 2 127 DLCErrorof CAN Receive in cylinder 3 in firing order Frame AT1IG1 NOX Sensor 1326 12 607 Toomany recognized misfires SCR system upstream cat in cylinder 4 in firing order length of frame incorrect 2659 0 1524 Physical range check high for 3224 9 128 TimeoutErrorof CAN Receive EGR exhaust gas mass flow Frame AT1IG1 2659 1 1525 Physical range check low for NOX sensor upstream TOW 3248 4 1047 Sensor error particle filter 2659 2 1523 Exhaust gas recirculation AGS downstream temperature sensor plausibility error signal range check low 2659 2 1527 AGS sensor temperature 3699 2 1616 DPFdifferential pressure exhaust gas mass flow sensor and a further sensor or plausibility error actuator CRT system def
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12. 2 16 SAE and Metric Fasteners Torque Charts 2 18 Scheduled Maintenance Procedures Part No 1258748 m 3 1 Pre Delivery Preparation 4 88 3 3 3 5 Genie Z 80 60 ix November 2014 TABLE OF CONTENTS Section Scheduled Maintenance Procedures continued Checklist A Procedures A 1 Inspect the Manuals and Decals 3 7 A 2 Perform Pre operation Inspection 3 8 A 3 Perform Function 00044 3 8 4 Perform Engine Maintenance Continental Models 3 9 A 5 Perform Engine Maintenance Deutz 3 9 A 6 Perform Engine Maintenance Perkins Models 3 10 A 7 Check the Hydraulic Filter Condition Indicators 3 10 8 Perform 30 Day 220000400 3 11 A 9 Perform Engine Maintenance Continental 106618 3 12 A 10 Grease Turntable Rotation Bearing and Rotate Gear 3 12 A 11 Perform Engine Maintenance Continental Models 3 13 A 12 Perform Engine Maintenance Perkins Models 3 13 A 13 Replace the Drive Hub
13. Ue Perkins 404F 22T Engine Fault Codes SPN Suspect Parameter Number FMI Failure Mode Identifier SPN FMI Description SPN FMI Description 29 3 Accelerator Pedal Position 2 172 3 Engine Air Inlet Temperature Voltage Above Normal Voltage Above Normal 29 4 Accelerator Pedal Position 2 172 4 Engine Air Inlet Temperature Voltage Below Normal Voltage Below Normal 91 3 Accelerator Pedal Position 1 190 0 Engine Speed High most severe 3 Voltage Above Normal 190 8 Engine Speed Abnormal Frequency 91 4 Accelerator Pedal Position 1 Pulse Width or Period Voltage Below Normal 58 3 Accelerator Pedal1 Low Idle Switch 100 1 Engine Oil Pressure Low most Voltage Above Normal severe 3 558 4 Accelerator Pedal1 Low Idle Switch 108 3 Barometric Pressure Voltage Below Normal Voltage Above Normal 638 6 Engine Fuel Rack Actuator 108 4 Barometric Pressure Current Above Normal Voltage Below Normal 639 14 J1939 Network 1 Special Instruction 110 3 Engine Coolant Temperature Voltage Above Normal 723 3 Engine Speed Sensor 2 Voltage Above Normal 110 4 Engine Coolant Temperature Voltage Below Normal 723 4 Engine Speed Sensor 2 Voltage Below Normal 110 15 Engine Coolant Temperature High least severe 1 723 8 Engine Speed Sensor 2 Abnormal Frequency 168 0 Battery Potential Power Input 1 Pulse W
14. 33 37 ft lbs 45 50 Nm 12 Solenoid valve 2 position 3 way Secondary boom down 33 37 ft lbs 45 50 13 Proportional solenoid valve Secondary boom extend retract 30 35 ft lbs 41 47 Nm 14 Check 1t ettet Differential sensing circuit secondary boom extend retract 8 10 ft lbs 11 14 Nm 15 Check valve 5 psi 0 34 bar AD Blocks flow from auxiliary pump 1 to function pump 1 30 35 ft lbs 41 47 Nm 16 Check valve 5 psi 0 34 bar AE e Blocks flow from function pump 1 to auxiliary pump 1 20 25 ft lbs 27 34 Nm 17 Check valve 5 psi 0 34 bar AF us Blocks flow from auxiliary pump 2 to function pump 2 20 25 ft lbs 27 34 Nm 18 Relief valve 3000 psi 207 bar AG Oscillate and platform manifold system 20 25 ft lbs 27 34 Nm 19 Check valve 5 psi 0 34 bar us Blocks flow from function pump 2 to auxiliary pump 2 20 25 ft lbs 27 34 Nm 20 Differential sensing valve 150 psi 10 3 Als Meters flow to functions 30 35 ft Ibs 41 47 Nm 21 Relief valve 3200 psi 220 6 bar AJ uis Boom functions system relief 30 35 ft lbs 41 47 Nm
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16. Primary boom up down Solenoid valve 2 position way H Primary boom retract gt Differential sensing circuit primary boom extend retract 10 Solenoid valve 2 position way J Primary boom extend 11 Differential sensing valve K Turntable rotate left right 12 Differential sensing valve D Primary boom extend retract 13 Differential sensing valve M Primary boom up down 14 Priority flow regulator valve gpm 11 4 L MIN N 00002 Controls flow to the oscillate and platform manifolds 15 Solenoid valve 3 position 4 way O Secondary boom extend retract Torque 30 35 ft Ibs 41 47 Nm 20 25 ft lbs 27 34 Nm 20 25 ft lbs 27 34 Nm 20 25 ft lbs 27 34 Nm 20 25 ft lbs 27 34 Nm 20 25 ft lbs 27 34 Nm 30 35 ft Ibs 41 47 Nm 33 37 ft lbs 45 50 Nm 8 10 ft lbs 11 14 Nm 50 55 ft lbs 68 75 Nm 30 35 ft lbs 41 47 Nm 30 35 ft Ibs 41 47 Nm 30 35 ft Ibs 41 47 Nm 30 35 ft Ibs 41 47 Nm 33 37 ft lbs 45 50 Nm Genie Z 80 60 Part No 1258748 MANIFOLDS Section 4 Repair Procedures October 2014 G
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21. 1 1 PRL PLU PLD JU JD 4 id ol FUNCTION 7 CE 7 7 l l 0 1 gpm l T PUMP 7 r a Q Lo 0 38 L min 0 1 4 2 5 L 7 ds 4 3200 psi 5 9 T 220 6 bar OSC T2 STR LS T5 FROM OC TO OC PMAN 5 2 4 6 HYDRAULIC ROTARY COUPLER 5 2 4 6 OSCILLATE CYLINDERS i 6 E PLATFORM MANIFOLD A A T A A FRONT LEFT FRONT RIGHT REAR LEFT REAR RIGHT i 3 alot STEERING STEERING STEERING STEERING LS N N B 5 cu in Lr v Wo 0 ACCUMULATOR 82 cc 44 4 id 44 5 15 FRR RLB RLR ARB RRR O 2WD DRIVE FRONT LEFT FRONT RIGHT MANIFOLD Il STEERING STEERING 3 8 4 S 7 T pm b of T 4 1 Jps ts rir FRB FRR gt 4 50 oom 2 5 gpm Haga e 0 NC a 9 5 7 L min 381 5 7 L min L Lmin 5 7 L min 3 8 Lmin 57 Lmin 1 e __ STIS 4 mM OL OR 9 i T3 d 8 1 0 090 i Erud Ee E 0762 ETET Ti LT Me WA mn 5 DE dd f Xn mH 1 8 LEFT
22. 2 2 Press and hold the enter button on the ground control panel while turning the key switch to platform controls 3 3 Press the minus button twice then press the enter button twice 1 4 Use the scroll button to scroll through the menu until RESET SECONDARY BOOM JOYSTICK DEFAULTS is displayed Press the button to select ves then press the button 5 5 Do not start the engine 6 6 Locate the secondary boom up down and extend retract joystick 7 Move the secondary boom up down extend retract joystick full stroke in the up extend direction and hold for 5 seconds then return to the center or neutral position Genie Part No 1258748 Z 80 60 8 Section 4 Repair Procedures PLATFORM CONTROLS Move the secondary boom up down and extend retract joystick full stroke in the down retract direction and hold for 5 seconds then return to the center or neutral position Result The alarm at the ground controls should sound for a successful calibration W Result If the alarm does not sound repeat calibration procedure Primary boom up down functions 1 Turn the key switch to the off position Press and hold the enter button on the ground control panel while turning the key switch to platform controls Press the minus button twice then press the enter button twice Use the scroll button to scroll through the menu until RESET PRIMARY BOOM UP DOWN
23. 3 15 Checklist B Procedures B 1 Inspect the Batteries 002 3 17 B 2 Inspect the Electrical 3 18 B 3 Test the Key Switch sssssssssssssssseeeee eene nnne nennen nnne 3 20 B 4 Check the Exhaust System sss eene 3 20 B 5 Inspect the Engine Air 2 3 21 B 6 Engine Maintenance Continental 3 22 B 7 Engine Maintenance Perkins Models 3 22 B 8 Check the Tires Wheels and Lug Nut Torque 2 3 23 9 Confirmthe Proper Brake Configuration 3 23 B 10 Check the Drive Hub Oil Level and Fastener Torque 3 24 11 Testthe Ground Control Override 2 222 4 00 3 25 B 12 Test the Platform Self leveling ssseeseeeeennen 3 26 Genie Z 80 60 Part No 1258748 November 2014 TABLE OF CONTENTS Section 3 Scheduled Maintenance Procedures continued B 13 Test the Engine Idle Select 3 27 B 14 Test the Fuel Select Operation Gasoline LPG Models 3 28 B 15 Test the Drive Brakes 3 29 B 16 Test the Drive Speed Stowed Position 3 29 B 17 Test the D
24. 100 default 5 increment 150 max and 50 min 100 default 5 increment 150 max and 50 min 100 default 5 TT Rotate ramp decel increment 150 max and 50 min Jib Up Down ramp decel 100 default 5 increment 150 max and 50 min 100 default 5 increment 150 max and 50 min 100 default 5 increment Secondary Boom ramp accel Secondary Boom ramp decel TT Rotate ramp accel Genie PartNo 1258748 Z 80 60 4 5 Section 4 Repair Procedures November 2014 DISPLAY MODULE With the key Reset Drive valve defaults YES NO switch off Primary Boom Up Down valve defaults YES NO switch to the Reset Secondary Boom valve defaults on position Release the button Reset TT Rotate valve defaults YES NO and press Allow Primary Boom Up Down speed zd a calibration YES NO Allow Primary Boom Ext Ret speed calibration YES NO Allow Secondary Boom Up Down speed calibration YES NO Allow TT Rotate speed calibration YES NO Reset Drive joystick defaults YES NO Reset Pri Boom Up Down joystick defaults YES NO Reset Pri Boom Ext Ret joystick defaults YES NO Reset Secondary Boom joystick defaults YES NO Reset TT Rotate joystick defaults YES NO Reset Steer joystick defaults YES NO Genie 4 6 Z 80 60 Part No 1258748 November 2014 Section 4 Repair Procedures DISPLAY MODULE Screen
25. 5 INVA 22 746 1 3 9 o9 NIA M22 ez va ig Hw d ulso 18 HM H u 1S02 ETL D ATA 109 LL dA AWA MO 1 X 02 D AIA MO LOY LL o oS vvd 817 i LEO e 9 O 4W18 38S242 o Qu 18 u8s 42 Qu 18 u8s 42 P Ez Nix tzva umna 38szc5 OL AW 13 oas oz va au n1a uasez 5 x M22 Woo8 og Aan oas ervae i8s nasoto OL gt 3uvds stra 4 amung PE 4ndNi 5 2551 27 744 19 315015 e 69 AW 1x3 5 a 3uvas 9t va RS 99 ATA 14 235 ag NACER 5 surss 51 086 5 SE e S DiN am fm o9 2 sN1u aATWA rt va yasau LION Zt 89 0 NIA 23S Maawa a SLHOM 8 1M I8 LM 8 AW NMG 23S 9 718 aastro g 18 aastro woog OL lt 19 1 e e OENE TNA 2 01 46 84802 _ _ 5 lt 9 0 ATA LAY Iud NMOG Woog 2 eg AW aNaixa3 nda 60 rd 18 384 05 18 38d 02 dob Z9 D NIA 1X3 Iud e e 80
26. Information Displayed Range With the key Set Unit levels to gravity switch off Unit Level Y axis Millivolts per degree Unit Level X axis Millivolts per degree Set Platform level to gravity Platform Level Sensor Millivolts per degree Reset Blue End Blue Side Steer Sensor YES NO Reset Yellow End Blue Side Steer Sensor YES NO Reset Blue End Yellow Side Steer Sensor YES NO Reset Yellow End Yellow Side Steer Sensor YES NO Reset All Steer Sensors YES NO Reset Primary Boom Angle Sensor YES NO Primary Boom angle 40deg YES NO Primary Boom angle 70deg YES NO With the key Reset Drive Functions YES NO Reset Switch off Reset Boom Function Speeds YES NO press and hold the Reset Lift Function Ramps YES NO button and Reset All Machine Require Calibration turn the key YES NO switch to the on position Clear All Safety Switch Faults YES NO Release the button and press ss Genie PartNo 1258748 Z 80 60 4 7 Section 4 Repair Procedures November 2014 DISPLAY MODULE Screen Enter Information Displayed With the key Length Limit No Limit NO LT Secondary Extend disabled EXT LT Secondary Function disabled SEC LT AC Generator Options NONE BELT LO HYDRL GHG10 Alarm No Motion MO AL Travel TR AL Descent DE AL Travel and Decent TD AL Lift Drive No NO CO Drive cut out while n
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28. lt N PartNo 1258748 Z 80 60 6 22 Section 6 Schematics November 2014 Electrical Schematic Engine Options Perkins 404F 22T Engine Wiring QW X8 138v 22 05 8 38 49 dS 12 TO CAN GATEWAY ENGINE CAN BUS SHEET 3 E R D227CAN D228CAN YL 08 8 gt v ovia 9 88 0 gt gt 0 2120 gt gt 6 8200 gt gt 0 SOLLSONOVIG Lecr PERKINS 404 TIERIV ENGINE 6 9 6661 NYO 49 NV2Z2CQ 91 6666 NVO 3NI9N3 Q3 18 13NS 29 65 60 dNNd Mv M3NS08 Q3 38 134v 7O 66 MOTO AYY Q34 18 1386 22 6zzr c HOLIMS A3 1 6277 1 M3MOd HOLIMS 8 39 05750 8 39 05750 HM N9ILCO HM NOILZO 6ccf NMOGLNHS ANION 8 50 ME LIYELO 60 666 AV 13H LYVLS ANION 4g aNo 2508 62zr 4 8 Hg aNo S6Z 6cer 9 8 M8 QN9 8 8 0 AM3LLVG 88 05 AM3LLVG N8 QN9 AM3LLVG M8 N9z0 9 8 0 2902 8zzn 8 408 607 DETAIL D 120 0 INTERNAL TERMINATING RESISTOR 13 12 HM 19 LINSE 19 SES 6ecr 1304 9 13 2 HM M9 L3Mv 2 6 6601 91719 MOTO 3 v8 361 62 79 AN3LLVG 8 08 8 x8 04 98 282
29. 65 Z 80 60 Part No 1258748 Section 4 Repair Procedures October 2014 MANIFOLDS 8 2 Function Manifold View 2 Index Schematic No Description Item Function Torque 1 Solenoid valve 2 position 2 way Secondary boom extend circuit 20 25 ft lbs 27 34 Nm 2 Relief valve 2600 psi 179 Quim Secondary boom extend 20 25 ft lbs 27 34 Nm 3 Proportional solenoid valve Bue Turntable rotate left right 20 25 ft lbs 27 34 Nm 4 Solenoid valve 3 position 4 way Sisi Turntable rotate left right 26 30 ft Ibs 35 41 Nm 5 Check valve s eie cosi JT Differential sensing circuit turntable rotate 8 10 ft lbs 11 14 Nm 6 Relief valve 1300 psi 89 6 bar Uso Primary boom extend 30 35 ft lbs 41 47 Nm 7 Solenoid valve 2 position 3 way 7 Primary boom 33 37 ft lbs 45 50 Nm 8 Proportional solenoid valve Wu Primary boom extend retract 30 35 ft lbs 41 47 Nm 9 Solenoid valve 2 position 3 way X uuu Primary boom down 33 37 ft lbs 45 50 Nm 10 Check Valve ates po Differential sensing circuit primary boom up down 8 10 ft lbs 11 14 Nm 11 Solenoid valve 2 position 3 way Zane Secondary boom up
30. Part No 1258748 2014 Section 3 Scheduled Maintenance Procedures B 13 Test the Engine Idle Select Operation A properly operating engine idle select function is essential to good engine performance and safe machine operation There are three settings Low idle turtle symbol allows the operator to control multiple boom and or drive functions simultaneously though at reduced speed This setting maintains a consistent low idle High idle rabbit symbol allows the operator to control multiple boom and or drive functions simultaneously This setting maintains a consistent high idle Foot switch activated high idle rabbit and foot switch symbols should be used for normal machine operation This selection activates high idle only when the foot switch is pressed down 1 Turn the key switch to ground controls 2 Pull out the red Emergency Stop button to the on position at both the ground and platform controls 3 Startthe engine from the ground controls 4 Push and release the rpm select button until high rpm is selected rabbit symbol O Result The engine should change to high idle 5 Pushandrelease the rpm select button until low rpm is selected turtle symbol Result The engine should return to low idle A TEREX COMI Part No 1258748 CHECKLIST B PROCEDURES 6 Turn the key switch to platform controls 7 Atthe platform controls press the engine idle select button until hi
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32. Section 3 Scheduled Maintenance Procedures CHECKLIST A PROCEDURES Fill the hub with oil from the top hole until the oil level is even with the bottom of the side hole Apply pipe thread sealant to the plugs Install the plugs Models with pipe plugs Apply pipe thread sealant to the plugs and install the plugs Models with O ring plugs Install the plugs into the drive hub Repeat steps 1 through 5 for the other drive hub Turntable Rotate Drive Hub Secure the turntable from rotating with the turntable rotation lock pin unlocked locked Remove the motor brake mounting bolts and then remove the motor and brake from the drive hub and set them to the side Component damage hazard Hoses can be damaged if they are kinked or pinched Remove the drive hub mounting bolts and use a lifting device to remove the drive hub from the machine ADANGER Tip over hazard Failure to secure the turntable from rotating iwht the turntable rotation lock pin could cause the machine to tip over resulting in death or serious injury A TEREX COMPAN November 2014 a motor b mounting bolts brake d drive hub e drive hub mounting bolts Remove the plug from the side of the drive hub Drain the oil from the hub into a container of adequate capacity Refer to Section 2 Specifications Install the drive hub Torque the drive hub mounting bolts to specification
33. Self clearing transient warning device Power up controller with the problem corrected Power up controller with the problem corrected Continued on next page A TEREX COMPANY 5 3 Section 5 Fault Codes November 2014 CONTROL SYSTEM FAULT CODES Error Source Error Effects Recovery Actions ENGINE SPEED underspeed Range check low oil Power up controller with the problem OIL PRESSURE Display message on LCD corrected WATER OIL TEMP Range check high temperature OIL PRESSURE SENSOR Fault check Display message on LCD Power up controller with the problem WATER OIL TEMP SENSOR corrected AXLE EXT RET BUTTONS Axle extend retract disabled display Power up controller with the problem message on LCD corrected CAN BUS Fault check Display message on LCD Power upiecntroller with the problem corrected Value at 5 0 V Value too high Limited speed and direction frozen at Power up controller with problem Value too low zero and neutral alarm sounds corrected PRIMARY BOOM UP DOWN Value at 0 V JOYSTICK TUTTI Not calibrated Joystick Speed and Direction frozen at Calibrate joystick zero and neutral Just calibrated inigate one Second beep praudible Self clearing transient warning device Value at 5 0 V Value too high Limited speed and direction frozen at Power up controller with problem Value too low zero and neutral alarm sounds corrected Value at 0 V No
34. to scroll through the menu until RESET DRIVE JOYSTICK DEFAULTS iS displayed Press the button to select ves then press the button Section 4 Repair Procedures er PLATFORM CONTROLS 5 Do not start the engine 6 Locate the drive steer joystick 7 Move the drive steer joystick full stroke in the forward direction and hold for 5 seconds then return to the center or neutral position 8 Move the drive steer joystick full stroke in the reverse direction and hold for 5 seconds then return to the center or neutral position Result The alarm at the ground controls should sound for a successful calibration Steer functions 2 1 Turn the key switch to the off position 2 Press and hold the enter button on the ground control panel while turning the key 3 switch to platform controls 3 Press the minus button twice thenpressthe 4 enter button twice 4 Use the scroll button to scroll through the menu until RESET STEER JOYSTICK DEFAULTS iS displayed Press the button to select yes 5 then press the 41 button 6 5 Do not start the engine 7 Locate the drive steer joystick 7 Move the drive steer joystick or thumb rocker switch if equipped full stroke in the left direction and hold for 5 seconds then return to the center or neutral position Genie 4 12 Z 80 60 8 November 2014 Move the drive steer joystick or thumb rocker switch if equipped
35. 1 Raise the secondary boom approximately 8 feet 2 4 m 2 Remove the engine tray retaining fastener Swing the engine tray out away from the machine a engine tray anchor hole b engine tray retaining fastener 3 Locate the engine tray anchor hole at the pivot end of the engine tray Section 3 Scheduled Maintenance Procedures CHECKLIST D PROCEDURES 4 Install the bolt that was just removed into the anchor hole to secure the engine tray from moving AWARNING Crushing hazard Failure to install the bolt into the engine tray to secure it from moving could result in death or serious injury 5 Confirm that each turntable mounting bolt is torqued in sequence to specification Refer to Section 2 Specifications 28 1 5 9 2 09 i3 16 12 0 17 226 o 25 300 29 26 0 o 9 14 5 10 o 19 62 Bolt torque sequence from above turntable 6 Lower the boom to the stowed position 7 Confirm that each bearing mounting bolt under the drive chassis is torqued in sequence to November 2014 o 6 13 7 12 186 Q 17 o 2 Bolt torque sequence from below chassis 8 Lowerthe secondary boom to the stowed position 9 Remove the engine tray retaining fastener from the engine tray anchor hole at the pivot end of the engine tray 10 Swing the engine tray in towards the machine 11 Install the bolt that was just removed into the original
36. 17 Install the hydraulic return filter housing onto the hydraulic tank 18 Install the hydraulic tank onto the machine 19 Install the two suction hoses to the suction strainers 20 Install the supply hose for the auxiliary power unit and the return filter hose Models with hydraulic tank shut off valves 21 Open the two hydraulic tank valves at the hydraulic tank 22 Fill the tank with hydraulic oil until the level is within the top 2 inches 5 cm of the sight gauge Do not overfill 23 Clean up any oil that may have spilled A TEREX COMI 24 Prime the pump Refer to Repair Procedure 7 2 How to Prime the Pump Note Always use pipe thread sealant when installing the suction hose fittings and the drain plug Component damage hazard The engine must not be started with the hydraulic tank shut off valves in the closed position or component damage will occur If the tank valves are closed remove the key from the key switch and tag the machine to inform personnel of the condition open closed Part No 1258748 2014 Section 3 Scheduled Maintenance Procedures E 2 Perform Engine Maintenance Perkins Models Engine specifications require that this procedure be every 2000 hours Proper engine maintenance following the engine manufacturer s maintenance schedule is essential to good engine performance and service life Failure to perform the maintenance procedures can lead t
37. 2 Press the fuel select button to gasoline mode 3 Startthe engine from the platform controls and allow the engine to run at low idle 4 Atthe platform controls press the engine idle select button until foot switch activated high idle rabbit and foot switch symbol is selected 5 Press down the foot switch to allow the engine to run at high idle O Result The engine should start promptly and operate smoothly in low and high idle A TEREX CON 6 Release the foot switch and shut the engine off by pushing the red Emergency Stop button in to the off position 7 Pull the red Emergency Stop button out to the on position at the platform controls 8 Press the fuel select button to LPG mode 9 Start the engine and allow it to run at low idle 10 Press down the foot switch to allow the engine to run at high idle Result The engine should start promptly and operate smoothly in low and high idle Note The engine may hesitate momentarily and then continue to run on the selected fuel if the fuel source is switched while the engine is running Part No 1258748 2014 Section 3 Scheduled Maintenance Procedures B 15 Test the Drive Brakes Proper brake action is essential to safe machine operation The drive brake function should operate smoothly free of hesitation jerking and unusual noise Hydraulically released individual wheel brakes can appear to operate normally when they are actually
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39. Note Software versions 1 04 and higher All ground control functions will operate from auxiliary control Refer to Repair Procedure 6 1 How to Determine the Revision Level Genie Z 80 60 How to Calibrate the Platform Overload System if equipped Calibration of the platform overload system is essential to safe machine operation Continued use of an improperly calibrated platform overload system could result in the system failing to sense an overloaded platform The stability of the machine is compromised and it could tip over Note Perform this procedure with the machine on a firm level surface 1 Turn the key switch to platform control Start the engine and level the platform 2 Determine the maximum platform capacity Refer to the machine serial plate 3 Remove all weight tools and accessories from the platform Note Failure to remove all weight tools and accessories from the platform will result in an incorrect calibration 4 Using a suitable lifting device place a test weight equal to the maximum platform capacity at the center of the platform floor Part No 1258748 November 2014 Section 4 Repair Procedures 5 Move the platform up and down by hand so it bounces approximately 2 5 to 5 cm 1 to 2 inches Allow the platform to settle O Result The alarm should be off The platform overload indicator light should be off at the platform controls and there should be no error message on the
40. Z 80 60 4 55 Section 4 Repair Procedures November 2014 ENGINES FORCE DPF REGENERATION allow the operator to force active regeneration of the DPF When Force mode is active the engine will enter regeneration once the engine reaches specific levels of DPF soot loading exhaust temperature and other constraints defined by the engine manufacturer This mode will be indicated by an LCD message while active 4 Turn the key switch to the on position 5 Press the plus button and the minus button at the same time to access the Operator Status menu 6 Press the enter button until FORCE DPF REGENERATION or INHIBIT DPF REGENERATION is displayed 7 Press the plus button or the minus button to select YES to change the regeneration mode from the default automatic mode The selection will automatically return to NO The LCD will display the current mode while it is Inhibited or Forced Note The LCD messages REGEN FORCED and WARNING HIGH EXHAUST SYSTEM TEMP will be displayed while a regeneration mode is running No service is required Note The LCD message REGEN INHIBITED is displayed while in the Inhibit Regeneration mode is active To exit this mode push in the Red emergency stop button Restart the engine Genie 4 56 2 80 60 Part No 1258748 November 2014 Section 4 Repair Procedures 6 1 Service Bypass Recovery Key Switch The ground control box contains two key sw
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42. 474 9 30 433 430 583 450 610 610 827 50 691 14 350 474 470 637 soo 678 60 908 50 759 8 480 650 640 7 60 922 910 1233 770 1044 42 530 718 710 92 750 1016 990 1342 840 1139 7 590 800 790 1071 970 1315 1290 1749 100 147 12 670 908 590 1206 1080 1464 1440 1952 71220 1654 12 930 1260 1240 1681 1510 2047 2010 2725 1700 2304 6 1460 1979 1950 2643 2370 3213 3160 4284 2670 320 42 1640 2223 2190 2969 2670 3620 3560 4826 300 4067 METRIC FASTENER TORQUE CHART This chart is to be used as a guide only unless noted elsewhere in this manual LUBED LUBED LUBED LUBED in ibs Mm in Ibs in Ibs Nm in Ibs Nm_ in Ibs Mm in Ibs Nm in Ibs Nm in Ibs Nm 16 18 21 24 41 463 54 618 58 663 78 884 68 775 91 10 3 19 305 36 407 69 7 87 93 105 100 113 132 15 116 132 155 176 45 512 60 683 116 132 155 176 167 189 223 252 195 221 260 294 ft Ibs ft lbs Nm ft Ibs Nm_ ft lbs Nm_ ft lbs Nm_ ft lbs Nm_ ft lbs Nm_ ft lbs Nm 26 9 36 5 144 196 279 37 8 25 1 341 486 66 649 88 108 147 40 543 774 105 469 636 269 365 229 311 337 458 4
43. 750 to 860 psi 51 71 to 59 3 bar 9 Flow regulator valve 1 5 5 7 L min KI 10 Flow regulator valve 1 0 3 8 L min KJ ius 11 Flow regulator valve 1 0 3 8 KK 12 Flow regulator valve 1 5 5 7 L min KL 13 Check valve 2 KM 14 Check valve 15 Check valve KO This list continues on the next page Genie Z 80 60 Function Torque Steer left right square end yellow side steer cylinder 26 30 ft lbs 35 41 Nm Steer left right square end blue side steer cylinder 26 30 ft lbs 35 41 Nm Load sensing circuit circle end yellow side steer cylinder retract 8 10 ft lbs 11 14 Nm Prevents steer cylinder from moving when not steering 20 25 ft lbs 27 34 Nm 26 30 ft lbs 35 41 Nm 26 30 ft lbs 35 41 Nm Oscillate cylinder blue side Oscillate cylinder yellow side Prevents steer cylinder from moving when not steering 20 25 ft lbs 27 34 Nm Oscillate circuit 20 25 ft lbs 27 34 Nm Circle end blue side steer cylinder extend circuit 20 25 ft lbs 27 34 Nm Circle end blue side steer cylinder retract circuit 20 25 ft lbs 27 34 Nm Circle end yellow side steer cylinder retract circuit 20 25 ft lbs 27 34
44. Value Too High Limited speed and direction frozen at Power up controller with the problem Value Too Low zero and neutral alarm sounds corrected Value at 0 V TURNTABLE ROTATE CW Fault check Limited speed and direction frozen at Power up controller with the problem TURNTABLE ROTATE CCW zero and neutral alarm sounds corrected TURNTABLE LEVEL TURNTABLE LEVEL Display message on LCD and sound Y DIRECTION Continued on next page A TEREX COMPANY Part No 1258748 Z 80 60 5 Section 5 Fault Codes November 2014 CONTROL SYSTEM FAULT CODES Error Source Error Type Effects Recovery Actions Sound audible warning and flash primary boom down LED at the medium rate and display message on Value at 5 0 V LCD screen PRI BOOM ANG SENSOR Correct problem SHORTED HIGH Primary boom up inhibited Primary boom velocity limited to 50 of default value Sound audible warning and flash primary boom down LED at the medium rate and display message on Value at 0 V LCD screen PRI BOOM ANG SENSOR Correct problem SHORTED LOW Primary boom up inhibited Primary boom velocity limited to 50 of default value PRIMARY BOOM ANGLE SENSOR Sound audible warning at the medium rate and display message on LCD Not calibrated screen PRI BOOM ANG SENSOR NOT CALIBRATED inhibit primary Calibrate primary boom angle sensor boom up from platform control Just calibrated Initiate one audible Self clearing transient wa
45. lt lt l r WHT NEUTRAL U BLK 220VAC al 12 5A PURPLE F45GEN 5 220 VAC REGULATOR 220VAC GENERATOR W REGULATOR 50508 November 2014 Section 6 Schematics EE Electrical Schematic Generator Options MTE Hydraulic Generator Option BLACK WHITE 2 GREEN RED 2 4 BLACK 4 BLUE GENERATOR C YELLOW C YELLOW WHITE WHITE WHITE 2 DTP04 4P 0 GENERATOR C SEEN JUMPER HARNESS 3 BLACK a E PURGE BI 1 4 120VAC 50Hz 1PH 077 H 120 60Hz 1PH 924 ENGINE HARNESS 8 T 898 ENGINE HARNESS 4 C P GENERATOR gt JUMPER HARNESS C DTPO4 4P d 7 0 V AC C GENERATOR gt gt 240 50Hz 1 PH Part No 1258748 Z 80 60 6 31 November 2014 Section 6 Schematics S SS Electrical Schematic Generator Options 32 2014 Section 6 Schematics Electrical Schematic Welder Generator Option 6 34 Section 6 Schematics November 2014 nc E
46. 2 Raise the end of the boom to a comfortable working height chest high then extend the boom 1 foot 30 cm 3 Measure each wear pad Result Replace the wear pad if it is less than specification If the wear pad is not less than specification shim as necessary to obtain minimum clearance with no binding Note The minimum shim clearance for the primary boom wear pads is 030 inch 76 mm and the maximum allowable shim clearance is 090 inch 2 29 mm The minimum shim clearance for the secondary boom wear pads is 030 inch 76 mm Boom wear pad specifications Minimum and the maximum allowable shim clearance is 125 Primary Boom inch 3 2 mm Top bottom and side wear pads inch Note If the wear pads are still within specification 15 9 mm refer to refer to Repair Procedure 4 2 How to Shim the Boom Primary Extension Boom 4 Extend and retract the boom through the entire Top wear pads 5 8 inch range of motion to check for tight spots that 15 9 mm may cause binding or scraping of the boom Side wear pads 1 2 inch Note Always maintain squareness between the 12 7mm outer and inner boom tubes Secondary Boom Top wear pads 1 e inch 12 7 mm Side and bottom wear pads 7 8 inch 22 2 mm Secondary Extension Boom Top wear pads 5 inch 15 9 mm Side wear pads 1 2 inch 12 7 mm Genie Part No 1258748 Z 80 60 3 45 Section 3 Scheduled Maintenance Procedures November 2014 CHECKLIST D PROCEDURES D 2 Ch
47. 26 gt RAILPSIG A26 RD BK RD D2 2 444 EGR PWR BOOST SIG 5D2 1 27 gt BTSIG A27 GR BK D104CAN BK WH 4 DIAG CAN LOW 255 02 1 28 255 A28 WH RD WATER IN FUEL 0228 YL 02 2 544 CUSTOMER CAN HIGH M SENS GND P D2 1 29 MSENGND OR C135WIF GR 5 q C135WIF GR 02 2 572 WATER IN FUEL 2 INJECTOR 35021 32 3 A32 BK WH P135SEN GR WH 31 FUELPRES BL FUEL PRES SIGNAL INJECTOR 15D2 1 33 INJ1 A33 GR WH P135SEN GR WH lt Dz 2 64 lt WATER IN FUEL 1 C34RET D2 1 35 C34RET GR WH 5 120 CLSWJPR OR 02 2 684 CLUTCH CAM SPDED2 1 37 CAMSPD A37 WH BK B C134KSP GR BK 4D2 2 884 KEY SW PWR CRANK SPD SHD D2 1 38 CRNKSPD SHD WH A R33STR WH D2 2 734 STARTER RELAY PWR CRANK SPEED D2 1 39 CRNKSPD A39 BL WH ENGINE CAN BUS DIOSCAN 0 lt 02 2 754 DIAG CAN HIGH BOOST SIG 5D2 1 40 BSTSIG A40 WH BK GATEWAY CUSTOMER CAN LOW BST PRES TEMP PD BSTPT A43 4 SHEET 3 0227 GR 02 2 764 D02 1 43 EGRPOGND BR D2 2 824 EGR GND P25SEN 5021 44 255 A44 BK WH 4 EGRPOSIG RD D2 2 854 EGR SIGNAL INJECTOR 2 D2 1 46 gt INJ2 A46 OR BK S E P110RET BK 02 2 874 COOLANT GND INJECTOR 4 D2 1 48 gt INU4 A48 BL WH 6 lt lt C135FP BL WH D2 2 804 FP RELAY PWR CAM SPEED 5D2 1 52 gt CAMSPD 52 C21ENG WH 02 2 714 IGN LAMP CAM SPEED SHIELD 5D2 1 53 CAMSPD SHD WH S DEUTZ DIAGNO
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49. AWARNING Tip over hazard Do not adjust the relief valve higher than specified 9 Start the engine and repeat steps 6 through 8 to confirm the relief valve pressure 10 Start the engine and raise the primary boom approximately 12 inches 30 cm Remove the block and lower the primary boom to the stowed position 11 Turn the engine off and remove the pressure gauge Part No 1258748 Genie Z 80 60 4 69 MANIFOLDS How to Adjust the Primary Boom Extend Relief Valve 1 Connect 8 0 to 5000 psi 0 to 350 bar pressure gauge to the LS port on the function manifold 2 Start the engine from the ground controls 3 Raise the boom to a horizontal position Turn the engine off 4 Locate the boom extended limit switch LSP1EO on the outside of the primary boom 5 Remove the limit switch mounting bracket retaining fasteners 6 Pullthe limit switch and bracket assembly out of the boom tube and let it hang down 7 Startthe engine from the ground controls and press and release the rpm select button until the engine changes to high idle 8 Simultaneously push and hold the function enable high speed button and the primary boom extend button with the primary boom fully extended Observe the reading on the pressure gauge Refer to Section 2 Specifications 9 Turn the engine off Use a wrench to hold the relief valve and remove the cap item U Section 4 Repair Procedures October 2014 MANIFOLDS 10 Adjust th
50. Complete information to perform this procedure is available in the appropriate operator s manual Refer to the Operator s Manual on your machine Part No 1258748 2014 Section 3 Scheduled Maintenance Procedures A 4 Perform Engine Maintenance Continental Models Engine specifications require that this procedure be performed daily or every 8 hours whichever comes first Proper engine maintenance following the engine manufacturer s maintenance schedule is essential to good engine performance and service life Failure to perform the maintenance procedures can lead to poor engine performance and component damage Oil level check Coolant level check Oil fuel and coolant systems check for leaks PCV system check Air filter discharge valve clean Required maintenance procedures and additional engine information are available in the Continental TME27 Owner s Manual Continental part number WM 10303 Continental TME27 Owner s Manual Genie part number 111901 A TEREX COMI Part No 1258748 CHECKLIST A PROCEDURES A 5 Perform Engine Maintenance Deutz Models Engine specifications require that this procedure be performed daily or every 8 hours whichever comes first Proper engine maintenance following the engine manufacturer s maintenance schedule is essential to good engine performance and service life Failure to perform the maintenance procedures can lead
51. This list continues on the next page moving when not steering Torque 26 30 ft lbs 35 41 Nm 26 30 ft lbs 35 41 Nm 20 25 ft lbs 27 34 Nm 20 25 ft lbs 27 34 Nm 20 25 ft lbs 27 34 Nm 20 25 ft lbs 27 34 Nm 20 25 ft lbs 27 34 Nm 26 30 ft lbs 35 41 Nm 20 25 ft lbs 27 34 Nm 8 10 ft lbs 11 14 Nm 20 25 ft lbs 27 34 Nm 20 25 ft lbs 27 34 Nm 8 10 ft lbs 11 14 Nm 8 10 ft lbs 11 14 Nm 20 25 ft lbs 27 34 Nm 20 25 ft lbs 27 34 Nm Genie 2 80 60 Part No 1258748 Section 4 Repair Procedures November 2014 MANIFOLDS KHG 87 2 80 60 Part No 1258748 Section 4 Repair Procedures November 2014 MANIFOLDS How to Adjust the Oscillate Relief Valve Note Perform this procedure with the boom in the stowed position Note This procedure will require two people 1 Remove the drive chassis cover from the square end of the machine 2 Connect a 0 to 5000 psi 0 to 350 bar pressure gauge to the test port on the steer oscillate manifold 3 Start the engine from the platform controls Press down the foot switch and manually activate one of the oscillate limit switches Hold the switch in the activated position and observe the reading on the pressure gauge Refer to Section 2 Specifications 5 Turn the engine off Use a wrench to hold the relief v
52. 1 Ignition Voltage Below Normal Voltage Above Normal 3241 15 Exhaust Gas Temperature 1 3484 4 Mftertreatmert 1 Ignition High least severe 1 Voltage Below Normal 3241 16 ExhaustGas Temperature 1 3556 6 Aftertreatmert1 Hydrocarbon High moderate severity 2 Doser 1 Current Above Normal 3242 1 Particulate Trap Intake Gas Temp 3610 Diesel Particulate Filter Outlet Low most severe 3 Pressure Sensor 1 3242 3 Particulate Trap Intake Gas Temp Voltage nove tional Voltage Above Normal 3610 4 BDieselParticulate Filter Outlet 1 3242 4 Particulate Trap Intake Gas Temp Voltage Below Normal Voltage Plo NOTAE Continued on next Genio Part No 1258748 Z 80 60 5 29 Section 5 Fault Codes November 2014 m Q _ PERKINS 404F 22TENGINE FAULT CODES SPN Suspect Parameter Number FMI Failure Mode Identifier SPN FMI Description SPN FMI Description 3713 7 DPF Active Regeneration Inhibited 4765 4 Aftertreatmert 1 Diesel Oxidation Due to System Timeout Catalyst Intake Gas Temperature NotResponding Properly Voltage Below Normal 3713 31 DPF Active Regeneration Inhibited 4765 15 Aftertreatmert 1 Diesel Oxidation Due to System Timeout Catalyst Intake Gas Temperature High least severe 1 3719 0 Particulate Trap 1 Soot Load Percent High most severe 3 4765 16
53. 1258748 About This Section This section contains detailed procedures for each scheduled maintenance inspection Each procedure includes a description safety warnings and step by step instructions Symbols Legend Safety alert symbol used to alert personnel to potential personal injury hazards Obey all safety messages that follow this symbol to avoid possible injury or death ADANGER Used to indicate the presence of an imminently hazardous situation which if not avoided will result in death or serious injury AWARNING Used to indicate the presence of a potentially hazardous situation which if not avoided could result in death or serious injury Safety alert symbol used to ACAUTION indicate the presence of a potentially hazardous situation which if not avoided may result in minor or moderate injury Used to indicate the presence of a potentially hazardous situation which if not avoided may result in property damage Indicates that a specific result is expected after performing a series of steps W Indicates that an incorrect result has occurred after performing a series of steps Section 3 Scheduled Maintenance Procedures November 2014 SCHEDULED MAINTENANCE PROCEDURES Maintenance Symbols Legend Note The following symbols have been used in this manual to help communicate the intent of the instructions When one or more of the symbols appear at the beginning of a maintenance proce
54. 41 47 Nm 13 Bi directional flow control valve 2 GPM 7 6 FM Equalizes pressure on both sides of divider combiner valve FQ 30 35 ft Ibs 41 47 Nm 14 Bi directional flow control valve 2 GPM 7 6 FN Equalizes pressure on both sides of divider combiner valve 30 35 ft Ibs 41 47 Nm 15 Check valve FO Drive motor anti cavitation 20 25 ft lbs 27 34 Nm 16 Flow divider combiner valve Controls flow to circle end drive motors in forward and reverse 90 100 ft Ibs 122 136 Nm 17 Flow divider combiner valve FQ uus Controls flow to divider combiner valves FJ and FP 90 100 ft Ibs 122 136 Nm 18 Check valve Drive motor anti cavitation 20 25 ft lbs 27 34 Nm Genie 4 94 Z 80 60 Part No 1258748 Section 4 Repair Procedures November 2014 MANIFOLDS Genie 95 Z 80 60 Part No 1258748 Section 4 Repair Procedures November 2014 MANIFOLDS 8 13 Valve Adjustments 4WD Traction Manifold How to Adjust the Charge Pressure Relief Valve Note Perform this procedure with the hydraulic oil temperature at 100 F to 150 F 38 C to 65 5 C Note This will
55. LS Receptacle REC LSR Recovery RCV LDS Retract Lockout RL LO Return RET LS Reverse REV LOF Right Front RF 5 Right Front Steer Sensor RFS MFV Right Rear RR PCN Right Rear Steer Sensor RRS PEL RPM RPM PLD Secondary Boom Angle Sensor SBS PLF Secondary Boom Elevated SBL PLU Sec Boom Down SBD PRF Sec Boom Extend SBE PRC Sec Boom Extend Retract Flow Control SER PRL Sec Boom Retract SBR PRR Sec Boom Up SBU PWR Sec Boom Up Dwn Flow Control SUD PSL Secondary Boom SB PTA This list continues on the next page PTS Genie Z 80 60 6 3 Section 6 Schematics November 2014 WIRE CIRCUIT LEGEND Definition Suffix Secondary Boom Lockout Valve Extend SLE Secondary Boom Lockout Valve Riser Down SLD Wire Coloring 1 All cylinder extension colors are solid and all Sensor SEN retract functions are striped black When using Spare SP black wire the stripe shall be white 5 P choke EA 2 Allrotations that are LEFT or CW are solid a 9 bab RIGHT or CCW are striped and black When the Starter STIR wire is black the stripe is white Steer Control Signal STC P Steering Valve Clockwise SCW All proportional valve wiring is striped Steering Valve Counter Clockwise SCC Temp Sender TSR Temp Switches TS Wire Color Legend Tether TET BL Blue Tilt Alarm X axis TAX BL BK Blue Black Tilt Alarm Y axis TAY BL RD Blue Red Turntable or Ground Control Panel TCN BL WH Blue White Turntable Rotate Flow Control TRF BK Black Turntab
56. November 2014 PLATFORM COMPONENTS 2 4 Platform Overload System The platform overload system is designed to prevent the machine from continuing to operate when the load in the plattorm exceeds maximum rated capacity Refer to the machine serial label for maximum capacity information If maximum platform capacity is exceeded the alarm will sound and the platform overload indicator lights will flash at the platform control and PLATFORM OVERLOAD will display on the LCD screen at the ground control The ground and platform controls will become disabled Before normal machine operation can continue the excess load will need to be removed from the platform If the excess load cannot be removed or if the operator at the platform controls is unable to correct the overloaded condition another person at the ground controls can operate the machine using auxiliary power There will be limited control of boom functions from the ground controls when using auxiliary power Auxiliary power can be used to correct the overloaded platform condition in order to resume normal safe operation of the machine Note The engine must be turned off to use auxiliary power Note Software versions 1 03 and lower All ground control functions will not operate with auxiliary control Refer to Repair Procedure 6 1 How to Determine the Revision Level Note Recovery mode must be used Refer to Repair Procedure 6 1 Service Bypass Recovery Keyswitch
57. Shut off valve Check valve 1 1 200 psi 13 8 bar e 1 i LE PENNE Relief valve with pressure setting Directional valve mechanically activated Pilot operated 3 position 3 way shuttle valve 2 P 50 50 Flow divider combiner valve with pressure balancing orifice and flow percentages Part No 1258748 Genie Hydraulic Symbols Legend Differential sensing valve IK Solenoid operated proportional valve _4 Priority flow regulator valve y Solenoid operated 2 position 3 way directional valve a 4 3000 psi 206 8 bar f 3 1 1 1 1 1 dioe 2 J Counterbalance valve with pressure and pilot ratio 2 position 2 way solenoid valve Directional valve pilot operated 2 position 2 way ERA Solenoid operated 3 position 4 way directional valve d 2 position 3 way shuttle valve Hydraulic oil cooler Brake Z 80 60 Section 6 Schematics November 2014 1 This page intentionally left blank Genie 6 16 Z 80 60 Part No 1258748 17 November 2014
58. full stroke in the right direction and hold for 5 seconds then return to the center or neutral position Result The alarm at the ground controls should sound for a successful calibration W Result If the alarm does not sound repeat calibration procedure Primary boom extend retract functions 1 Turn the key switch to the off position Press and hold the enter button on the ground control panel while turning the key switch to platform controls Press the minus button twice then press the enter button twice Use the scroll button to scroll through the menu until RESET PRIMARY BOOM EXTEND RETRACT JOYSTICK DEFAULTS is displayed Press the button to select ves then press the button Do not start the engine Locate the primary boom extend retract joystick Move the primary boom extend retract joystick full stroke in the extend direction and hold for 5 seconds then return to the center or neutral position Part No 1258748 November 2014 x Move the primary boom extend retract joystick full stroke in the retract direction and hold for 5 seconds then return to the center or neutral position Result The alarm at the ground controls should sound for a successful calibration Result If the alarm does not sound repeat calibration procedure Secondary boom up down and extend retract functions 1 Turn the key switch to the off position
59. joysticks are stored in memory at the turntable controls If a joystick controller error occurs or if a a platform controls ALC 1000 joystick is replaced it will need to be calibrated circuit board before that particular machine function will operate b primary boom extend retract See 1 3 How to Calibrate a Joystick Joystick v secondary boom up extend and down retract joystick Each joystick controller should operate smoothly d drive steer joystick controller and provide proportional speed control over its entire range of motion LED circuit board primary boom up down and turntable rotate left right joystick gt Genie PartNo 1258748 Z 80 60 4 9 Section 4 Repair Procedures November 2014 PLATFORM CONTROLS 1 1 ALC 1000 Circuit Board Note When the ALC 1000 circuit board is replaced the joystick controllers will need to be calibrated See 1 3 How to Calibrate a Joystick How to Remove the ALC 1000 Circuit Board 1 Push in the red Emergency Stop button to the off position at both the ground and platform controls 2 Locate the cables that connect to the bottom of the control box Tag each cable and its location at the control box Tag and disconnect the cables from the bottom of the platform control box 4 Remove the control cable plug retaining fasteners from the bottom of the platform control box 5 Remove the platform control box lid retaining
60. properly supported 8 Remove the barrel end pivot pin retaining fasteners 9 Place a rod through the barrel end pivot pin and twist to remove the pin Part No 1258748 November 2014 Section 4 Repair Procedures 10 Working at the pivot end of the boom support and slide the extension cylinder out of the boom extension AWARNING Crushing hazard The extension cylinder could fall when removed from the extension boom if not properly supported Component damage hazard Be careful not to damage the primary boom angle sensor PBAS when removing the cylinder from the primary boom Component damage hazard Hoses and cables can be damaged if they are kinked or pinched Note Note the length of the cylinder after removal For ease of installation the cylinder must be at the same length for reinstallation Part No 1258748 Genie Z 80 60 BOOM COMPONENTS 4 5 Primary Boom Angle Sensor A properly functioning primary boom angle sensor PBAS is essential to safe machine operation The primary boom angle sensor is used to limit the angle of the primary boom relative to ground The ECM at the ground controls TCON monitors the position and angle of the primary boom using the signal from PBAS The PBAS signal is used to control the ramping of the primary boom as well as velocity control limiting the speed of the primary boom to 1 3 feet 0 4 meters per second How to Replace the Primary Boom Angle Sensor
61. second beep Self clearing transient warning device Value at 5 0 V Value too high Limited speed and direction frozen at Power up controller with problem Value too low zero and neutral alarm sounds corrected Value at 0 V Value at 5 0 V Value too high Limited speed and direction frozen at Power up controller with problem Value too low zero and neutral alarm sounds corrected Value at 0 V Value at 5 0 V Value too high Limited speed and direction frozen at Power up controller with problem Value too low zero and neutral alarm sounds corrected Value at 0 V Value at 5 0 V Value too high Limited speed and direction frozen at Power up controller with problem Value too low zero and neutral alarm sounds corrected Value at 0 V LF STR ANG SNSR RF STR ANG SNSR LR STR ANG SNSR RR STR ANG SNSR LF STEER VALVE RF STEER VALVE Limited speed and direction frozen at Power up controller with the problem Fault check LR STEER VALVE zero and neutral alarm sounds corrected RR STEER VALVE FOOTSWITCH TIMEOUT a Display message on LCD display Recycle power Continued on next page A TEREX COMPANY Part No 1258748 Z 80 60 5 9 Section 5 Fault Codes November 2014 CONTROL SYSTEM FAULT CODES Control System Fault Codes How to Clear Secondary Boom Safety Switch Faults Note Beginning with software release 2 0 the secondary boom envelope switches will latch and faults mus
62. uo rte d Dee e ema eerta 6 18 Electrical Schematic Engine Options Deutz TD2 9 Engine 6 19 Electrical Schematic Engine Options Perkins 404F 221 6 22 Electrical Schematic Engine Options Perkins 404F 22T Engine 0 6 23 Genie Part No 1258748 Z 80 60 XV 2014 TABLE OF CONTENTS Section6 Schematics continued Electrical Schematic Engine Options Perkins 804D 4 6 26 Electrical Schematic Engine Options Continental TME27 Engine rsisi esa eiee ian a 6 27 Electrical Schematic Safety 6 30 Electrical Schematic Generator Options 6 31 Electrical Schematic Welder Generator Option 6 34 Electrical Schematic Generator Options Hydraulics 6 35 Electrical Schematic 50508 at end of manual Hydraulic Schematic 2 Wheel Drive 2 4 Wheel Steer 6 38 Hydraulic Schematic 4 Wheel Drive 2 and 4 Wheel Steer 6 39 Genie Xvi Z 80 60 Part No 1258748 November 2014 Section 2 Specifications Specifications Machine Specifications Fluid ca
63. 05 116 d moner tha expected Y Y ECT gt 210 F and RPM gt 600 217 d ly ECT gt 230 F and RPM gt 600 IAT 113 IAT Voltage High Y IAT voltage gt 4 95 vdc 112 IAT Voltage Low Y IAT voltage lt 0 05 vdc 111 IAT higher than expected 1 Y Y IAT gt 200 F and RPM gt 1000 127 IAT higher than expected 2 Y IAT gt 210 F and RPM gt 1000 BP 2229 BP Pressure High BP pressure gt 16 psi 129 BP Pressure Low lt 8 3 Battery 563 Voltage High YY Voltage gt 18 vdc Voltage 562 Voltage Low Voltage lt 9 5 vdc and RPM gt 1500 5V 643 5VE1 High Voltage Y 5VE1 gt 5 4 vdc External 642 5VE1 Low Voltage Y 5VE1 4 6 vdc TPS 123 TPS1 High Voltage Y TPS1 voltage gt 4 8 122 TPS1 Low Voltage Y TPS1 voltage lt 0 2 223 TPS2 High Voltage Y TPS2 voltage gt 4 8 222 TPS2 Low Voltage Y TPS2 voltage lt 0 2 221 TPS1 gt than TPS2 Y TPS1 percent TPS2 percent gt 20 121 TPS1 lt than TPS2 Y TPS1 percent TPS2 percent lt 20 2112 Unable to reach gt TPS Y target TPS actual TPS gt 20 2111 Unable to reach lt TPS target TPS actual TPS lt 20 2135 TPS1 2 simultaneous Y Uses same parameters as individual voltages out of range TPS1 2 voltage fault detection above 5 32 2 80 60 Part No 1258748 November 2014 Section 5 Fault Codes CONTINENTAL TME27 ENGINE FAULT CODES
64. 118 119 120 121 122 123 124 125 126 127 128 41708 low Outrigger lowered Outrigger raised Pothole protector up Pothole protector down Proprietary data buss i e ITT or AP Proprietary data buss i e ITT or AP Spare Alternator field Engine status Sensor pwr Sensor return Steer signal Steer signal to solenoid valve Multi function valve Load moment overweight Load moment underweight Hydraulic oil cooler Flashing beacon Lift speed reduction Hydraulic pressure sensor output Oil cooler fan Axle oscillate LEFT Axle oscillate RIGHT Primary boom angle signal operational Secondary boom angle signal operational Secondary boomlockout Ext Enable Secondary boom lockout Riser Down Enable ECU test switch Low engine speed OR BK 64 Power for operational switches BK BL WH 65 Low fuel indication WH RD BL 66 Drive enable WH BK BL 67 Secondary boom not stowed OR RD 68 Primary boom lowered OR RD operational BK WH BL 69 Primary boom 1 extended BL WH 70 Primary boom 2 retracted BK RD BL BK 71 Primary boom 2 extended GN 72 Secondary boom extend GR GN BK 73 Secondary boom retract RD RD 74 Primary 1 Lockout BL WH RD WH 75 Primary 2 Lockout GR WH BL 76 Pri boom 3 extended BK WH 77 Lower angle 1 operational OR WH BK 78 Upper angle 2 operational RD BK 79 power from TCON ESTOP OR RD N A 80 Can 2 0 J1939 Shield BK RD GR 81 Can 2 0 J1939 Low RD BK YL 82 Can
65. 17 D81CAN 18 D82CAN 19 UNUSED 20 TETFUNC WH 21 TETGND BR 22 6 RD 23 5 OR 1 GNDDCON BR 2 P21DCON RD 3 P53LS WH BK 4 P54ENG BK WH 5 S56PRV RD 6 P21DCON RD 7 P58LS RD BK 8 5595 GR WH 9 S121PBU GR 10 P53LS WH BK 11 P53LS WH BK 12 5595 GR WH 13 C64LS OR BL 14 C65LOF BL WH 15 C66DREN BL 16 C73SBR BL RD 17 C68PBD RD 18 C64LS OR BL 19 C70PBR BL WH 20 C71PBE BL BK 1 C67SBD BL 22 C77SBU WH 23 V74PRLO RD 24 V75PRLO RD WH 25 SNSR GND BR 26 BOOM ANGLE PWR 27 G119SR BL 28 C124SBL RD BK SENSOR INPUT 33 SEC ANGLE SENSOR INPUT 34 P30 1 VLVRET1 BR 2 C35RPM BK RD 3 C21IGN WH 4 C34SA BK WH 5 V30FWD WH 6 V31REV WH BK 7 C46HN WH 8 C39LP BL RD 9 C33STR BK 10 C30EDC WH 11 C31EDC WH BK 12 C25PSR WH BK 13 C26TSR WH RD 14 RET85TTSR GR 15 P85TTSR GR 16 VLVRET2 BR 17 UNUSED 18 C41RPM OR BK 19 UNUSED 20 C83TAX GR WH 21 C84TAY GR BK 22 C45GEN GR WH 23 VLVRET3 BR 35 VLVRET1 BR 1 BATVLV RD 2 BATGND BR 3 BATGND BR 4 BATECU RD Genie 29 C77AS WH TCON 29 UNUSED 30 C78PS WH BK TURNTABLE 30 VLVRET6 BR 31 P56PRV RD CONTROLLER 31 UNUSE
66. 2 0 J1939 High OR GR WH 83 Tilt signal x axis RD GR BK 84 Tilt signal y axis OR GR 85 Tilt Sensor power BL OR 86 Hydraulic filter restricted OR RD 87 Platform level safety power GR RD BK 88 Platform level safety output GR BK BR 89 Platform level safety ground RD BK RD BK 90 Proximity kill RD WH 91 Gate Interlock RD WH WH BK 92 Motor speed LO HI WH RD 93 Motor bypass WH RD WH 94 Load sensor OR 95 Tether ESTOP return WH BK RD 96 Tether power BK 97 Tether ESTOP power GR WH 98 J1708 high OR RD Genie 6 6 Z 80 60 Part No 1258748 2014 Section 6 Schematics Color Circuit and Primary function WIRE CIRCUIT LEGEND Color Circuit and Primary function RD BK 129 Descentalarm BL WH 163 Priextend retract signal WH RD 130 Travel alarm RD WH 164 Pri up down signal BL 131 Motion alarm WH RD 165 TT Rotate signal GR 132 Platform load input OR 166 Boom length signal safety GR WH 133 Platform load alarm OR BK 167 Boom length signal operational GR BK 134 Key switch power BL RD 168 Primary boom hydraulic valve BL WH 135 lockout RD 136 Power to safety module GN 169 Envelope active LED RD WH 137 Propel power P 38 WH RD 170 Load sense relay source RD BK 138 Priboom up sec boom dwn Ext WH BK 171 Load sense relay sink P 11 30 BL 172 flow control ground WH RD 139 Turntable rot FC safety P 39 BK 173 Ext Ret flow control ground OR RD 140 Boom envelope safety
67. 2 47 High battery voltage warning 175 0 740 Physical range check high for threshold exceeded oiltemperature 168 2 48 Low battery voltage warning 175 745 Highoiltemperature warning threshold exceeded threshold exceeded 168 45 Sensor error battery voltage 175 746 High oil temperature shut off signal range check high threshold exceeded 168 4 6 Sensor error battery voltage 175 1 741 Physical range check low for oil signal range check low temperature 171 3 417 Sensorerrorenvironment 175 2 738 Sensor oiltemperature temperature signal range plausibility error check high 175 2 739 Sensor oiltemperature 171 4 418 JSensorerrorenvironment plausibility error temperature signal range oil temperature too high check low 175 3 743 Sensorerror oiltemperature 172 0 1182 Physical range check high for signal range check high intake airtemperature 175 4 744 Sensorerror oiltemperature 172 1 1183 Physical range check low for signal range check low intake airtemperature 190 389 Enginespeed above warning 172 2 9 Sensor ambient air threshold FOC Level 1 temperature plausibility error 190 2 421 Offset angle between crank 172 2 983 Intake air sensor plausibility and camshaft sensor is error too large 172 3 981 Sensor error intake air signal 190 8 419 Sensor camshaft speed range check high disturbed signal 172 4 982 Sensor error intake air sensor signal range check low Part No 1258748 Z 80 60 5 15 Section 5 Fault Codes m
68. Aftertreatmert 1 Diesel Oxidation Catalyst Intake Gas Temperature Percent High moderate severity 2 5487 3 Aftertreatmert 1 Burner Unit 4016 6 High Current Auxiliary Power Relay Combustion Chamber Temperature 1 Current Above Normal Voltage Above Normal 4201 3 Engine Speed Sensor 1 5487 4 Aftertreatmert 1 Burner Unit Voltage Above Normal Combustion Chamber Temperature 4201 4 Engine Speed Sensor 1 Voltage Below Normal 6581 6 Aftertreatmert 1 Hydrocarbon 4201 8 Engine Speed Sensor 1 Doser 2 Current Above Normal Abnormal Frequency Pulse Width or Period 4201 10 Engine Speed Sensor 1 Abnormal Rate of Change 4765 1 Aftertreatmert 1 Diesel Oxidation Catalyst Intake Gas Temperature Low most severe 3 4765 3 Aftertreatmert 1 Diesel Oxidation Catalyst Intake Gas Temperature Voltage Above Normal A TEREX COMPANY 5 30 Z 80 60 Part No 1258748 November 2014 Section 5 Fault Codes Continental TME27 Engine Fault Codes Engine Fault Codes Continental Models How to Retrieve Continental Engine Fault Codes The ECM constantly monitors the engine by the use of sensors on the engine The ECM also uses signals from the sensors to initiate sequential fuel injection and make constant and instantaneous changes to ignition timing fuel delivery and throttle position to maintain the engine s running condition at its highest efficiency while at the same time k
69. Charged air pressure above factor exceeding the maximum shut off threshold drift limit plausibility error 102 4 777 Sensorerrorchargedair 132 11 2 Air flow sensor load correction press signal range check low factor exceeding drift limit plausibility error 105 996 Highchargedair cooler temperature warning 132 11 3 Air flow sensor low idle threshold exceeded correction factor exceeding the maximum drift limit 105 997 Highchargedaircooler temperature shut off 132 11 4 Air flow sensor load correction threshold exceeded factor exceeding the maximum drift limit 105 3 994 Sensorerrorchargedair temperature signal range 157 3 877 Sesnorerrorrail pressure check high signal range check high 105 4 995 Sensorerrorchargedair 157 4 878 Sensorerrorrail pressure temperature signal range signal range check low check low Genie A TEREX COMPANY 5 14 Z 80 60 Part No 1258748 2014 Section 5 Fault Codes DEUTZ TD 2 9 L4 ENGINE FAULT CODES SPN Suspect Parameter Number FMI Failure Mode Identifier KWP Keyword Protocol SPN FMI KWP Description SPN FMI KWP Description 168 0 1180 Physical range check high for 4 481 Highlowfueltemperature battery voltage warning threshold exceeded 168 1 1181 Physical range check low for 174 482 HighLow fuel temperature shut battery voltage off threshold exceeded 168
70. ENGINES 12 Carefully pull the pump and bell housing assembly away from the engine and secure it from moving Component damage hazard Hoses can be damaged if they are kinked or pinched 13 Remove the flex plate mounting fasteners and remove the flex plate from the engine flywheel Perkins 804D models 14 Tag and disconnect the wiring from the bell housing 15 Remove the exhaust pipe clamp at the muffler Burn hazard Hot engine parts can ACAUTION cause severe burns 16 Remove the muffler mounting bracket fasteners Remove the muffler and bracket assembly from the engine 17 Remove the hose clamps from the air cleaner elbow and the engine intake manifold 18 Remove the air cleaner mounting bracket fasteners Remove the air cleaner and bracket assembly from the engine 19 Support the drive pump with an appropriate lifting device Remove all of the remaining bell housing to engine fasteners Part No 1258748 Genie Z 80 60 20 Carefully pull the pump and bell housing assembly away from the engine and secure it from moving Component damage hazard Hoses can be damaged if they are kinked or pinched 21 Remove the flex plate mounting fasteners and remove the flex plate from the engine flywheel Perkins 404F 22T models 22 Tag and disconnect the wiring from the bell housing 23 Remove the fasteners supporting the muffler assembly from the bell housing Burn hazard Hot engine parts can ACAUTION
71. Exhaust 0 0098 in Reserve capacity 6 25A rate 200 minutes 0 25 mm Alternator output 90A 12V DC Lubrication system Fan belt deflection 3 8 to 1 2 in Oil pressure 2000 rpm 40 60 psi 9 to 12 mm 2 8 4 1 bar Oil capacity 10 6 quarts including filter 10 liters Continuous improvement of our products is a Genie policy Product specifications are subject to change without notice Part No 1258748 Z 80 60 2 13 Section 2 Specifications November 2014 SPECIFICATIONS Perkins 404F 22T Engine Lubrication system Displacement 134 cuin Oil Pressure 40 to 60 psi 2 2 liters 2000 rpm 1 4 to 3 bar Oil capacity 9 4 11 2 quarts Number of cylinders 4 4 including filter 8 9 10 6 liters Bore and stroke 3 31 x 3 94 inches TE 84 100 mm Oil viscosity requirements Horsepower 58 2500 rpm Below 86 F 30 C 5W 20 43 2 KW 2500 0 to 40 C 10W 30 Firing order 1 3 4 2 Above 14 F 10 C 15W 40 Standby idle 1100 rpm Units ship with 15W 40 5W 40 with Cold Start Options Lowidle 1500 rpm Extreme operating temperatures may require the use of alternative engine oils For oil requirements refer to the Engine Operator Handbook on your machine Highidle 2500 rpm a p Oil pressure sending unit Oil pressure switch point 14 2 psi 1 bar Compression ratio 23 3 1 MER Fuel injection system Compression pressure 426 psi UE 29 4 bar Injection pump make Zexel Pressure p
72. Genie Part No 1258748 Z 80 60 6 19 November 2014 Section 6 Schematics Electrical Schematic Engine Options Deutz TD2 9 Engine Wiring 20 21 November 2014 Section 6 Schematics Electrical Schematic Engine Options Perkins 404F 22T Engine 6 22 November 201 4 Section 6 Schematics Electrical Schematic Engine Options Perkins 404F 22T Engine 9 A a4 18 NUESEZd ES0508H VSL 82 A ay va auveced gt gt 9 Szzr 2 8 a HM L33G 19 HW 18 d36 14 gt gt z szzr 5 35 111 318v1NNnL 338930 QU VSrEd 00 a Sy 1V 135 gt S Sezr Q3 18 1386 2 Q8 8 134 22 B8 14 1389910 HM 49 1382 08 8 08 8 z 8 04 8 S 8 13 022 5 29 5 0 B HM ON 19 8 13 022 Q3 3Md0Z2 t H g B 8 uiseeo 1 gt 437009 10 8 5 5 4 8 840 0918 OMNVYGAH 8 39 dS3 19 9122 T 28 138990 9 2 Ei 7 HOLIMS dW3L YOLVYINIO OV t eg SXV A TW 5 5 8 8 Wed 01 38 0N910 1 1 OV p 98 4 900 WWA NYOH
73. JOYSTICK DEFAULTS is displayed Press the button to select ves then press the button Do not start the engine Locate the primary boom turntable rotate joystick Move the boom turntable rotate joystick stroke in the up direction and hold for 5 seconds then return to the center or neutral position Section 4 Repair Procedures er PLATFORM CONTROLS x Move the boom turntable rotate joystick full stroke in the down direction and hold for 5 seconds then return to the center or neutral position Result The alarm at the ground controls should sound for a successful calibration Result If the alarm does not sound repeat calibration procedure Turntable rotate functions 1 2 Turn the key switch to the off position Press hold the enter button on the ground control panel while turning the key switch to platform controls Press the minus button twice then press the enter button 1 twice Use the scroll button to scroll through the menu until RESET TURNTABLE ROTATE LEFT RIGHT JOYSTICK DEFAULTS is displayed Press the button to select ves then press the button Do not start the engine Locate the primary boom turntable rotate joystick Move the boom turntable joystick full stroke in the left direction and hold for 5 seconds then return to the center or neutral position Move the boom turntable joystick full stroke in the right
74. Mi 9 i x em 2 1 5 MANIFOLD 4 eoo psi Ma i eg jur i CDR CDL 55 bar L2SPEED FOUR WHEEL STEER MANIFOLD t ee IOSCILLATE MANIFOLD p i RBRAKE l OE 5 l HS0077K TWO WHEEL STEER MANIFOLD 6 38 Z 80 60 PartNo 1258748 November 2014 Section 6 Schematics Hydraulic Schematic 4 Wheel Drive 2 and 4 Wheel Steer
75. Mode Recovery is only to be used as a last attempt to lower the platform when the operator in the platform is unable to do so system failure or in emergency situations AWARNING Bodily injury hazard When using recovery mode the platform may not fully lower to the ground when the recovery mode is completed Failure to use only suitable equipment and or practices to allow the operator to safely exit the platform could result in death or serious injury AWARNING Bodily injury hazard Platform leveling is not active when using recovery mode The platform could reach high out of level conditions when using this mode The operator will need to secure themself to the platform to prevent falling injury Genie 2 80 60 The Recovery mode allows the platform to be lowered in the event the operator in the platform is unable to lower the platform using the platform controls system failure or emergency situations The recovery sequence will automatically retract the primary boom and then lower the primary boom using the auxiliary power unit to allow the operator at the platform controls to exit the platform 1 Turn the main key switch to the off position Remove the key from the main key switch and insert the key into the service bypass recovery key switch 2 Turn and hold the service bypass recovery key Switch to the recovery position The switch must be held in the recovery position Result The auxiliary power unit wil
76. Note Perform this procedure on a firm level surface with the boom in the stowed position 1 Remove the retaining fasteners from the boom end cover at the pivot end of the primary boom Remove the cover from the machine 2 Locate the primary boom angle sensor inside the primary boom at the boom pivot pin 3 Tag and disconnect the electrical connector from the sensor 4 Remove the angle sensor mounting bracket retaining fasteners 5 Remove the wing nut from the threaded rod Do not disconnect the threaded rod from the clevis yoke Section 4 Repair Procedures November 2014 BOOM COMPONENTS 6 Remove the angle sensor and bracket assembly 7 Remove the sensor retaining fasteners from the sensor bracket Remove the angle sensor 8 Install the new angle sensor onto the mounting bracket 9 Install the angle sensor and bracket assembly Note The sensor should be installed rotated in a fully counter clock wise position 10 Insert the threaded rod through the threaded rod adjustment bracket 11 Move the threaded rod to the top of the slotted hole Tighten the wing nut and hex nut towards each other 12 Connect the electrical connector to the angle sensor 13 Calibrate the primary boom angle sensor See How to Calibrate the Primary Boom Angle Sensor Tip over hazard Failure to calibrate the primary boom sensor could result in the machine tipping over resulting in death or serious injury Genie 2 80
77. Operation Manual Perkins part number SEBU8609 Perkins 800D Series Operation Manual 4 Replace the Engine Air Filter Element Engine specifications require that this procedure be performed every 500 hours or six months whichever comes first Maintaining the engine air filter in good condition is essential to good engine performance and service life Failure to perform this procedure can lead to poor engine performance and component damage Note Perform this procedure with the engine off 1 Release the latches the air cleaner cap Remove the end cap from the air cleaner canister 2 Remove the filter element 3 Use a damp cloth to wipe the filter sealing surface and the inside of the outlet tube Make sure that all contaminant is removed before the filter is inserted 4 Check new filter element gasket for damage before installing 5 Install the new filter element 6 Install the end cap on the canister and secure Genie part number 111332 Note Be sure the discharge slot is pointing down Perkins 404F Series Operation Manual Genie part number 1251562 Genie A TEREX COMI Part No 1258748 Section 3 Scheduled Maintenance Procedures November 2014 CHECKLIST C PROCEDURES 5 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 properl
78. Refer to Section 2 Specifications Install the brake and motor onto the drive hub Torque the motor brake mounting bolts to specification Refer to Section 2 Specifications Fill the hub with oil from the side hole until the oil level is even with the bottom of the hole Apply pipe thread sealant to the plug Install the plug Adjust turntable rotation gear backlash Refer to Repair Procedure 9 1 How to Adjust the Turntable Rotation Gear Backlash Part No 1258748 2014 Section 3 Scheduled Maintenance Procedures A 13 Perform Engine Maintenance Perkins Models Engine specifications require that this procedure be performed every 200 hours Proper engine maintenance following the engine manufacturer s maintenance schedule is essential to good engine performance and service life Failure to perform the maintenance procedures can lead to poor engine performance and component damage Required maintenance procedures and additional engine information are available in the Perkins 804D 33 Operation and Maintenance Manual Perkins part number SEBU7853 00 Perkins 804D 33 Operation and Maintenance Manual Genie part number To access the engine 1 Removethe engine tray retaining fastener located under the engine tray Swing the engine tray out away from the machine and secure it from moving AWARNING Crushing hazard Failure to install the fastener into the engine tray anchor hole to secur
79. Result The primary boom does not stop Immediately release the function enable button and lower the boom Repeat this procedure beginning with step 1 Tip over hazard If the boom does not stop at 65 immediately release the function enable button and lower the primary boom Failure to lower the boom could cause the machine to tip over resulting in death or serious injury Genie 2 80 60 4 6 Secondary Boom Cable Track The secondary boom cable track guides the cables and hoses running up through the inside of the secondary boom It can be repaired link by link without removing the cables and hoses that run through it Removal of the secondary boom cable track is required to repair it How to Remove the Cable Track Note The secondary boom cable track must be removed with the secondary boom extension cylinder See 4 9 How to Remove the Secondary Boom Extension Cylinder How to Repair the Cable Track Component damage hazard The boom cable track can be damaged if it is twisted A cable track repair kit is available through the Genie Industries Service Parts Department 1 Remove the secondary boom extension cylinder Note The secondary boom extension cylinder must be removed as an assembly with the cable tracks cable track trays and cable track support tubes from the platform end of the secondary boom See 4 9 How to Remove the Secondary Boom Extension Cylinder 2 Visually inspect the cable track and deter
80. Turntable rotate functions Raise the primary boom until it no longer rests on the boom cradle 2 Press and hold the enter button on the ground control panel while turning the key switch to ground controls 3 Press the plus button twice then press the Move the joystick full stroke in either the left or minus button twice right direction until a drive enable zone is reached Move the joystick in the opposite direction full stroke until the alarm sounds Now move the joystick in the opposite direction full stroke until the alarm sounds again Return the joystick to center 4 Press the scroll button until the function to be adjusted is displayed 5 Press the plus button to increase the speed or press the minus button to decrease the speed 13 Once the function speeds have been set press and hold the engine start button e until the engine shuts off Do not press the red Emergency Stop button Note Approximately 3 seconds after the engine shuts off the alarm at the ground controls will sound to indicate the speed settings are being saved in memory Release the button 14 At the ground controls turn the key switch to the off position wait three seconds and then turn the key switch to platform controls 6 Press the enter button a to save the setting in memory 7 Perform this procedure until the machine function speed meets specification 15 Inspect the displa
81. and 4 Wheel Steer 40
82. and a suitable workshop Attempting this procedure without these skills and tools could result in death or serious injury and significant component damage Dealer service is strongly recommended Note Perform this procedure with the boom in the stowed position Note When removing a hose assembly or fitting the O ring on the fitting and or hose end must be replaced and then torqued to specification during installation Refer to Section 2 Hydraulic Hose and Fitting Torque Specifications 1 Remove the jib boom See 3 1 How to Remove the Jib Boom 2 Remove the fasteners securing the limit switch to the primary boom at the pivot end of the boom Do not disconnect the wiring Move the limit switch to a safe location 3 Tag and disconnect the wire harness from the primary boom angle sensor PBAS Note The primary boom angle sensor is located inside the primary boom at the pivot end Genie 2 80 60 4 Tag disconnect and plug the primary boom extension cylinder hydraulic hoses Cap the fittings on the cylinder Tag disconnect and plug the hydraulic hoses routed through the primary boom at the union AWARNING Bodily injury hazard Spraying hydraulic oil can penetrate and burn skin Loosen hydraulic connections very slowly to allow the oil pressure to dissipate gradually Do not allow oil to squirt or spray 5 Attach a lifting strap from an overhead crane to the barrel end of the primary boom lift cylinder 6 Remov
83. and the display will show P9B SAFETY FAULT and P11 SAFETY FAULT W Result If the engine does not stop and the secondary boom continues to extend the secondary boom 1 retracted safety limit switch LSS1RS is out of adjustment or the wiring circuit is faulty and will need to be replaced or repaired 7417117143 2 Bodily injury hazard If the secondary boom continues to extend without stopping the engine stop immediately and retract the secondary boom Failure to retract the secondary boom could result in death or serious injury 24 Remove the wire jumpers installed in step 22 and connect the wire harness to LSS2AO 25 Re connect the Deutsch connector from the secondary boom 2 angle safety limit switch LSS2AS removed in step 20 A TEREX CON B 21 Test the Primary Boom Self leveling Note The primary boom self leveling function is adjustable on machines with software revision 1 03 and lower This function is not adjustable on machines with a software revision higher than 1 03 Refer to Repair Procedure 6 1 How to Determine the Revision Level Automatic primary boom self leveling throughout the full cycle of secondary boom raising and lowering is essential for safe machine operation The primary boom is maintained level by the communication between the platform level sensor and the turntable level sensor If the platform becomes out of level the computer at the ground controls will open the appropriate solenoid va
84. be removed with the secondary boom tube on the machine Note The extension cylinder can be removed without completely disassembling the boom See 4 9 How to Remove the Secondary Boom Extension Cylinder AWARNING injury hazard The procedures in this section require specific repair skills lifting equipment and a suitable workshop Attempting this procedure without these skills and tools could result in death or serious injury and significant component damage Dealer service is strongly recommended Note When removing a hose assembly or fitting the O ring on the fitting and or hose end must be replaced and then torqued to specification during installation Refer to Section 2 Hydraulic Hose and Fitting Torque Specifications Follow the disassembly steps to the point required to complete the repair Then re assemble the secondary boom by following the disassembly steps in reverse order 1 Remove the primary boom See 4 2 How to Remove the Primary Boom Section 4 Repair Procedures November 2014 BOOM COMPONENTS 2 Tag disconnect and plug the hydraulic hoses at the primary boom lift cylinder Cap the fittings on the cylinder AWARNING Bodily injury hazard Spraying hydraulic oil can penetrate and burn skin Loosen hydraulic connections very slowly to allow the oil pressure to dissipate gradually Do not allow oil to squirt or spray 3 Attach a lifting strap from an overhead crane to the lug on the b
85. boom until the platform is resting on the blocks just enough to support the platform Note Do not rest the entire weight of the boom on the blocks 4 Tag disconnect and plug the hydraulic hoses from the platform leveling cylinder at the bulkhead fittings located inside the boom tube at the platform end Cap the bulkhead fittings on the boom tube AWARNING Bodily injury hazard Spraying hydraulic oil can penetrate and burn skin Loosen hydraulic connections very slowly to allow the oil pressure to dissipate gradually Do not allow oil to squirt or spray 5 Remove the pin retaining fasteners from the platform leveling cylinder rod end pivot pin Do not remove the pin 6 Remove the external snap rings from the barrel end pivot pin Do not remove the pin 7 Support and secure the jib boom cylinder to the jib boom with a strap or other suitable device Protect the cylinder rod from damage Crushing hazard The jib boom ACAUTION cylinder will fall if not properly supported when the platform level cylinder rod end pivot pin is removed Part No 1258748 Genie Z 80 60 PLATFORM COMPONENTS 8 Use 8 soft metal drift to remove the barrel end pivot pin Crushing hazard The platform AWARNING and jib boom will fall when the platform leveling cylinder barrel end pivot pin is removed if not properly supported 9 Support the rod end of the platform level cylinder 10 Use a soft metal drift to tap the platform le
86. bypass pressure 3 5 bar schematic items O and S Hydraulic tank return filter 10 micron with 2 position 2 way solenoid valve 10V DC 3 3 Q 25 psi 1 7 bar bypass schematic items J 2 position 2 way solenoid valve 10V DC 6 3 Q schematic items Manifold Component TT 2 position 3 way solenoid valve 10V DC 6 3 Q Specifications schematic items H V X Z AA EE and EF Plug torque 2 position 3 way solenoid valve 12V DC 90 schematic items BC BD CE CF SAE No 2 50 in Ibs 6 Nm FB and FC SAE No 4 14 ft Ibs 18 9 Nm SAE No 6 23 ft lbs 31 2 Nm SAE No 8 36 ft lbs 48 8 Nm SAE No 10 62 ft lbs 84 1 Nm SAE No 12 84 ft lbs 113 9 Nm Continuous improvement of our products is a Genie policy Product specifications are subject to change without notice Genie 2 6 Z 80 60 Part No 1258748 November 2014 Engine coolant Section 2 Specifications r SPECIFICATIONS Capacity 11 5 quarts 10 9 liters Coolant temperature switch Torque 8 18 ft Ibs 11 24 Nm Temperature switch point 230 F 112 C Alternator Output 95A 13 8V DC Continuous improvement of our products is a Genie policy Product specifications are subject to change without notice Part No 1258748 Z 80 60 2 7 Section 2 Specifications November 2014 SPECIFICATIONS Continental TME27 Engine Displacement 164 cu in 2 68 liters Number of cylinders 4 Bore and stroke 3 58 x 4 06 inches
87. cable clamp from the jib boom pivot pin ACAUTION Crushing hazard The jib boom may fall if not supported when the jib boom pivot pin is removed Part No 1258748 November 2014 Section 4 Repair Procedures 10 Tag disconnect and plug the slave cylinder hydraulic hoses from the bulkhead fittings at the platform end of the primary boom Cap the bulkhead fittings AWARNING Bodily injury hazard Spraying hydraulic oil can penetrate and burn skin Loosen hydraulic connections very slowly to allow the oil pressure to dissipate gradually Do not allow oil to squirt or spray 11 Tag disconnect and plug the jib boom cylinder hydraulic hoses Cap the fittings AWARNING end injury hazard Spraying ydraulic oil can penetrate and burn skin Loosen hydraulic connections very slowly to allow the oil pressure to dissipate gradually Do not allow oil to squirt or spray 12 Remove the cotter pin from the platform end of the cable track tube Note Always replace the cotter pin with a new one when installing the cable track 13 Remove the fasteners from the cable track guide at the platform end of the primary boom Remove the cable track guide from the machine 14 Tag and disconnect the electrical connector from the limit switch at the pivot end of the primary boom 15 Remove all hose clamps for the primary boom lift cylinder hydraulic hoses Note The primary boom lift cylinder hydraulic hose clamps are located behind
88. check low signal range check low 51 5 1223 Actuator EGR Valve open load 97 3 464 Sensor error water in fuel signal range check high 51 6 1014 Actuator error EGR Valve signal range check high 97 4 465 Sensor error water in fuel signal range check low 97 12 1157 Water in fuel level prefilter maximum value exceeded Part No 1258748 Z 80 60 5 13 Section 5 Fault Codes November 2014 4 DEUTZ TD 2 914 ENGINE FAULT CODES SPN Suspect Parameter Number FMI Failure Mode Identifier KWP Keyword Protocol SPN FMI KWP Description SPN FMI KWP Description 100 0 734 Highoilpressure warning 108 3 412 Sensor error ambient air threshold exceeded press signal range check high 100 735 High oil pressure shut off 108 4 413 Sensor error ambient air threshold exceeded press signal range check low 100 1 736 Lowoilpressure warning 110 0 9 High coolant temperature threshold exceeded warning threshold exceeded 100 1 737 Low oil pressure shut off 110 0 99 High coolant temperature shut threshold exceeded off threshold exceeded 100 3 732 Sensor error oil pressure signal 110 3 96 Sensor error coolant range check high temp signal range check high 100 4 733 Sensor error oil pressure 110 4 97 Sensor error coolant sensor signal range check low temp signal range check low 102 2 88 Charged air pressure above 111 1 101 Coolant level too low warning threshold 132 11 1 Air flow sensor load correction 102 2 89
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90. except extend 13 Using a suitable lifting device lift the additional test weight from the platform Result The platform overload indicator lights should turn off at both the ground and platform controls and the alarm should not sound Note There may be an 2 second delay before the overload indicator lights and alarm turn off A TEREX COMI 14 Start the engine and test all machine functions from the ground controls Result All ground control functions should operate normally 15 Turn the key switch to platform control 16 Test all machine functions from the platform controls Result All platform control functions should operate Note If the platform overload system is not operating properly Refer to 2 4 How to Calibrate the Platform Overload System if equipped 17 Using a suitable lifting device remove the remaining test weights from the platform Part No 1258748 June 2012 4 Section 3 Scheduled Maintenance Procedures Checklist D Procedures D 1 Check the Boom Wear Pads Maintaining the boom wear pads in good condition is essential to safe machine operation Wear pads are placed on boom tube surfaces to provide a low friction replaceable wear pad between moving parts Improperly shimmed wear pads or continued use of extremely worn wear pads may result in component damage and unsafe operating conditions 1 Start the engine from the ground controls
91. failure could result in a machine tip over Component damage may also result if problems are not discovered and repaired in a timely fashion Note The tires on this machine are foam filled and do not need air added to them with the exception of High Flotation tires 1 Check all tire treads and sidewalls for cuts cracks punctures and unusual wear 2 Check each wheel for damage bends and cracked welds 3 Check each lug nut for proper torque Refer to Section 2 Specifications A TEREX Part No 1258748 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 drive hub disconnect cap to be sure it is in the engaged position disengaged position engaged position 2 Be sure the free wheel valve on the drive pump is closed clockwise Note The free wheel valve is located on the drive pump a drive pump b screwdriver lift pump d free wheel valve Note The free wheel valve should always remain closed Section 3 Scheduled Maintenance Procedures November 2014 CHECKLIST B PROCEDURES B 10 Check the Drive Hub Oil Level and Fastener Torque Failure to maintain proper drive hub oil levels may cause the machine to perform poorly and continued use may c
92. fasteners Open the control box lid 6 Locate the ALC 1000 circuit board mounted to the inside of the platform control box Genie 2 80 60 7 Attach a grounded wrist strap to the ground screw inside the platform control box AWARNING Electrocution hazard Contact with electrically charged circuits could result in death or serious injury Remove all rings watches and other jewelry Component damage hazard Electrostatic discharge ESD can damage printed circuit board components Maintain firm contact with a metal part of the machine that is grounded at all times when handling printed circuit boards OR use a grounded wrist strap 8 Carefully disconnect the wire connectors from the circuit board 9 Remove the ALC 1000 circuit board mounting fasteners 10 Carefully remove the ALC 1000 circuit board from the platform control box How to Remove the LED Circuit Board 1 Push in the red Emergency Stop button to the off position at both the ground and platform controls 2 Remove the platform control box lid retaining fasteners Open the control box lid Part No 1258748 November 2014 Section 4 Repair Procedures 3 Locate the LED circuit board mounted to the inside of the platform control box lid AWARNING Electrocution hazard Contact with electrically charged circuits could result in death or serious injury Remove all rings watches and other jewelry Component damage hazard Electrostatic discharg
93. filter 12 1 liters Starter motor Current draw normal load 140 200A Cranking speed 250 350 rpm Continuous improvement of our products is a Genie policy Product specifications are subject to change without notice Genie Part No 1258748 Z 80 60 2 9 Section 2 Specifications November 2014 SPECIFICATIONS Battery Auxiliary power units Type 6 DC Quantity 2 AH rating 285AH Reserve capacity 25A rate 745 minutes Battery Engine starting and control system Type 12V DC Group 31 Quantity 2 Cold cranking ampere 1000A Reserve capacity 6 25 rate 200 minutes Alternator output 80A 14V DC Fan belt deflection 3 8 to 1 2 inch 9 to 12 mm Continuous improvement of our products is a Genie policy Product specifications are subject to change without notice A TEREX COMPANY 2 10 Z 80 60 Part No 1258748 November 2014 Section 2 Specifications Deutz TD 2 9 L4 Engine Displacement Number of cylinders Bore and stroke 177 cu in 2 9 liters 4 3 6 x 4 3 inches 92 x 110 mm SPECIFICATIONS Oil viscosity requirements 22 F to 86 F 30 C to 30 C 5W 30 synthetic 4 F to 90 F 20 C to 32 C 10W 40 Above 23 F 5 C 20W 50 Horsepower 74 2 2600 rpm EM 55 3 kW 2600 rpm Units ship with 15W 40 Extreme operating temperatures may require the use of Firing order 1 3 4 2 alternative engine oils For oil requi
94. ft Ibs 22 Nm 6 Connector fitting c 11 ft lbs 15 Nm Check CBF Prevents oil flowing into generator 35 40 ft lbs 47 54 Nm CBC Part No 1258748 Z 80 60 4 89 Section 4 Repair Procedures November 2014 P m t MANIFOLDS 8 10 Traction Manifold 2WD The 2WD traction manifold is mounted inside the drive chassis at the circle end of the machine Index Schematic No Description Item Function Torque 1 Check valve 5 psi 0 34 bar Drive motor anti cavitation 30 35 ft lbs 41 47 Nm 2 Check valve 5 psi 0 34 bar EB Drive motor anti cavitation 30 35 ft lbs 41 47 Nm 3 Orifice 0 031 in 0 79 mm EG uu Brake and 2 speed circuit 4 Check ED nike Keeps brakes released in case of temporary loss of charge pressure 20 25 ft lbs 27 34 Nm 5 Solenoid valve 2 position way EE Brake release 26 30 ft lbs 35 41 Nm 6 Solenoid valve 2 position 3 way 2 speed drive motor shift 26 30 ft Ibs 35 41 Nm 7 Relief valve 280 psi 19 3 bar EG 22 Charge pressure circuit 20 25 ft lbs 27 34 Nm 8 Shuttle valve position way Charge pressur
95. ft lbs 27 34 Nm 7 Flow regulator valve 1 0 3 8 JG Blue side steer cylinder retract 2 222222 1 20 25 ft lbs 27 34 Nm 8 Check ValVe eet tte ere JE us Load sensing circuit blue side steer cylinder retract 8 10 ft lbs 11 14 Nm 9 Check valve 3 pes Prevents steer cylinder from moving when not steering 20 25 ft lbs 27 34 Nm 10 Check valve Prevents steer cylinder from moving when not steering 20 25 ft lbs 27 34 Nm Genie 4 78 Z 80 60 Part No 1258748 November 2014 Section 4 Repair Procedures MANIFOLDS JJ 00 9 Genie Part No 1258748 Z 80 60 4 79 Section 4 Repair Procedures November 2014 i MANIFOLDS This list continues on the next page Two Wheel Steer and Oscillate Manifold continued Index Schematic No Description Item Function Torque 11 Flow regulator valve 1 5 5 7 L min Yellow side steer cylinder extend 00 20 25 ft lbs 27 34 Nm 12 Flow regulator valve 1 0 3 8 L min JB Yellow side steer cylinder retract 22 20 25 ft lbs 27 34 Nm 13 Check valve 65 psi 4 5 bar Prevents
96. gpm 9 5 cc 11 4 L min Flow rate 2300 rpm 5 gpm Oscillate manifold 19 L min Oscillate relief pressure item BE or CH 800 psi 55 1 bar Continuous improvement of our products is a Genie policy Product specifications are subject to change without notice Genie A TEREX COMPANY Part No 1258748 Z 80 60 Section 2 Specifications November 2014 SPECIFICATIONS Drive manifold Valve Coil Resistance Hot oil relief pressure 280 psi Specifications Note The following coil resistance specifications Brakes are at an ambient temperature of 68 F 20 C As valve coil resistance is sensitive to changes in air Brake release pressure 215 psi temperature the coil resistance will typically 14 8 bar increase or decrease by 4 for each 18 F 20 C Drive motors that your air temperature increases or decreases from 68 F 20 C Displacement per revolution variable 0 9 to 2 7 cuin 2 speed motor 14 710 45 00 Proportional solenoid valve 12V DC 480 Hydraulic tank return filter schematic items G W and AB High pressure filter Beta gt 200 Proportional solenoid valve 12V DC 9Q schematic items R High fi i 2 us 3 position 4 way solenoid valve 12 DC 9Q schematic items BA BB CA CB CP CQ Medium pressure filter Betas 200 GB GP and GQ Medium pressure filter 51 psi 3 position 4 way solenoid valve 10V DC 6 3 Q
97. lift cylinder barrel end pivot pin 7 Use 8 soft metal drift to remove the and let the cylinder hang down AWARNING hazard The jib boom could become unbalanced and fall if not properly supported when the jib boom lift cylinder barrel end pivot pin is removed 8 Secure the jib boom bellcrank to prevent it from moving 9 Remove the hose and cable clamp from the jib boom pivot pin 10 Remove the pin retaining fastener from the jib boom pivot pin Do not remove the pin 11 Place blocks under the platform leveling cylinder for support Protect the cylinder from damage 12 Use a soft metal drift to remove the pin Carefully remove the jib boom from the primary boom Crushing hazard The jib boom AWARNING could become unbalanced and fall if not properly supported when removed from the machine PartNo 1258748 Genie Z 80 60 JIB BOOM COMPONENTS 13 Remove the pin retaining fasteners from the jib boom lift cylinder rod end pivot pin Do not remove the pin 14 Slide both of the jib boom leveling arms off of the jib boom cylinder rod end pivot pin and lay them off to the side 15 Attach a lifting strap from an overhead crane to the lug on the rod end of the jib boom lift cylinder 16 Attach a lifting strap from a second overhead crane to the jib boom bellcrank 17 Use a soft metal drift to remove the jib boom lift cylinder rod end pivot pin Remove the jib boom lift cylinder and jib
98. liters Number of cylinders 4 Bore and stroke 3 78 x 4 92 inches SPECIFICATIONS Oil viscosity requirements 22 F to 86 F 30 C to 30 C 5W 30 synthetic 4 F to 104 F 20 C to 40 C 10W 40 Above 5 F 15 C 15W 40 96 125 mm Units ship with 15W 40 Horsepower Extreme operating temperatures may require the use of Net intermittent 2400 rpm 74 55 kw alternative engine oils For oil requirements refer to the Engine Operator Handbook on your machine Induction system turbocharged Oil emperatursawitch Firing onset Installation torque 8 18 ft lbs Low idle 1500 rpm 11 24 Nm 383 Hz Oil temperature switch point 275 F High idle 2350 rpm 135 C 599 Hz Oil pressure switch ONTA 4 Installation torque 8 18 ft lbs Compression pressure 11 24 Nm Pressure psi or bar of the lowest cylinder must be at least 75 of the highest cylinder Oil pressure switch point 22 psi 1 5 bar Governor centrifugal mechanical ae Fuel injection system Valve clearance cold AEN Injection pump make Motorpal Intake 0 012 in FEN 0 3 mm Injection pump pressure maximum 15 000 psi Exhaust 0 020 in 1034 bar 0 5 mm 7 Injector opening pressure 3046 psi Lubrication system 210 bar Oil pressure hot 40to 60psi Fuel requirement eee For fuel requirements refer to the engine Operator s Oil capacity 12 8 quarts Manual on your machine including
99. not differ by a minimum of 20 the coil and or its internal diode are faulty and the coil should be replaced Part No 1258748 November 2014 Section 4 Repair Procedures Turntable Rotation Components 9 1 Turntable Rotation Assembly How to Remove a Turntable Rotation Assembly Note When removing a hose assembly or fitting the O ring on the fitting and or hose end must be replaced and then torqued to specification during installation Refer to Section 2 Hydraulic Hose and Fitting Torque Specifications Note Perform this procedure with the platform between the circle end tires and with the machine on a firm level surface 1 Secure the turntable from rotating with the turntable rotation lock pin unlocked locked 2 Remove the ground controls side fixed turntable cover 3 Tag disconnect the hydraulic hoses from the turntable rotation motor Cap the fittings on the motor Genie Part No 1258748 Z 80 60 4 Attach a lifting strap from an overhead crane or other suitable lifting device to the lifting eye on the turntable rotation assembly 5 Remove the turntable rotator mounting bolts and remove the turntable rotation assembly from the machine 6 Repeat steps 3 through 5 for the other turntable rotation assembly Tip over hazard If the turntable rotation lock pin is not properly installed machine stability is compromised and the machine could tip over when the drive hub is removed from t
100. not fully operational AWARNING Collision hazard Be sure that the machine is not in free wheel or partial free wheel configuration See B 8 Confirm the Proper Brake Configuration Note Select a test area that is firm level and free of obstructions 1 Mark a test line on the ground for reference 2 Start the engine from the platform controls 3 Press the engine rpm select button until the foot switch activated high idle rabbit and foot switch symbol is selected then lower the boom into the stowed position 4 Choose a point on the machine i e contact patch of a tire as a visual reference for use when crossing the test line 5 Bring the machine to top drive speed before reaching the test line Release the drive controller when your reference point on the machine crosses the test line 6 Measure the distance between the test line and your machine reference point Refer to Section 2 Specifications Note The brakes must be able to hold the machine on any slope it is able to climb A TEREX COMI Part No 1258748 CHECKLIST B PROCEDURES B 16 Test the Drive Speed Stowed Position Proper drive function movement is essential to safe machine operation The drive function should respond quickly and smoothly to operator control Drive performance should also be free of hesitation jerking and unusual noise over the entire proportionally controlled speed range Note Select a test area that is firm level and
101. number SEBU8609 Perkins 800D Series Operation Manual Genie part number 111332 Perkins 404F Series Operation Manual Genie part number 1251562 Part No 1258748 2014 Section 3 Scheduled Maintenance Procedures Checklist E Procedures E 1 Test or Replace the Hydraulic Oil Replacement or testing of the hydraulic oil is essential for good machine performance and service life Dirty oil and suction strainers may cause the machine to perform poorly and continued use may cause component damage Extremely dirty conditions may require oil changes to be performed more often Note Before replacing the hydraulic oil the oil may be tested by an oil distributor for specific levels of contamination to verify that changing the oil is necessary If the hydraulic oil is not replaced at the two year inspection test the oil quarterly Replace the oil when it fails the test Note Perform this procedure with the boom in the stowed position 1 GM Ford and Continental models Turn the valve on the LPG tank clockwise to the off position if equipped Then slowly disconnect the hose from the LPG tank 2 GM Ford and Continental models Open the clamps from the LPG tank straps and remove the LPG tank from the machine if equipped 3 Models with hydraulic tank shut off valves Locate the two hydraulic tank valves at the hydraulic tank through the access hole underneath the turntable Close the valve
102. of adequate capacity Refer to Section 2 Specifications Install the drive hub Torque the drive hub mounting bolts to specification Refer to Section 2 Specifications Install the brake and motor onto the drive hub Torque the motor brake mounting bolts to specification Refer to Section 2 Specifications Fill the hub with oil from the side hole until the oil level is even with the bottom of the hole Apply pipe thread sealant to the plug Install the plug Adjust turntable rotation gear backlash Refer to Repair Procedure 9 1 How to Adjust the Turntable Rotation Gear Backlash Section 3 Scheduled Maintenance Procedures November 2014 CHECKLIST D PROCEDURES D 6 Replace the Hydraulic Filter Elements Genie requires that this procedure be performed annually or every 1000 hours whichever comes first Perform this procedure more often if dusty conditions exist Replacement of the hydraulic filters is essential for good machine performance and service life A dirty or clogged filter may cause the machine to perform poorly and continued use may cause component damage Extremely dirty conditions may require that the filter be replaced more often Bodily injury hazard Beware of ACAUTION hot oil Contact with hot oil may cause severe burns Note Perform this procedure with the engine off Hydraulic return filter 1 Open the ground controls side turntable cover and locate the hydraulic return filter mounte
103. of service bypass is required The Service Bypass mode will allow the platform to be manually leveled when an out of envelope condition exists In the event that the platform angle is greater than 10 from level the boom angle and platform level functions are disabled Use of the Service Bypass mode will allow the platform to be manually adjusted to within the normal operating envelope 4 5 Only auxiliary power can be used to correct an out of level platform fault 1 Turn the engine off 2 Turn the main key switch to ground controls Remove the key from the main key switch and insert the key into the service bypass recovery key switch Note The main key switch must remain in the ground control position 3 Turn the service bypass recovery key switch to the service bypass position Section 4 Repair Procedures November 2014 GROUND CONTROLS 4 Using auxiliary power operate the platform level toggle switch to level the platform Note Only the auxiliary power unit can be used to correct an out of level platform fault 5 Turn the service bypass recovery key switch to the run position 6 Remove the key from the service bypass recovery key switch and insert the key into the main key switch Note If the Service Bypass function has been used there may be faults with the machine Check the LCD screen on the ground control box for machine faults then contact trained service personnel How to Use the Recovery
104. reset the function speed to original factory settings begin with step 10 Note Perform this procedure with the machine parked on a firm level surface which is free of obstructions 1 Start the engine from the platform controls 2 Press down the foot switch Note Be sure the engine rpm is set to foot switch activated high idle Function threshold 3 Select a joystick controlled function that needs to have the threshold set 4 Slowly move the joystick off center in either direction just until the machine function starts to move then move the joystick very slowly towards the neutral or center position just before the machine function stops Do not let go of the joystick 5 While holding the joystick in position press the engine start button at the platform controls to set the joystick controller threshold PartNo 1258748 Genie Z 80 60 PLATFORM CONTROLS 6 Repeat steps 3 through 5 for each joystick controlled machine function primary boom up down and turntable rotate left right primary boom extend retract secondary up down and extend retract drive forward reverse and steer left right 7 Once the threshold has been set press and hold the engine start button until the engine shuts off Do not press the red Emergency Stop button Note Approximately 3 seconds after the engine shuts off the alarm at the ground controls will sound to indicate the threshold settings are being saved in mem
105. slowly to allow the oil pressure to dissipate gradually Do not allow oil to squirt or spray Fitting Torque Specifications 3 Remove the pump mounting fasteners 1 Models without hydraulic tank shutoff valves Remove the drain plug from the hydraulic tank and completely drain the tank into a suitable container Refer to Section 2 Specifications Models with hydraulic tank shutoff valves Close the two hydraulic tank valves located at the hydraulic tank Component damage hazard The engine must not be started with the hydraulic tank shutoff valves in the closed position or component damage will occur If the tank valves are closed remove the key from the key switch and tag the machine to inform personnel of the condition open closed Part No 1258748 Z 80 60 Genie Carefully remove the pump Component damage hazard Be sure to open the two hydraulic tank valves if equipped and prime the pump after installing the pump See 7 2 How to Prime the Pump Section 4 Repair Procedures November 2014 HYDRAULIC PUMPS 7 2 Drive Pump The drive pump is a bi directional variable displacement piston pump The pump output is controlled by the electronic displacement controller EDC located on the pump Any internal service to the pump should only be performed at an authorized Sauer Danfoss service center Contact the Genie Industries Service Department to locate your local authorized service center H
106. steer sensor cover retaining fasteners Do not remove them 6 Rotate the steer sensor cover either clockwise or counterclockwise Measure the distance between the inside of tire and the chassis side plate on both sides of the axle GE a Peak Square end 1 G Circle end Measure here 7 Repeat step 4 until the tire is parallel with the chassis 8 Tighten the steer sensor cover fasteners 9 Repeat steps 2 through 6 for the other square end steer sensor 4 102 Genie 2 80 60 Circle end steer sensors 10 At the platform controls press the square end steer mode button 11 Locate the steer sensor on top of the yoke pivot pin 12 Loosen the steer sensor cover retaining fasteners Do not remove them 13 Rotate the steer sensor cover either clockwise or counterclockwise Measure the distance between the inside of tire and the chassis side plate on both sides of the axle Measure here 8 A 2 c Circle end Square end C4 B 2 Ss 57 4 gt Y 4 14 Repeat step 4 until the tire is parallel with the chassis 15 Tighten the steer sensor cover fasteners 16 Repeat steps 9 through 13 for the other circle end steer sensor 17 At the platform control
107. the cable track PartNo 1258748 Genie Z 80 60 BOOM COMPONENTS 16 Support the end cover from the secondary boom at the pivot end of the primary boom 17 Remove the cover retaining fasteners and remove the cover from the machine AWARNING Crushing hazard The secondary boom hose cover could become unbalanced and fall if not properly supported when removed from the machine 18 Tag disconnect and plug each hydraulic hose from the bulkhead fittings that lead to the cable track Cap the fittings AWARNING ie injury hazard Spraying ydraulic oil can penetrate and burn skin Loosen hydraulic connections very slowly to allow the oil pressure to dissipate gradually Do not allow oil to squirt or spray 19 Tag and disconnect each electrical connector to wiring that leads to the cable track 20 Pull all hoses and electrical cables through the opening in the primary boom at the pivot end 21 Secure the upper and lower cable tracks together 22 Attach a lifting strap from an overhead crane to the cable track 23 Remove all cable track mounting fasteners 24 Carefully remove the cable track from the machine and lay it on a structure capable of supporting it Component damage hazard The boom cable track can be damaged if it is twisted Component damage hazard Cables and hoses can be damaged if they are kinked or pinched Section 4 Repair Procedures November 2014 BOOM COMPONENTS How to Repair
108. the off position with the key removed Wheels chocked All external AC power supply disconnected from the machine PartNo 1258748 Genie Z 80 60 4 1 Repair Procedures About This Section Most of the procedures in this section should only be performed by a trained service professional in a Suitably equipped workshop Select the appropriate repair procedure after troubleshooting the problem Perform disassembly procedures to the point where repairs can be completed To re assemble perform the disassembly steps in reverse order Symbols Legend A Safety alert symbol used to alert personnel to potential personal injury hazards Obey all safety messages that follow this symbol to avoid possible injury or death Used to indicate the presence of an imminently hazardous situation which if not avoided will result in death or serious injury AWARNING Used to indicate the presence of a potentially hazardous situation which if not avoided could result in death or serious injury With safety alert symbol used to ACAUTION indicate the presence of a potentially hazardous situation which if not avoided may cause minor or moderate injury Used to indicate the presence of a potentially hazardous situation which if not avoided may result in property damage Note Used to indicate operation or maintenance information Indicates that a specific result is expected after performing a series of step
109. to poor engine performance and component damage Oil level check Coolant level check Oil fuel and coolant systems check for leaks e Fuel pre filter drain water Air filter discharge valve clean Fuel filter separator check drain Exhaust system inspect Required maintenance procedures and additional engine information are available in the Deutz 2011 Series Operation Manual Deutz part number 0312 3547 ORthe Deutz 2 9 L4 Series Operation Manual Deutz part number 0312 3893 Deutz 2011 Series Operation Manual Genie part number 139320 Deutz 2 9 L4 Series Operation Manual Genie part number 1251561 Section 3 Scheduled Maintenance Procedures November 2014 CHECKLIST A PROCEDURES A 6 Perform Engine Maintenance Perkins Models Engine specifications require that this procedure be performed daily or every 8 hours whichever comes first Proper engine maintenance following the engine manufacturer s maintenance schedule is essential to good engine performance and service life Failure to perform the maintenance procedures can lead to poor engine performance and component damage Oil level check e Coolant level check Oil fuel and coolant systems check for leaks Fuelpre filter drain water Air filter discharge valve clean Perkins 800D Series Operation Manual Perkins part number SEBU8324 OR the Perkins 404F Series Operation Manual Perkins part number SEBU8609 Per
110. to step 2 Result Each wear pad does not meet minimum specification Replace any wear pad that does not meet minimum specification Proceed to step 2 Extend the boom until the wear pads are accessible Loosen the wear pad mounting fasteners Install the new shims under the wear pad to obtain zero clearance and zero drag Tighten the mounting fasteners Extend and retract the boom through an entire cycle Check for tight spots that could cause binding or scraping Note Always maintain squareness between the outer and inner boom tubes Part No 1258748 Genie Z 80 60 Section 4 Repair Procedures Wear Pad Specifications Primary boom wear pad specifications Top bottom and side wear pads platform end of boom Side and bottom wear pads pivot end of boom Top wear pads pivot end of boom Secondary boom wear pad specifications Top and side wear pads extension end of boom Bottom wear pads extension end of boom Top wear pads pivot end of boom Bottom and side wear pads pivot end of boom BOOM COMPONENTS Minimum 5 8 inch 15 9 mm 1 2 inch 12 7 mm 5 8 inch 15 9 mm Minimum 5 8 inch 15 9 mm 1 2 inch 12 7 1 2 inch 12 7 mm 7 8 inch 22 2 mm Section 4 Repair Procedures November 2014 BOOM COMPONENTS How to Remove the Primary Boom AWARNING 2odily injury hazard This procedure requires specific repair skills lifting equipment
111. valve 2 position 3 way FB 2 speed drive motor shift 26 30 ft Ibs 35 41 Nm 3 Solenoid valve 2 position 3 way EG usd Brake release 26 30 ft lbs 35 41 Nm 4 Check valve FD Keeps brakes released in case of temporary loss of charge pressure 20 25 ft Ibs 27 34 Nm 5 Shuttle valve 3 position way EE Charge pressure circuit that directs hot oil out of low pressure side of drive pump 30 35 ft lbs 41 47 Nm 6 Relief valve 280 psi 19 3 bar EE Lau Charge pressure circuit 20 25 ft lbs 27 34 Nm 7 Orifice 0 030 0 76 mm FG au Brake and 2 speed circuit 8 Check 2 4222 aue Drive motor anti cavitation 20 25 ft lbs 27 34 Nm 9 Check Drive motor anti cavitation 30 35 ft lbs 41 47 Nm 10 Flow divider combiner valve EJ o Controls flow to square end drive motors in forward and reverse 90 100 ft Ibs 122 136 Nm 11 Check valve 5 psi 0 34 bar Drive motor anti cavitation 20 25 ft lbs 27 34 Nm 12 Bi directional flow control valve 2 GPM 7 6 EL uus Equalizes pressure on both sides of divider combiner valve FJ 30 35 ft Ibs
112. whether or not the Emergency Stop button on the platform controls is in the on or OFF position This function is particularly useful if the operator at the platform controls cannot return the boom to the stowed position 1 Push in the platform red Emergency Stop button to the off position 2 Start the engine from the ground controls 3 Atthe ground controls operate each boom function through a partial cycle O Result All boom functions should operate a drive hub b 2 If necessary add oil until the oil level is even with the bottom of the plug hole opening 3 Apply pipe thread sealant to the plug and install the plug in the drive hub 6 Checkthe torque of the turntable rotate drive hub mounting fasteners Refer to Section 2 Specifications A TEREX COMPANY Part No 1258748 Z 80 60 3 25 Section 3 Scheduled Maintenance Procedures November 2014 CHECKLIST B PROCEDURES B 12 Test the Platform Self leveling Automatic platform self leveling throughout the full cycle of primary boom raising and lowering is essential for safe machine operation The platform is maintained level by the communication between the platform level sensor and the turntable level sensor If the platform becomes out of level the computer at the ground controls will open the appropriate solenoid valve s at the platform manifold to maintain a level platform A platform self leveling failure creates a
113. 00000 Cc PIN NUMBERING FOR 11 C111LRS OR 12 C111RFS OR 13 1111 5 OR 14 VLVRET2 BR 15 V32BRK WH RD 16 V36LRS BL 17 V37LRS BL BK 18 V36RFS BL 19 P110RT BK 20 P109ANG GR WH 21 V37RFS BL BK 22 V36LFS BL J21 23 PIN BLACK CONNECTOR 23 PIN CONNECTOR PCON PCON DCON DCON PLATFORM PLATFORM DRIVE CHASSIS DRIVE CHASSIS CONTROLLER CONTROLLER CONTROLLER CONTROLLER J22 J21 J32 J31 1 VLVRET7 BR 1 GND PCON BR 1 VLVRET BR 1 GND DCON BR 2 UNUSED 2 P52PCON BL RD 2 V61AXRT GR 2 P21DCON WH 3 C17PRL GR 3 UNUSED 3 V60AXEX GR WH 3 P53LS RD 4 C18PRR GR BK 4 S56PRV RD 4 V29MS RD WH 4 UNUSED 5 C43JU GR 5 UNUSED 5 UNUSED 5 S56PRV RD 6 C44JD GR BK 6 UNUSED 6 V52AFV BL RD 6 C61AXRT GR 7 C14PLU OR 7 P56PRV RD 7 V52REV BL RD 7 UNUSED 8 C15PLD OR BK 8 UNUSED 8 V36RRS BL 8 AXLE RET GND 9 UNUSED 9 UNUSED 9 V37RRS BL BK 9 C61LS GR 10 R90PXS RD BK 10 D80SHIELD 10 C111RRS OR 10 D80SHLD 11 9232 12 RS232 TXD 13 BOOT 14 UNUSED 15 C61LS A GR 16 UNUSED 17 D81CAN GR 18 D82CAN YL 19 RS232 GND 20 UNUSED 21 UNUSED 22 UNUSED 22 PTSRET BR 22 UNUSED 23 PIN 23 P87PTS RD 23 P23PCON BK CONNECTORS 23 V37LFS BL BK 23 C61LS A GR Genie 6 10 Z
114. 016 2 1259 Amount of air is not plausible to EGR cooler downstream pump speed warning threshold exceeded 524016 2 1260 Calculated amount of air is not 523960 1 1012 Physical range check low for plausible to HFM reading EGR cooler downstream temp 524016 11 1258 sensor electrical fault 523960 1 1459 High exhaust gas temperature EGR cooler downstream shut 524021 11 1263 Burner fuel line pipe leak off threshold exceeded behind Shut Off Valve 523980 14 1187 Bad quality of reduction 524024 11 1302 Deviation of the exhaust gas agent detected temp setpoint to actual value downstream DOC too high 523981 11 918 Urea tankwithoutheating plausibility error 523982 0 360 Powerstage diagnosis disabled high battery voltage 524029 2 1432 Timeout Error of CAN Receive Frame ComEGRActr exhaust 523982 1 361 Powerstage diagnosis disabled gas recirculation positioner low battery voltage 524030 7 1440 EGR actuator internal error 523988 3 1245 Charginglamp short circuit to battery 524031 13 1441 EGRactuator calibration error 523988 4 1246 Charginglamp 524032 2 1442 EGR actuator status message short circuit to ground EGRCust is missing 523988 5 1243 Charginglamp open load 524083 7 1443 EGRactuator due to overload in Save Mode 523988 12 1244 Charginglamp over temp 524034 3 1438 Discseparator 523998 4 1327 Injector cylinder bank 2 slave short circuit to battery short circuit 524034 4 1439 Discseparator 523999 12 132
115. 10 degrees from gravity and will disable the primary and secondary boom up down functions and the platform level up down functions LSS2AO Limit switch Secondary Boom 2 Angle Operational Switch Secondary boom angle full extension angle up all the way secondary boom extend allowed LSS3AO Limit switch Secondary Boom 3 Angle Operational Switch Secondary boom elevated to 30 35 degrees Used to switch platform primary boom leveling parameters LSS2AS Limit switch Secondary Boom 2 Angle Safety Switch Secondary boom angle full extension angle up all the way secondary boom extend allowed Backup switch for LSS2AO Part No 1258748 Genie 2 80 60 me LSS2AS 2 1 LSS1TRO JIB T LSS3AO BOOM TURNTABLE e ANGLE SENSOR PLATFORM ANGLE Ij LSA10S 1 LSS1RO Limit switch Secondary Boom 1 Retract Operational Switch Secondary boom fully retracted secondary boom down allowed LSS1RS Limit switch Secondary Boom 1 Retract Safety Switch Secondary boom fully retracted secondary boom down allowed Backup switch for LSS1RO 155140 Limit switch Secondary Boom 1 Angle Operational Switch Open when the secondary boom is fully lowered closes when the boom is raised out of the stowed position This switch limits the drive speed and disables the drive motor destroke The other contacts close when the boom is fully lowered allowing th
116. 1AR adjustment value programming IMA injector 3 in firing order 523769 9 284 Timeout Error of CAN Receive Frame Passive TSC1AR 523898 13 562 check of missing injector adjustment value programming 523770 9 285 Timeout Error of CAN Receive IMA injector 4 in firing order Frame Passive TSC1DE 523910 6 1261 Air Pump over current 523776 9 291 Timeout Error of CAN Receive Frame TSC1TE active 523913 3 74 Sensor error glow plug control diagnostic line voltage signal 523777 9 292 Passive Timeout Error of CAN range check high Receive Frame TSC1TE Setpoint 523913 4 75 Sensor error glow plug control diagnostic line voltage signal 523778 9 293 Active Timeout Errorof CAN range check low Receive Frame TSC1TR 523914 3 78 Glow plug control short circuit 523779 9 294 Passive Timeout Error of CAN to battery Receive Frame TSC1TR 523914 4 79 Glow plug control short circuit 523788 12 299 TimeoutError of CAN Transmit to ground Frame TrbCH Status Wastegate 523914 5 76 Glow plug control open load 523793 9 202 TimeoutErrorof CAN Receive 523914 5 1216 Glow plug control release line Frame UAA10 AGS sensor short circuit error service message 523914 11 1217 Glow plug control internal error 523794 9 203 TimeoutErrorof CAN Receive Frame UAA11 523914 12 77 Glow plug control powerstage AGS sensor data overtemperature 523895 13
117. 2 613 Internal ECU monitoring home mode exceeded PRV detection reported error 523470 11 831 The PRV 523612 12 614 Internal monitoring this operating point with a detection reported error pressure shock X 523612 12 615 Internal ECU monitoring 523470 11 832 Railpressure out of tolerance detection reported error range 8 523612 12 616 Internal monitoring 523470 12 828 OpenPressure Relief Valve detection reported error PRV shut off condition ST 523612 12 617 Internal ECU monitoring 523470 12 829 OpenPressure Relief Valve detection reported error PRV warning condition 523612 12 618 Internal ECU monitoring 523470 14 830 Pressure Relief Valve PRV is detection reported error open 523612 12 619 Internal ECU monitoring 523550 12 980 T50 start switch active for detection reported error too lon 3 523612 12 620 Internal ECU monitoring 523601 13 948 Sensorsupply voltage monitor detection reported error 3error ECU E 523612 12 621 Internal ECU monitoring 523603 9 126 TimeoutErrorof CAN Receive detection reported error Frame AMB Ambient Temperature Sensor 523612 12 623 Internal ECU monitoring detection reported error 523605 9 300 TimeoutErrorof CAN Receive Frame TSC1AE 523612 12 624 Internal ECU monitoring Traction Control detection reported error 523606 9 301 TimeoutErrorof CAN Receive 523612 12 625 Internal ECU monitoring Frame TSC1AR Retarder detection reported error 5
118. 210 ft lbs 284 Nm Drive motor mounting bolts lubricated 80 ft Ibs use blue thread locking compound 108 4 Nm Drive motor mounting bolts dry 110 ft Ibs 149 Nm Drive hub oil plug O ring seal 13 ft Ibs 18 Nm Continuous improvement of our products is a Genie policy Product specifications are subject to change without notice Genie A TEREX COMI Part No 1258748 Section 2 Specifications November 2014 SPECIFICATIONS Hydraulic Hose and Fitting Torque Specifications Your machine is equipped with Parker Seal Lok fittings and hose ends Genie specifications require that fittings and hose ends be torqued to specification when they are removed and installed or when new hoses or fittings are installed Seal Lok Fittings hose end ORFS SAE Dash size Torque 4 10 ft lbs 13 6 Nm 6 30 ft lbs 40 7 Nm 8 40 ft lbs 54 2 Nm 10 60 ft lbs 81 3 Nm 12 85 ft lbs 115 Nm 16 110 ft lbs 150 Nm 20 140 ft lbs 190 Nm 24 180 ft lbs 245 Nm JIC 37 Fittings swivel nut or hose connection SAE O ring Boss Port tube fitting installed into Aluminum all types SAE Dash size Torque Ne fitting Adj 4 14 ft lbs 19 Nm 6 23 ft lbs 31 2 Nm 8 36 ft lbs 54 2 Nm 10 62 ft lbs 84 Nm 12 84 ft lbs 114 Nm 16 125 ft lbs 169 5 Nm 20 151 ft lbs 204 7 Nm 24 184 ft lbs 249 5 Nm Jambnut
119. 23612 12 387 Internalsoftware error 523612 12 627 Internal ECU monitoring injection cut off detection reported error 523612 12 612 Internal ECU monitoring 523612 12 628 Internal ECU monitoring detection reported error detection reported error PartNo 1258748 Z 80 60 5 21 Section 5 Fault Codes November 2014 m J JP DEUTZ TD 2 9 L4 ENGINE FAULT CODES SPN Suspect Parameter Number FMI Failure Mode Identifier KWP Keyword Protocol SPN FMI KWP Description SPN FMI KWP Description 523612 12 637 Internal ECU monitoring 523615 596 Metering unit Fuel System detection reported error short circuit to battery low side 523612 12 1170 Internalsoftware error ECU 523615 4 595 Metering unit Fuel System short circuit to ground high side 523612 14 973 Softwarereset CPU SWReset 0 523615 4 597 Metering Unit Fuel System 523612 14 974 Softwarereset CPU SWReset 1 short circuit to ground low side 523612 14 975 Softwarereset CPUSWReset 2 593615 5 592 Metering unit Fuel System 523613 0 856 Maximum positive deviation of open gag rail pressure exceeded 523615 12 593 Metering unit Fuel System RailMeUnO powerstage overtemperature 523613 0 857 Maximum positive deviation of 523619 2 488 Physical range check high for rail pressure in metering unit exhaust gas temperature exceeded RailMeUn1 upstrem
120. 3 Remove the pin retaining fasteners from the oscillate cylinder rod end pivot pin Use a soft metal drift to remove the pin 4 Attach a lifting strap from an overhead crane to the barrel end of the oscillating cylinder 5 Remove the pin retaining fasteners from the oscillate cylinder barrel end pivot pin Use a soft metal drift to remove the pin Crushing hazard The oscillate ACAUTION cylinder may become unbalanced and fall if not properly supported when removed from the machine 6 Remove the oscillate cylinder from the machine 4 105 Section 4 Repair Procedures November 2014 m S1 AXLE COMPONENTS This page intentionally left blank Genie 4 106 Z 80 60 Part No 1258748 November 2014 Section 5 Fault Codes Observe and Obey Troubleshooting and repair procedures shall be completed by a person trained and qualified on the repair of this machine Immediately tag and remove from service damaged or malfunctioning machine Repair any machine damage or malfunction before operating the machine Unless otherwise specified perform each repair procedure with the machine in the following configuration Machine parked on a firm level surface Boom in stowed position Turntable rotated with the boom between the circle end yellow arrow wheels Turntable secured with the turntable rotation lock pin Key switch in the off position with the key re
121. 4 Repair Procedures S B DISPLAY MODULE To Enter Information Displayed With the key Metric English measurement units Use buttons to change Switch off Display Language English German French Spanish Portuguese Italian Dutch and Swedish Check new translations Check scrolling of messages in Spanish with more than 75 characters Drive With the key Forward Not Stowed Drive Speed pct 120 default 50 min Functions switch off press and Forward Low Drive Speed pct 120 default 50 min hold the Forward High Drive Speed pct 12096 max and 5096 min button and 100 default turn the key Reverse Not Stowed Drive Speed pct 120 max and 50 min SWEN 100 default on position Release Reverse Low Drive Speed pct 120 max and 50 min and press High Drive Speed pct 120 max and 50 min 6 aja 100 default Drive Accel pct 125 max and 25 min 100 default Drive Decel pct 125 max and 25 min 100 default Speed limit on steer angle 100 max and 0 min 75 default Genie PartNo 1258748 Z 80 60 4 3 Section 4 Repair Procedures November 2014 DISPLAY MODULE Boom With the key Primary Boom Up speed Stowed 12096 max and 50 min Functions switch off 100 default Speeds press and Primary Boom Up speed not Stowed 12096 max and 50 min hold the o 100 default button and turn the Pri
122. 4 CONDUCTOR Es NOT USED 8 GA 5 CONDUCTOR e um Dee WHITE A BRASS GFI GREEN sd REEN A B C D EF SX CONTROLLER GREEN 12GA ie WH E BLACK _ um ENEE EEEE oe BR 1 12 GA 3 CONDUCTOR 12 GA 3 CONDUCTOR RD 2 4 ENCLOSURE 3 PIN COLOR CKT PCON DB1CAN GR t i BK PS2PCON A J21 18 gt D82CAN YL 2 WH C30EDC 3 WH BK 4 BR GND1 5 5 BK P52PCON 6 WH C30EDC A 9 J129 GR 7 WH BK C31EDC A YEL 8 PLUG 8 6 9 RD WH 10 GR BK V150HG r ae 1 1 1 11 BK P52PCON ss 5 5 5 12 BR GND TCON i mE 3 BR 1 DCON J129 MEC 0 RS232 CONNECTOR 5 8 8 8 TERM CIRCUIT 2 1 ATA 7 A A TxD RD WH 1159 11 52 TIME DELAY MODULE 1 4 SECOND B RxD 5 8 4 3 5 1240005 __ BATTERY C SNG 036 GND g g WM A2 SENSOR POWER 5 VDC 6 6 WW BATTERY JING 124 ohms 2COM 5 m 000 5 V151HG GR B1 VALVE 0 FWD COIL 4 5 5 82 VALVE 1 NC a6ND OMRON RELAY 1 a V150HG GR BK B3 DIGITAL OUTPUT BYPASS OMRON 5 SW INPUT E NA RS232TxD C1 TxD J129 B gt RS232RxD C2 RxD 9 C3 BOOT J159 5 5 V V TO EDC HARNESS V D1 ANALOG 0 JOYSTICK a AUXILIARY 8 m lt z 7 8
123. 5 FRONTLEFT FRONT RIGHT s 71 l E 8 we 4 e es STEERING STEERING 50 n 50 b D 280 psi L 4 1 ae 7 2 gpm 19 3 bar 1 Mi 2gpm 1 2 amp Ps is 7 61 5 7 6 L min PO OL OR eX xd g are Re 19 ioe tae 9 99 e pee ay pum i 7 Lin 5 7 L min B Lmin 57 Umi min 5 7 Lmin 2 4 dA t d eX HT eX d Its f 1 ___ 215 an 4 TL DELL p e o E 191 9 9 9 l l rt 5 1 sso OOM og 1 0 030 inch Uy ya IF 9 42 5 7 L min 3 8 L min 5 7 L min 3 8 um Som ot NUS 1 11 8 ad 1 9 e t 1 REAR OSCILLATE MANIFOLD r pre CDL 800 pel i LBRAKE EBRAKE l FOUR WHEEL STEER MANIFOLD 55 bar op L2SPEED L2SPEED 4 4 1 e R2SPEED R2SPEED OSCILLATE MANIFOLD CDR CDL RBRAKE TEST ROME 4 LLL 50077 I TWO WHEEL STEER MANIFOLD Genie PartNo 1258748 Z 80 60 6 39 November 2014 Section 6 Schematics E o PcC v e 1 Hydraulic Schematic 4 Wheel Drive 2
124. 5 5 5 vE 59 6 REMOTE DISABLE P o6 C226TEL BL 8 a Ei 17 1 8 lio 588445 220000 a a P 548 CO Qus KEY SWITCH PWR P1 04 P23PCON BK 4 gt 5 IGNITION STATUS 1 03 amp 21 1 2 a 2 GROUND p1 02 GND BR 5 5 gt 084992 _ lt z on 9 gt o SYS POWER P1 01 B1BAT RD ua v 26 lt i 93as lt Zz ovrasi as X HM OU HM WOU L3 5 1 5 m 5 PEE 1 ONE azo 18542 ain a assetd 0 aut fajon au ayn 3185521 QWHN 318SSZLA 7 6 uaao aasivu F D u340 aasivu HM n8SL 2 5 2 5 2 5 9 ay xIz 0 551 ste 25 lt 1 9 0 571090 8 0 5 HW 5 Hw o osf 5 92 5 92 5 92 Je ost aO zai I8 00 S1095 8 uo sqvo5 L amp a 7 lt q yah T aal dy adl 4 e OVISS1 xj al 5 oviss m l2 HM z HM a a 1959 g HWwa1aseztd 2 1 t 8 HMW Q T8S9ZLA 185921 Sua 40 u3do 138 5 ug
125. 50 610 166 225 331 450 442 600 458 622 612 830 909 1233 A TEREX COMPANY Z 80 60 Part No 1258748 2014 Section 3 Scheduled Maintenance Procedures Scheduled Maintenance Procedures Observe and Obey Maintenance inspections shall be completed by a person trained and qualified on the maintenance of this machine Scheduled maintenance inspections shall be completed daily quarterly six months annually and every two years as specified on the Maintenance Inspection Report AWARNING Failure to perform each procedure as presented and scheduled could result in death serious injury or substantial machine damage Immediately tag and remove from service damaged or malfunctioning machine Repair any machine damage or malfunction before operating machine Machines that have been out of service for a period more than three months must complete the quarterly inspection Unless otherwise specified perform each procedure with the machine in the following configuration Machine parked on a firm level surface Boom in the stowed position Turntable rotated with the boom between the circle end yellow arrow wheels Turntable secured with the turntable rotation lock pin Key switch in the off position with the key removed Wheels chocked All external AC power supply disconnected from the machine A TEREX COMI Part No
126. 500 psi 0 3 1 14 L min 4 73 L min 3 79 L min 4 751 3 791 27 9 172 LA Or Ld Tr a Ok 1300 psi 1300 psi 8 89 6 bar 89 6 bar Q4 LT 9 5 A A 3 X GCSE PMP2 1 2 9 5 1O HEE ao S 7 3625 psi J PTEST2 W 4 Hg 19 H iL an J isl l 17 t Vea 19 3000 psi Jl 1 3625 207 0 030 inch 250 0 2 1 x LSTEST 0 762 mm vel 9 PRL PRR PLU PLD JU JD 4 Qr i ice 1 FUNCTION T ori PUMP AUXILIARY Nu PUMP C8 7 pee ec E 4 114 LUmin 8 mi pr MEIST ET Ale H 17 H TA 1 72 bar 9 3200 psi H 1 5 4 2206 bar i x 5 TANK lo i osc T2 STR LS 5 TO OC PMAN 3 1 5 211416 HYDRAULIC ROTARY COUPLER 1 2B 3 1 5 2A 4 16 OSCILLATE CYLINDERS ot 44 12 A eee PLATFORM MANIFOLD 6 BEAR iA A FRONT LEFT FRONT RIGHT REAR LEFT REAR RIGHT NI RIGHT M o 1 T STEERING STEERING STEERING STEERING Ls 345 bor 71 5 221 MX ACCUMULATOR 82 con 4 us 44 IE 7 52 ET aa
127. 559 Check of missing injector 523919 2 1378 Sensorairpump airpressure adjustment value programming plausibility error UME neon Mining Ore 523920 2 1379 Sensor exhaust gas back 523896 13 560 check of missing injector pressure burner adjustment value programming plausibility error IMA injector 2 in firing order Genie A TEREX COMPANY Part No 1258748 Z 80 60 5 23 Section 5 Fault Codes m J JP DEUTZ TD 2 9 L4 ENGINE FAULT CODES November 2014 SPN Suspect Parameter Number FMI Failure Mode Identifier KWP Keyword Protocol SPN FMI KWP Description SPN FMI KWP Description 523922 7 1262 Burner Shut Off Valve 523936 12 169 TimeoutError of CAN Transmit blocked closed Frame EEC3VOL2 Engine send messages 523922 7 1264 Burner Shut Off Valve blocked open 523946 0 1158 Zerofuelcalibration injector 1 in firing order 523929 0 109 FuelBalance Control integrator maximum value exceeded injector 1 in firing order maximum value exceeded 523946 1 1164 Zerofuel calibration injector 1 in firing order 523929 1 115 FuelBalance Control integrator minimum value exceeded injector 1 in firing order minimum value exceeded 523947 1159 Zerofuelcalibration injector 2 in firing order injector 2 in firing order maximum value exceeded 523947 1 1165 Zerofuel ca
128. 60 How to Calibrate the Primary Boom Angle Sensor Note Perform this procedure on a firm level surface with the boom in the stowed position Note A digital level will be required to perform this procedure 1 Pull out the red Emergency Stop button at the platform controls From the ground control box turn the key switch to ground control and pull out the red Emergency Stop button while holding the enter button 3 or 4 seconds until the engine symbol appears on the display at the ground control box then release 2 Enter sensor calibration mode by pressing the buttons at the ground controls in the following sequence e 3 Press the scroll button until RESET PRIMARY BOOM ANGLE SENSOR is shown on the display 4 Press the plus button to select yes then press and hold the enter button to accept 5 Press the scroll button s until exir is shown on the display Press the plus button to select yes then press and hold the enter button a to accept Result The alarm should sound Result The alarm does not sound Repeat this procedure beginning with step 1 Part No 1258748 November 2014 Section 4 Repair Procedures 6 Loosen the Primary Boom Angle Sensor PBAS assembly bracket fasteners attached to the primary boom Loosen the wing nut and hex nut on the threaded rod to allow the threaded rod to move upward Tighten the fasteners 7 Set
129. 600 58 8 x8 d4 595 62 1 8 8 y9 auy 8 88 08 8 385 6606 2 8 8 88 08 29 581 622 1 9 8 HW Q3 8 HW QN 19 31 62 2 19 8 19 510 6 1 8 8 13 022 8 13 022 gt 62747 c NYNLIY AVT34 YIMOd 8 1340022 gt 0 62411 1 NYNLIY ay ymd0Z9 022 2 0 622r 1VN9IS AVT34 YIMOd y8 a1S 2 15990 8 61 660 IVN9IS 13VIS 3NION3 ENGINE ECU ECM CONNECTOR 2 80PIN PERKINS SUPPLIED HARNESS ES0508H a G 6 23 Z 80 60 Part No 1258748 November 2014 Section 6 Schematics Electrical Schematic Engine Options Perkins 404F 22T Engine Wiring 24 25 November 2014 Section 6 Schematics EE Electrical Schematic Engine Options Perkins 804D Engine Section 6 Schematics November 2014 peum JY s Mr Electrical Schematic Engine Options Perkins 804D Engine N M SYS_POWER 4224 GREY 8 TELEMATICS POWER HARN ENGINE BATGND BR 5 5 07 SYS BAT GND BATGND BR SPT5 03 BATECU GND BATECU RD SPT5 04 BATECU PWR 8 ISS on c ST ouo P224 03 STATUS S NOTE FOR ACTIVE LOW TELEMATICS SYSTEMS C229TEL IS CONNECTED TO 2 STUD ON RELAY BLOCK ACT
130. 7 5 N a D2 ANALOG 1 NC 2 PUMP 9 5 92 5 2 PIN COLOR CIRCUIT GR BK 8 D3 DIG IN 3 NC 8 g 55 mo 1 WH RD P52PCON A gt E1 NOT USED m 5 2 WH C30EDC GR 2 j E2 USED 5 3 wWH BK C31EDC NOT USED 2 5 4 BK RD GND1 AX f 5 BL RD P52PCON WH RD 6 RD C30EDC A p 7 RD BK WH 057 2 c 89 8 OR RD GND2 g 9 GRWH C45GEN 5 5 WH BK 9 X F1 DIGINO 10 p GR BK MISOHG 3 8 I A A 7 mE 2 F2 DIG IN 1 GENERATOR ON A A 11 RD WH P52PCON BK RD 5 5 PRESSURE SWITCH F3 DIGIN2 2 gt 8 12 GR GND 8 a AA Yrs SX CONTROLLER 8 st BYRD 2 A1159 7 3 C574 5 48 A 5 lt 5 gt RD E RD 1 RD BK 6 A A OR RD a 7159 12 GND Y75 2 PILOT PRESSURE SIGNAL 1041 27 lt FROM GENERATOR MANIFOLD RD WH ou a TTT EA DIVERTER MANIFOLD ES0508H m m 2 Genie 8 8 5 4 6 34 Z 80 60 Part No 1258748 November 2014 Section 6 Schematics _ Electrical Schematic Hydraulic Generator Options N M L K J l H G
131. 8 7 9 3 sec Stowed position 40 ft 40 45 sec 12 2 m 40 45 sec Raised or extended position Drive speed maximum models with Hi flotation tires 40 ft 13 6 14 5 sec 12 2 13 6 14 5 Stowed position 40 ft 62 70 sec 12 2 62 70 sec Raised or extended position Gradeability Refer to Operator s Manual Braking distance maximum High range on paved surface 6 ft 1 88m Continuous improvement of our products is a Genie policy Product specifications are subject to change without notice A TEREX COMI 2 2 Function speeds Primary boom up retracted retracted 35 to 65 60 to 70 seconds Primary boom down retracted retracted 35 to 65 75 to 85 seconds Secondary boom up retracted 38 to 48 seconds Secondary boom down retracted 38 to 48 seconds Primary boom up extended 35 to 65 80 to 96 seconds Primary boom down extended 35 to 65 80 to 96 seconds Primary Boom extend 48 to 52 seconds Primary Boom retract 38 to 42 seconds Jib Boom up 23 to 33 seconds Jib Boom down 21 to 31 seconds Platform Rotate 160 10 to 14 seconds Turntable rotate 360 boom fully retracted 114 to 126 seconds Turntable rotate 360 boom extended 200 to 240 seconds Part No 1258748 November 2014 Section 2 Specifications Hydraulic Oil Specifications Hydraulic
132. 8 Injector powerstage output short circuit to ground Slave defect 524034 5 1436 Disc Separator open load 524014 1 1254 Air pressure glow plug flush line below limit 524034 12 1437 DiscSeparator powerstage over temperature Part No 1258748 Z 80 60 5 25 Section 5 Fault Codes m J JP DEUTZ TD 2 9 L4 ENGINE FAULT CODES November 2014 SPN Suspect Parameter Number FMI Failure Mode Identifier KWP Keyword Protocol SPN FMI KWP Description SPN FMI KWP Description 524035 12 1341 Injector diagnostics time out 524108 9 1669 Timeouterror of CAN error in the SPI communication Transmit Frame ComEGRTVActr 524057 1505 Electric fuel pump fuel pressure build up error 524109 1679 Timeouterror of CAN Receive Frame 524097 1663 Timeout error of CAN Transmit ComRxEGRTVActr Frame DPFBrnAirPmpCtl 524110 1670 Timeout error of CAN 524098 1664 Timeout error of CAN Transmit Transmit Frame Frame ComDPFBrnPT ComETVActr 524099 1665 Timeouterror of CAN Transmit 524111 1680 Timeouterror of CAN Frame ComDPFC1 Receive Frame 524100 1666 Timeout error of CAN Transmit COmEAEDYACH Frame ComDPFHisDat 524112 1671 Timeout ComITVActr 524101 1667 TimeouterrorofCAN Transmit 524113 1681 Timeout error of CAN 524102 1674 Timeout error of CAN Coron Ty Receive Frame 524114 1659 Timeo
133. 80 60 Part No 1258748 November 2014 Section 6 Schematics Turntable Controller Pin Legend R r 92 15 cc J14 WHITE 5 00000006 35 T D CONNECTOR Sa AN 200170001 N 3 J13 A WHITE 2928 PIN NUMBERING FOR es Pin CCC 5545 23 PIN CONNECTOR t CONNECTORS x m ne 4 PIN 89 n FUNCTION xe CONNECTOR D J12 TE BLACK AER as CCC i E CONNECTOR a PIN NUMBERING FOR 35 PIN J11 8 CONNECTORS 5 CCC FSS 222 9 TURNTABLE TURNTABLE TURNTABLE TURNTABLE 2 CONTROLLER CONTROLLER CONTROLLER CONTROLLER J11 J12 J13 J14 PIN NUMBERING FOR 4 PIN CONNECTOR 1 GNDPCON BR 2 P52PCON BL RD 3 C46HN WH 4 C470UT WH BK 5 P23PCON BK 6 S56PRV RD 7 P56PRV RD 8 R48LP WH RD 9 R49LP WH BK 10 D80 SHIELD 11 UNUSED UNUSED 13 UNUSED 14 S132LDS BL WH 15 P97TET BK 16 UNUSED
134. 91 x 103 2 mm Horsepower 59 2500 rpm 44 kW 2500 rpm Firing order 1 3 4 2 Compression ratio 8 2 1 Compression pressure Pressure psi or bar of the lowest cylinder must be at least 75 of the highest cylinder Low idle computer controlled 1600 rpm Frequency 53 33 Hz High idle computer controlled 2500 rpm Frequency 83 33 Hz Valve clearance warm Intake 0 014 in 0 36 mm Exhaust 0 018 in 0 46 mm Lubrication system Oil pressure 40 to 60 psi 2 75 to 4 14 bar Oil capacity 7 quarts including filter 6 65 liters Oil viscosity requirements Units ship with 15W 40 Extreme operating temperatures my require the use of alternative engine oils For oil requirements refer to the Engine Operator Handbook on your machine Continuous improvement of our products is a Genie policy Product specifications are subject to change without notice A TEREX COMI Fuel Requirement For fuel requirements refer to the engine Operator s Manual on your machine Electronic fuel pump Fuel pressure static 55 psi 3 8 bar Fuel flow rate 0 42 1 59 L min Batteries Type 12V DC Group 31 Quantity 2 Cold cranking ampere 1000A Reserve capacity 6 25 rate 200 minutes Alternator output Fan belt deflection 65A Q 13 8V DC 1 2 inch 12 mm 2 8 Z 80 60 Part No 1258748 November 2014 Section 2 Specifications Deutz TD2011L04i Engine Displacement 220 9 cu in 3 62
135. 935 725 080 Genie Germany Phone 0800 180 9017 Phone 0049 4221 491 821 Fax 0049 4221 491 820 Genie North America Phone 425 881 1800 Toll Free USA and Canada 800 536 1800 Fax 425 883 3475 Genie Australia Pty Ltd Phone 61 7 3375 1660 Fax 61 7 3375 1002 Genie China Phone 86 21 53853768 Fax 86 21 53852569 Genie Singapore Phone 65 67533544 Fax 65 67533544 Genie Japan Phone 81 3 6436 2020 Fax 81 3 5445 1231 Genie Korea Phone 82 2 558 7267 Fax 82 2 558 3910 Genie U K Phone 0044 1476 584 333 Fax 0044 1476 584 330 Genie Brasil Phone 55 11 4082 5600 Fax 55 22 4082 5630 Genie Mexico City Phone 52 55 5666 5242 Fax 52 55 5666 3241 Genie Holland Phone 31 183 581 102 Fax 31 183 581 566 California Proposition 65 Warning The exhaust from this product contains chemicals known to the State of California to cause cancer birth defects or other reproductive harm Service Manual Z 80 60 from serial number Z8013 4592 Part No 1258748 RevA RCM G
136. AGE6 GION3IOS 5 arvis 18 5 MMd noaLva 5 lt 108 sas OTS sire 52 12313 Xnv 5 BLACK 4 PIN POWER HARN 0 _ ni Nvo 70 9224 310038 po rzz4 8 19720 X 501015 HoLmsLoos 50 9224 0 4955 901015 030015 F0 zza 901015 60 24 22 lt 246 lt 6 43004745 0 524 lt G 1224 GREY 8 TELEMATICS 6 27 a 2 80 60 G Part No 1258748 ES0508H November 2014 Section 6 Schematics Electrical Schematic Engine Options Continental TME27 Engine 28 November 2014 Section 6 Schematics EN NEM v U Mu Q qp i ur Electrical Schematic Safety Circuits 6 30 Section 6 Schematics November 2014 Electrical Schematic Safety Circuits P12 03 03 NCP 04 P20B 02 P114 06 114 08 20 03 12 09 ECU 1 P6R1 gt P53LS WH BK gt lt S59SBE GR WH lt lt RD lt gt AL A WH gt S12SBL BL WH P 11 21 22 WH RD i P12 34 MONITOR P12 11 LSSIRS RD BK WH BK LOWER LIMIT gt P 30 ECU P14 YELLOW 18 19 CABLE PB
137. AN Part No 1258748 Be sure that the battery separator wire connections are tight Fully charge the batteries and allow them to rest at least 6 hours Remove the battery vent caps and check the specific gravity of each battery cell with a hydrometer Note the results Check the ambient air temperature and adjust the specific gravity reading for each cell as follows Add 0 004 to the reading of each cell for every 10 5 5 C above 80 26 7 C Subtract 0 004 from the reading of each cell for every 10 5 5 C below 80 F 26 7 Result All battery cells display an adjusted specific gravity of 1 277 or higher The battery is fully charged Proceed to step 11 Result One or more battery cells display a specific gravity of 1 217 or below Proceed to step 8 Perform an equalizing charge OR fully charge the batteries and allow them to rest at least 6 hours Remove the battery vent caps and check the specific gravity of each battery cell with a hydrometer Note the results Section 3 Scheduled Maintenance Procedures November 2014 CHECKLIST B PROCEDURES 10 Check the ambient air temperature and adjust the specific gravity reading for each cell as follows e Add 0 004 to the reading of each cell for every 10 5 5 C above 80 F 26 7 C e Subtract 0 004 from the reading of each cell for every 10 5 5 C below 80 26 7 C O Result All battery cells display a specific gravit
138. ARNING injury hazard This procedure requires specific repair skills lifting equipment and a suitable workshop Attempting this procedure without these skills and tools could result in death or serious injury and significant component damage Dealer service is strongly recommended Note When removing a hose assembly or fitting the O ring on the fitting and or hose end must be replaced and then torqued to specification during installation Refer to Section 2 Hydraulic Hose and Fitting Torque Specifications 1 Raise the primary boom to a horizontal position 2 Extend the primary boom until the primary boom extension cylinder rod end pivot pin is accessible 3 Remove the access cover from the pivot end of the primary boom Genie 2 80 60 4 Place blocks under the barrel end of the primary boom extension cylinder for support 5 disconnect and plug the primary boom extension cylinder hydraulic hoses Cap the fittings on the cylinder AWARNING Bodily injury hazard Spraying hydraulic oil can penetrate and burn skin Loosen hydraulic connections very slowly to allow the oil pressure to dissipate gradually Do not allow oil to squirt or spray 6 Working at the platform end of the boom remove the external snap rings from the extension cylinder rod end pivot pin 7 Use a soft metal drift to remove the pin AWARNING Cushing hazard The primary boom could fall when removed from the extension boom if not
139. AS 18 19 CABLE SWHARNESS H MONITOR P12 10 03 NCFOP 04 2 5 lt BK SEC EXT PRI UP VALVE TCON LOWER LIMIT LSS2AS RAISED VALVE J14 07 SW HARNESS PURPLE 12 BLACK 35 PIN TCON J14 21 AC GENERATOR SECDOWN 013 22 P20B 12 WAY DEUTSCH VALVEP J14 12 STARTER RELAY 2 Safety Circuits P6R1 P14 P12 P11 AND P30 P114 12 WAY DEUTSCH QPBAS J13 09 P12 04 P20B 01 P114 04 Ge P114 02 P20B 12 01 NC 02 12 07 To P6R2 gt P54ENG BK WH 9 4 BK WH gt lt lt gt 2 gt gt SJ1 WH RD 2 80 BRO 5815 RD BK gt lt lt lt gt P 9B gt IGN FUEL RELAY 48 19 CABLE PBAS 18 19CABLE LOWER LIMIT LSSIRS3EXT LOWER LIMIT 013 03 12 08 SW HARNESS SW HARNESS P10 S LOWER LIMIT i i YELLOW TCON P12 12 SW HARNESS 01 NCFO 02 J RD4i BR9 3 TCON P12 BLACK 35 PIN TCON LSS2AS RAISED P20B 12 WAY DEUTSCH PURPLE D P114 12 WAY DEUTSCH PBAS Safety Circuits P6R2 P10 P18 AND P9B NOT SLEEP MODE AND FOOT SW PLAT DOWN JIB DOWN PLAT JIB UP 12V P11 02 04 P21 02 E PLAT ROT CW P17 08 RECOVERY SW V 4 parr POON 52 PCON WH lt P52 PCON WH lt P7R PLAT ROT CCW gt 5 RD P56PRV RD SEC COMP PRICOMP P22 23 P55 05 P55 06 P22 15 P21 07 02 P11 07 P17 10 CABLE CABLE P87PTS RD RES du L cmt RD BK lt P22 56 RD WH gt gt P56P
140. CK 23 PIN PCON RF STEER LEFT RR STEER LEFT 5 TO P22 WHITE 23 PIN PCON VALVE VALVE FOOT SW PRI BM EXT RET P34 DEUTSCH DTP 2 PIN CONN 032 21 032 09 8 12V amp P22 16 P22 17 VALVEP P 14 03 P18 DEUTSCH DTP 2 PIN CONN RF STEER RIGHT RR STEER RIGHT BAT Ur P6 R56FTS RD C56FTS RD gt TT ROT P31 BLACK 23 PIN DCON VALVE VALVE PLATFORM VALVE 55 6 WAY DEUTSCH AT PLAT LEVEL SENSOR J32 18 J32 08 MANIFOLD P14 04 PAUX HYD P17 16 WAY MOLEX TCON SPARE VALVE HARNESS 032 03 P14 32 Safety Circuits P7R Genie 6 30 Z 80 60 Part No 1258748 ES0508H Belt Driven Generator Option CB 87a 3 J32 ENG HARN P32 GEN HARN 0 CA5GEN GN WH WT RD 12VDC lt lt h RD BAT GND BR 23 GN 85 P114BAT RD S WHT NEUTRAL BR R45GEN A lt lt BR YL BAT GND lt lt 5 YL BR P45GEN B lt lt 5 1 BR PURPLE F45GEN lt lt b PR 110 VAC REGULATOR ca C Z UTO AUT RESET CB 4 L BLK 120VAC 120VAC GENERATOR W REGULATOR RDM2vDC lt lt b J32 ENG HARN P32 GEN HARN BR R45GEN A E C45GEN GN WH 1 P WT BAT GND BR 2 GR P114BAT RD 3 p BK e RD YL BAT GND E BR PA5GEN B
141. D 32 PRIMARY ANGLE 415 32 C27AUX RD 1 VLVRET4 BR 2 RD WH 3 CO9PERF BK RD 4 COGTRF WH RD 5 C12FBFC BL WH 6 C72SBE BL WH 7 CO1PBU RD 8 CO2PBD RD BK 9 CO7PBE BK 10 CO8PBR BK WH 11 UNUSED 12 C115SD BL BK 13 R49LP WH BK 14 VLVRETS BR 15 S73SLD GR BK 16 UNUSED 17 S10SLE BL 18 C114LS BK RD 19 UNUSED 20 C73SBR BL RD 21 C72SBE BL WH 22 UNUSED 23 C113MFV OR RD 24 UNUSED 25 COATRL WH 26 COSTRR WH BK 27 VLVRTN7 BR 8 UNUSED 33 P125SBLE WH RD 34 P126SBLD WH BK 35 UNUSED Part No 1258748 Z 80 60 6 11 Section 6 Schematics November 2014 H E ERROR QU cn Engine Relay and Fuse Panel Legend Deutz TD2011L04i models CR23 Lights Option CR28 CR17 F20 20A F23 30A B1 Eng Run Hi Lo RPM Eng Str Alt Battery At Field Gooler E22 F7 20A Be etay Y Glow Plug Cooler Battery CR5 R21 CR1 CR15 Horn Relay lgnition Start Relay Glow Plug Ground Deutz 2 9TF models CR2 CR17 27 30A F23 30A Eng Run Oil Power Eng St Att 93 Alt Field Cooler F22 60A F7 30A B2 Relay Relay Glow plug Horn Options Battery CR28 CR5 CR39 CR23 Ead Fuel Pump Horn Relay Engine Lights Relay pes ng Shutdown Option
142. E27 ENGINE 04 18 d16 2 HM NOIIZ 2 GENERATOR RELAY CRIS 8 HARNESS RD 1 1 ape 5 TO 120 OR 220VAC HYDRAULIC GENERATOR EI RASGEN GR WH C45GEN 1 SR srv amp 5 5 lf 020 3 4 YOLVYINID Ov 2574 SIXV 11 2514 E 0 SXv X 11 95513 lt CEE 01 E513 g so nauso YOLVYINID OW ZEZ AIVA 14 13 210 USNS LIL 4 No usLic8d GNOTUSNS 114 LL lt 8 0516813 di31 EE 6 0 3unss34d 10 amp 8 H4 usdsz A34 203 7275 8 H 2031 2 203 CMTS 4 203060 YILYVIS 50513 9 usceo 193135 SV9 d1 99513 qu 18 di6co NYH 32 35 72514 HM NUH9F2 AJY Pon Md EE aMMd h231V8 T3n3 N9I 55513 Hw Noltzo FILLOMHL 20517 au xa nauseo NLY 3ATVA 331000 531009 MS dal 203 102 WAG NYOH 35 DETAIL CONTINENTAL TME27 ENGINE YOLVNYAL WV ENGINE HARN J13 WHITE 23 PIN YOLOVLNOD GH xnv dWNd GAH Xnv C226TEL BL NOTE FOR ACTIVE LOW TELEMATICS SYSTEMS C229TEL IS CONNECTED TO B2BAT STUD ON RELAY BLOCK ACTIVE HIGH SHOWN P116HYD RD BIBAT RD TO P4 32 WHITE 35 PINS P
143. Every 3000 hours or 2 years Heavy duty coolant replace Every 12000 hours or 6 years Extended life coolant replace Required maintenance procedures and additional engine information are available in the Perkins 404F Series Operation Manual Perkins part number SEBU8609 Perkins 404F Series Operation Manual Genie part number 1251562 Part No 1258748 November 2014 Section 4 Repair Procedures Observe and Obey Repair procedures shall be completed by a person trained and qualified on the repair of this machine Immediately tag and remove from service damaged or malfunctioning machine Repair any machine damage or malfunction before operating the machine Before Repairs Start Read understand and obey the safety rules and operating instructions in the Operator s Manual on your machine Be sure that all necessary tools and parts available and ready for use Use only Genie approved replacement parts Read each procedure completely and adhere to the instructions Attempting shortcuts may produce hazardous conditions Unless otherwise specified perform each repair procedure with the machine in the following configuration Machine parked on a firm level surface Boomin the stowed position Turntable rotated with the boom between the circle end yellow arrow wheels Turntable secured with the turntable rotation lock pin Key switch in
144. F E D 1 2 HYDRAULIC GENERATOR OPTION MTE HYDRAULIC GENERATOR OPTION HYDRAULIC WELDER OPTION FUNCTION 3 FUNCTION PUMP COOLER DANE 17 GPM 17 GPM PUMP ___ CIR 1 r 1 L DIVERTER Cap SSS MANIFOLD 4 IN PRESSURE URE FILTER g 00831 Zw f cea ett cj ezoPsie BE a 8 BAR rn Ran l N O 5 I Le J PN MTR MTRA MANIFOLD L 222 e 6 FUNCTION OIL gt x 5 MANIFOLD i COOLER PMP M 55 oL 6 8 FUNCTION TO OC COOLER G2 G1 MANIFOLD 1 12 5 KW GENERATOR 7 8 50508 Genie Part No 1258748 Z 80 60 6 35 November 2014 Section 6 Schematics E S 44 Hydraulic Schematic Hydraulic Generator Options 37 November 2014 Section 6 Schematics pE OOM Hydraulic Schematic 2 Wheel Drive 2 and 4 Wheel Steer Section 6 Schematics November 2014 pe o an7 Hydraulic Schematic 2 Wheel Drive 2 and 4 Wheel Steer
145. Fluid Specifications Genie specifications require hydraulic oils which are designed to give maximum protection to hydraulic systems have the ability to perform over a wide temperature range and the viscosity index should exceed 140 They should provide excellent antiwear oxidation corrosion inhibition seal conditioning and foam and aeration suppression properties Cleanliness level minimum 15 13 Water content maximum 200 ppm Recommended Hydraulic Fluid Hydraulic oil type Chevron Rando HD Premium MV Viscosity grade 32 Viscosity index 200 Optional Hydraulic Fluids Biodegradable Petro Canada Environ MV46 Fire resistant UCON Hydrolube HP 5046 Shell Tellus S2 V 32 Shell Tellus S2 V 46 Chevron 5606A Mineral based Note Genie specifications require additional equipment and special installation instructions for the approved optional fluids Consult the Genie Industries Service Department before use Optional fluids may not have the same hydraulic lifespan and may result in component damage Continuous improvement of our products is a Genie policy Product specifications are subject to change without notice A TEREX COM Part No 1258748 SPECIFICATIONS Note Extended machine operation can cause the hydraulic fluid temperature to increase beyond it s maximum allowable range If the hydraulic fluid temperature consistently exceeds 200 F 90 C an optional oil cooler may be require
146. Fuelfilter water separator replace V belts replace Charge air cooler drain lube oil condensate Cold starting device if equipped check Hoses and clamps inspect replace Engine mounts inspect tighten Required maintenance procedures and additional engine information are available in the Deutz 2011 Series Operation Manual Deutz part number 0312 3547 OR the Deutz 2 9 L4 Series Operation Manual Deutz part number 0312 3893 Deutz 2011 Series Operation Manual Genie part number 139320 Deutz 2 9 L4 Series Operation Manual Genie part number 1251561 A TEREX D 9 Perform Engine Maintenance Perkins Models Engine specifications require that this procedure be performed every 1000 hours Proper engine maintenance following the engine manufacturer s maintenance schedule is essential to good engine performance and service life Failure to perform the maintenance procedures can lead to poor engine performance and component damage 804D Models Alternator check Engine valve lash inspect adjust Starter check Turbocharger check 404F Models Alternator and fan belts replace Crankcase breather canister replace Engine valve lash check Turbocharger inspect Required maintenance procedures and additional engine information are available in the Perkins 800D Series Operation Manual Perkins part number SEBU8324 OR the Perkins 404F Series Operation Manual Perkins part
147. G 7 Startthe engine from the platform controls 8 Move rpm select switch to high rpm rabbit symbol Genie Z 80 60 9 Begin driving the machine forward at a medium speed while one person monitors the pressure gauge Continue driving until the pressure stabilizes Note The pressure reading should be approximately 40 psi 2 8 bar less than the pressure reading taken in step 3 10 If it is not stop the machine and adjust the internal hex socket on the pressure relief valve item EG either up or down Turn it clockwise to increase the pressure or counterclockwise to decrease the pressure 11 Drive the machine forward and check the pressure 12 Continue making small adjustments until the pressure reading on the gauge is approximately 40 psi 2 8 bar less than the pressure reading taken in step 3 13 Turn the engine off and remove the pressure gauge Part No 1258748 November 2014 Section 4 Repair Procedures n t MANIFOLDS This page intentionally left blank Genie PartNo 1258748 Z 80 60 4 93 Section 4 Repair Procedures November 2014 P m t MANIFOLDS 8 12 Traction Manifold 4WD The 4WD traction manifold is mounted inside the drive chassis at the circle end of the machine Index Schematic No Description Item Function Torque 1 Check valve 5 psi 0 34 bar FAs ech Drive motor anti cavitation 30 35 ft lbs 41 47 Nm 2 Solenoid
148. Genie A TEREX BRAND Serial Number Range 2 80 60 from 28013 4592 1258748 RevA November 2014 November 2014 Introduction Important Read understand and obey the safety rules and operating instructions in the appropriate operator s manual on your machine before attempting any maintenance or repair procedure This manual provides detailed scheduled maintenance information for the machine owner and user It also provides troubleshooting fault codes 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
149. Genie 4 66 Z 80 60 Part No 1258748 October 2014 Section 4 Repair Procedures MANIFOLDS AJ Al Part No 1258748 Z 80 60 4 67 Section 4 Repair Procedures October 2014 MANIFOLDS 8 3 Valve Adjustments Function Manifold How to Adjust the System Relief Valve Note Perform this procedure with the boom in the stowed position 1 Locate the boom retracted limit switch LSP1RO limit switch on the outside of the primary boom at the pivot end of the primary boom 2 Tag and disconnect the wire harness from the limit switch and install a wire jumper between pins 1 and 2 of the limit switch connector Place another wire jumper between pins 3 and 4 of the limit switch connector Connect a 0 to 5000 psi 0 to 350 bar pressure gauge to the port on the function manifold 4 Startthe engine from the ground controls 5 Press andrelease the rpm select button until the engine changes to high idle 6 Simultaneously push and hold the function enable high speed button and the primary boom retract button with the primary boom fully retracted Observe the reading on the pressure gauge Refer to Section 2 Specifications Genie 2 80 60 7 Turn the engine off Use a wrench to hold the relief valve and remove the cap item AJ 8 Adjust the internal hex socket Turn it clockwise to increase the pressure or counterclockwise to decrease the pressure Inst
150. Ground Controls 6 1 Service Bypass Recovery Keyswitch 4 57 6 2 CircuitBoards one e Tet ae Dee ARE pea tes 4 59 6 3 4 60 Genie Part No 1258748 Z 80 60 November 2014 TABLE OF CONTENTS Section 4 Repair Procedures continued Hydraulic Pumps Fanchon PUMP uidet te een E a 4 61 7 Drive Pump eio tee PR E 4 62 4 2 Manifolds 8 1 Function Manifold 4 64 82 Function Manifold 2 4 66 8 3 Valve Adjustments Function 4 68 8 4 200 0 0 0 00 4 74 85 Turntable Rotation 4 76 8 6 Platform Rotate nnnm 4 77 8 7 2 Wheel Steer and Oscillate 2 4 78 8 8 4 Steer and Oscillate 4 84 8 9 Oil Diverter Manifold Welder Option 4 89 8 10 Traction Manifold 2 8 4 90 8 11 Valve Adjustments 2WD Traction Manifold 4 92 8 12 Traction Manifold 4 94 8 13 Valve Adjustments 4WD Traction 4 96 B14 Valve 4 97 Turntable Rotati
151. H S 12 gt eS Su xcd 2 a a 00 L ENG SPEED BK RD 5 11 5 ea th d ro ta Qu Aud9ss r9 5 2 bu E GND1 BR 10 q 22 2 T9 5 Oo AXLE RET GR E a 3 250 9 STARTBK GI 9 5 gt NODd zo 1a 4 A NOT USED 8 9 5 9 t 3 DRV ENBLBL WH 5 7 5 ig ee T RJ ENG START BK 6 zd es Sa 5 START ASST BK WH START ASST BK WH 5 Seb gt 0 a AUX PUMP RD S 4 255 2 o a 5 m od amp GEN ON OFF GR WH 5 3 So lt lt we T AA OMA 5 M C T lt soc e o HORN RETF GR S 2 SHH 5 9 5 89 550 T z og L zee 4 AUXPUMPRD SHORN EWR PDST 8 8 2 9 2 z E I o a z zz zz T F4 lt lt ame TEE T J abe e i 25 a 5 slo a zi 58 fer sp eg 5 413 B62 GEN ON OFF GR WH 5 lt 1499 EN r at o o o lt LOS uj os z gt gt a zm jeg ons End 0 HORN RTN GR 5 1 a a 5 1 i 1 1 E H 2 Be a z 5 5 5 s SF 1 oii 0 n A 2 75 Sa gt HORN PWR RD S 2 se Gol
152. IVE HIGH SHOWN FUSE INFO F7 COOLER 8 ENG SIR ALT 5 820 H O RPM F22 GLOW PLUGS J15 BLACK 4 PIN J13 WHITE 23 PIN HARN B C26TSR WH RD C33STR BK li SP 2P13 06 REV C46HRN WH 3PT3 07 C33STR BK 3PT3 09 C35RPM BK RD SPT3 07 THROTTLE SPT3 03 IGN FUEL C34SA BK WH SPT3 04 PT3 05 FWD C30EDC WH SPT3 T0 EDC FWD C3IEDC WH BK EDC REV C25PSR WH BK 3PT3 12 C26TSR WH RO 3PT3 T3 YR PT CAIRPM OR 8K 3 18 FR AN BIBAT R0 gt BIBAT RI 3 5 C25PSR WH BK 0 8 En P34SA BK WH O Hu pm P3SRPM RD t 2 rs mE kL EE T N 11 0 i 3 Lid END zu is 8 8 Sk 8 58 8 8 OP de DETAIL A PERKINS 8040 ENG Part No 1258748 ES0508H Section 6 Schematics Continental TME27 Engine Electrical Schematic Engine Options November 2014 TCON ENGINE a 5 8 be z o OY MSA E HM 18 1539012 OY HM YSL9ZI bite pw LNV1009 y8 HA uSdGzo ame 1 p 18 13380 0 051 2 66 7 HW 18 1538012 s 553 ES 3NI9N3 38 30 Wdillko LAMP VEHICLE INTERFACE CONTINENTAL TM
153. LCD display at the ground controls Proceed to step 6 Result The alarm is sounding The platform overload indicator light is flashing at the platform controls and PLATFORM OVERLOAD should is displayed on the LCD screen at the ground controls Slowly tighten the load spring adjustment nut in a clockwise direction in 10 increments until the overload indicator light turns off and the alarm does not sound Proceed to step 8 Note The platform will need to be moved up and down and allowed to settle between each adjustment Note There may be a 2 second delay before the platform overload indicator light and alarm responds PartNo 1258748 Genie Z 80 60 4 23 PLATFORM COMPONENTS 6 Move the platform up and down by hand so it bounces approximately 2 5 to 5 cm 1 to 2 inches Allow the platform to settle O Result The alarm should be off The platform overload indicator light should be off at the platform controls and there should be no error message on the LCD display at the ground controls Slowly loosen the load spring adjustment nut in a counterclockwise direction in 10 increments until the overload indicator light flashes at both the platform and ground controls and the alarm sounds Proceed to step 7 Result The alarm should be sounding The platform overload indicator light should be flashing at the platform controls and PLATFORM OVERLOAD should be displayed on the LCD screen at the ground con
154. MS 50 1165 LPG Cat Monitor Y Y EGO2 RMS gt 0 005 phi and EGO2 Adaptive Learn Key Cycle RMS gt EGO1 RMS 50 and EGO2 RMS gt CL waveform RMS 50 PartNo 1258748 Z 80 60 5 33 Section 5 Fault Codes CONTINENTAL TME27 ENGINE FAULT CODES November 2014 9 E E t 2 38585 a2 gos 28552323 System Code Fault Name 5 2 2 5 Fault Conditions EGO 134 EGO Open Lazy Pre cat 1 EGO cold persistently gt 120 seconds Sensors 154 EGO Open Lazy Post cat 1 EGO cold persistently gt 120 seconds Injectors 261 Injector Loop Open or Injector off state low side lt 4 vdc Low Side Short to Ground and battery voltage gt 9 0 262 Injector Coil Shorted YIY Y Injector on state low side gt 4 vdc and battery voltage lt 16 vdc Bower 686 Control Ground Relay 685 Relay Coil Short Control 687 Relay Coil Short to Pwr Coil Tach 2618 Tach Output Ground Short Does not turn on MIL Output 2619 Tach Output Short to Pwr Does not turn on MIL EPR 1171 EPR Delivery Pressure Y Y MJ actual commanded press gt 4 in H20 Diagnostics gt than expected LPG 1172 EPR Delivery Pressure Y Y MJ actual commanded press 4 in H20 than expected 1173 EPR Comm Lost Y Y No MJ packets received within 500 ms 1174 EPR Voltage Supply High Y Y 1175 EPR Voltage Supply Low Y Y 1176 EPR Int
155. NG Flectrocution hazard Contact with schematic items O and S electrically charged circuits could result in death or serious injury 2 position 2 way solenoid valve 10V DC 3 3 Q Remove all rings watches and schematic items J other jewelry 2 position 2 way solenoid valve 10V DC 6 3 Q Note If the machine has been in operation allow schematic items C and P the coil to cool at least 3 hours before performing 2 position 3 way solenoid valve 10V DC 639 this test schematic items H V X Z AA EE and EF 1 Tagand disconnect the wiring from the coil to 2 position 3 way solenoid valve 12V DC 90 be tested schematic items BC BD CE CF FB and FC 2 Testthe coil resistance using a multimeter set to resistance Q Refer to the Valve Coil Resistance Specification table W Result If the resistance is not within the adjusted specification plus or minus 1096 replace the coil Genie Part No 1258748 Z 80 60 4 97 Section 4 Repair Procedures November 2014 MANIFOLDS How to Test a Coil Diode Properly functioning coil diodes protect the electrical circuit by suppressing voltage spikes Voltage spikes naturally occur within a function circuit following the interruption of electrical current to a coil Faulty diodes can fail to protect the electrical system resulting in a tripped circuit breaker orcomponent damage AWARNING Electrocution hazard Contact with electrically charged circuits could result in death or seriou
156. Nm Circle end yellow side steer cylinder extend circuit 20 25 ft lbs 27 34 Nm Load sensing circuit circle end blue side steer cylinder retract 8 10 ft lbs 11 14 Nm Load sensing circuit circle end blue side steer cylinder extend 8 10 ft lbs 11 14 Nm Load sensing circuit circle end yellow side steer cylinder extend 8 10 ft lbs 11 14 Nm Part No 1258748 Section 4 Repair Procedures November 2014 MANIFOLDS KHG 85 2 80 60 Part No 1258748 Section 4 Repair Procedures November 2014 MANIFOLDS Four Wheel Steer and Oscillate Manifold continued Index Schematic No Description Item Function 16 Solenoid valve 3 position 4 way KP Steer left right circle end blue side steer cylinder 17 Solenoid valve 3 position 4 way Steer left right circle end yellow side steer cylinder 18 Flow regulator valve 1 0 3 8 Square end left side steer cylinder retract 19 Check valve KS Load sensing circuit square end blue side steer cylinder retract 20 Check valve 65 psi 4 5 bar KT uus Prevents steer cylinder from moving when not steering 21 Check valve 65 p
157. Option R21 CR15 ignition Glow Plug Ground 70A 70A Continental models CR23 Lights Option CR17 F17 30A B1 Oil Cooler Engine Battery Relay F7 20A B2 Oil Cooler Battery CR5 pri CR1 _ Start Rela Horn Relay Ground y Genie Z 80 60 Part No 1258748 2014 Section 6 Schematics ENGINE RELAY AND FUSE PANEL LEGEND Perkins 804D models CR28 CB20 10 F23 30A B1 Eng Run j Hi Lo RPM Eng Str Alt Battery Alt Field F22 60 F7 20A B2 Relay Glow plug Cooler Battery CR4 CR5 RPM Relay Horn Relay R21 Ignition Ground Perkins 404F 22T models Bi CR2 Battery Eng Run Alt Field Relay Fuel Pump Horn Relay ECU Power Lights Relay pond ABD Ignition Glow Plug Air Pump e Ground Perkins Tier 4 Fuse Panel B1 Bgttery F28 15A E 7 5A urner Air Pump F29 5A F30 10A ECU Batt 1 ECU Batt 2 Linear SLND ARD INJ1 F32 10A F31 10A ECU Batt 4 ECU Batt 3 Lamp amp Relay ARD INJ2 ECU Power Relay Genie Part No 1258748 Z 80 60 Section 6 Schematics November 2014 Electrical Symbols Legend 1 BLK 4 H P WaT 153 Foot switch Quick disconnect terminal Coil Limit switch Horn button solenoid or relay normally open KS1 a WH
158. PANY Part No 1258748 CHECKLIST D PROCEDURES turntable dial indicator drive chassis turntable rotation bearing Adjust the dial indicator need to the zero position Elevate the riser but do not extend it Move the primary boom and jib to horizontal and fully extend Note the reading on the dial indicator Result The measurement is less than 0 063 inch 1 6 mm The bearing is good Result The measurement is more than 0 063 inch 1 6 mm The bearing is worn and needs to be replaced Move the boom sections to the positions indicated in step 3 Visually inspect the dial indicator to be sure the needle returns to the Zero position Section 3 Scheduled Maintenance Procedures November 2014 CHECKLIST D PROCEDURES 9 Remove the dial indicator and rotate the turntable 90 10 Repeat steps 4 through 9 until the rotation bearing has been checked in at least four equally spaced areas 90 apart 11 Lower the boom to the stowed position and turn the machine off 12 Remove the dial indicator from the machine A TEREX CON D 5 Replace the Drive Hub Oil Replacing the drive hub oil is essential for good machine performance and service life Failure to replace the drive hub oil at yearly intervals may cause the machine to perform poorly and continued use may cause component damage Drive Hubs 1 Select the drive hub to
159. RV RD WH gt gt gt PCON PLATFORM PLATFORMTILT PLATFORM PCON 4 SINE MP i MANIFOLD SENSOR MANIFOLD 74HC08 HARNESS HARNESS S T lt P11 BLACK 35 TCON is 5 04 ROUND DEUTSCH CONN 8 WAY i 5 21 BLACK 23 PIN p 0 P22 WHITE 23 PRIUP DN FC P55 6 WAY DEUTSCH AT PLAT LEVEL SENSOR TCON BRS E P17 16 WAY MOLEX TCON 14 02 ircui SM NOT SLP MODE SEC BM FC Safety Circuits P22 and P22R AUX HYD J14 06 RECOVERY SW Z TM TCON MODE SM AH Pi7 12 17 09 P15 TO 6 FE FUNC ENABLE P7 TOON RECOVERY TM FE PLD 1 TCON 17 08 TO 12V _ pz SM AH P gt S56PRV RD RECOVERY BATT 74HC08 Sw y P12 05 P34 01 lan P18 01 P31 06 To A tr P7R gt Eck S56PRV RD gt gt S56PRV RD lt 2 gt SPARE VALVE TCON LOWERLIMIT ELECTRIC DRIVE 7 SWITCHHARN ROTATOR CHASSIS J32 02 7 P31 05 TO P11 06 01 P21 04 FWD VALVE lt P7R gt LF STEERLEFT LR STEER LEFT L 3 S56PRV RD lt lt S56PRV RD lt lt P7 gt 13 05 VALVE Mee 032 23 32 17 SECCOMP PRICOMP PCON mn LF STEER RIGHT LR STEER RIGHT CABLE CABLE 13 06 P11 BLACK 35 PIN TCON VALVE VALVE PM PCON MODE P12 BLACK 35 TCON J32 22 J32 16 SM NOT SLP MODE A P21 BLA
160. SCR CAT 523613 0 858 Railsystem leakage detected 523698 11 122 Shutoff request from RailMeUn10 supervisory monitoring function 523613 0 859 Maximum negative deviationof 523717 12 125 TimeoutErrorof CAN Transmit rail pressure in metering unit Frame AmbCon exceeded RailMeUn2 Weather environments 523613 0 860 Negative deviation of rail 523718 3 1488 SCRmainrelay short circuit to pressure second stage battery only CV56B RailMeUn22 523718 4 1489 SCRmainrelay short circuit to 523613 0 862 Maximum rail pressure ground only 56 exceeded RailMeUn4 ENT 523718 5 1486 SCRmainrelay open load 523613 1 861 Minimumrail pressure only CV56B exceeded RailMeUn3 523718 12 1487 SCRmainrelay powerstage 523613 2 864 Setpoint of metering unit over temperature only CV56B overrun mode not plausible 523766 9 281 Timeout Error of CAN Receive 523615 3 594 Meteringunit Fuel System Frame Active TSC1AE short circuit to battery highside 523767 9 282 TimeoutErrorof CAN Receive Frame Passive TSC1AE A TEREX COMPANY 5 22 Z 80 60 Part No 1258748 November 2014 Section 5 Fault Codes 1 DEUTZ TD 2 914 ENGINE FAULT CODES SPN Suspect Parameter Number FMI Failure Mode Identifier KWP Keyword Protocol SPN FMI KWP Description SPN FMI KWP Description 523768 9 283 TimeoutErrorof CAN Receive 523897 13 561 check of missing injector Frame Active TSC
161. STICS IAG M D228CAN YL gt Q eo a DIOSCAN BK RD SyDIAG H 8 l zx 5 15915 5 SS 5 DI04CAN BK WH y D AG G ecizl s 5 1 i DIAG F 595088 98 5 0505 Q D227CAN GR gt aea 120 8556681 592 859 4229522 0 7 TEP EREET PEEPE TAIT C134KSP GR BK y DIAG A 99 gt gt 5 5 5 9 20 2 2 ELE 052222 825 6 FUEL PRESSURE MSENGND OR lt lt 9 ol 9 N e e 9 o 0 e 9 FUELPRES BL E P d d d a d d d RR d RR MSENPWR GR WH 4 IN IN 8 99596 68564 8655659 5 5 3 zz lt 2 gt 8552255255222255522121232852552245 458 ENGINE BLOCK gt 5555557 26 2 58 80855 lt 55525 gt 22 0 gt 2 gt 6 lt 6 0 95 5 o5 55559595 5 5 8 5 555 5 9 5 5 55 55 2 6 22 2 2 9 2 gt lt ES0508H 22 0 2222 55 53 5564 2 5 gt 5 5 455577408 827 5 5 6 8 22
162. Schematic No Description Item Function Torque 1 Counterbalance valve Turntable rotation brake release 35 40 ft lbs 47 54 Nm 2 Counterbalance valve HB Turntable rotate left 35 40 ft lbs 47 54 Nm Op a4 Genie Part No 1258748 Z 80 60 4 77 Section 4 Repair Procedures November 2014 nnr MANIFOLDS 8 7 Two Wheel Steer and Oscillate Manifold The Two Wheel Steer and Oscillate manifold is mounted inside the drive chassis at the square end of the machine Index Schematic No Description Item Function Torque 1 Solenoid valve 3 position 4 way JA os Steer left right yellow side steer cylinder 26 30 ft lbs 35 41 Nm 2 Solenoid valve 3 position 4 way JB Steer left right blue side steer cylinder 26 30 ft lbs 35 41 Nm Solenoid valve 2 position 3 way Oscillate cylinder blue side 26 30 ft lbs 35 41 Nm Solenoid valve 2 position 3 way JD Oscillate cylinder yellow side 26 30 ft Ibs 35 41 Nm 5 Relief valve 750 to 860 psi 51 71 to 59 3 bar JE Oscillate 20 25 ft lbs 27 34 Nm 6 Flow regulator valve 1 5 5 7 L min JE see Blue side steer cylinder extend circuit 20 25
163. Section 6 Schematics S Kxo DO 2 LL LILLLLLLLDALLDLL LELULDGLL DOLLIA MILLLZ OOLLLLL LGKEAENLOS GKHC A x xv Electrical Schematic Engine Options Deutz TD2 9 Engine November 201 4 Electrical Schematic Engine Options Section 6 Schematics Deutz TD2 9 Engine 50508 2 80 60 B a 858 818 HM NOIIZ 7 14 8 4 3028 MOSN3S i HM 89 1384v 2 gal 538030 5 9 5 08 EI S 1V 135 m e WAVY 805835 Ge 334930 02 0 E 58 MOTO gt VAL B o o HM 9N3IZ2 amp 437009 0 08 8 HM QAH9LI9 HOLIMS dW3L T gs 5 Seat S pa ox B E 8 H 1 5 8 1 NYOH L__qu yseey ENLIA Z 1a P YOLVYINID OV HM 18 d3S 12 LU SV X LL 1L HM L3USEIO HW 18 d3S 13 1303 YOLYNUALT BIEI MoLVIBN39 ov ZEI RES WWA OIEI g Md USNS LL 2 A dd M8 v00N9 c HM 138124 gt dH NW amp 5 wl L M NI 5 3 203 HM 18 d3S 19 003 03 2 19 1006 102
164. Sensor Left Rear Left Rear Steer Sensor Limit Switch Lift Speed Reduction Load Sensor Lockout Low RPM Low fuel Motor Shift Speed Multi Function Valve Platform Control Primary Ext Ret Lockout Platform Level Down Platform Level Flow Control Platform Level Up Platform Rotate Flow Control Platform Rotate Control Platform Rotate Left CCW Platform Rotate Right CW Power Power to Length Sensor Platform Tilt Alarm Platform Tilt Sensor Part No 1258748 Section 6 Schematics u Henn WIRE CIRCUIT LEGEND Suffix Definition Suffix FE Pressure Comp Enable PCE Pressure Sender PSR GND Pressure Switches PS HRN Primary Boom Angle Sensor PBS HS Primary Boom Down PBD HG Primary Boom Ext Ret Lockout Valve PBL IGN Primary Boom Extend PBE JBD Primary Boom Extend Retract Flow Control PER JBU Primary Boom Retract PBR JBS Primary Boom Angle Sensor PBS JUD Primary Boom Down PBD JD Primary Boom Ext Ret Lockout Valve PBL JFC Primary Boom Extend PBE JSV Primary Boom Extend Retract Flow Control PER JU Primary Boom Retract PBR JER Primary Boom Up PBU JBE Primary Boom Up Dwn Flow Control PUD JBR Primary Boom Extend Retract Signal PLS JRL Primary Boom Up Down Signal PES JRR Primary Lockout PL JPW Primary Length Sensor PSL LPS Propel Signal JPL LF Program Setup Enable PSE LFS Propel Lockout PLL Proportional Valve PRV LRS Proximity Sensor PXS
165. T 21 21 1 PLATFORM 7 T GROUND 15 NO 0 T circuits connect H1 m Emergency Stop is Oil temperature button normally switch closed Horn or alarm Key switch normally open T circuits X connect V 2 T gt Ap cTsi Hydraulic ydraulic Flashing beacon Power relay cooling fan Connection oolant peratura p terminal switc normally open Aux TS2 Pump Gauge Auxiliary pump Circuits crossing NC no connection 510 Toggle switch SPDT Oil pressure switch pda normally closed Resistor with ohm value Diode Hour meter mb E IED E Gauge sending unit Tilt sensor patery Toggle switch DPDT 0 A 25A aad Fuse zig with amperage Be NE gt Battery separator Control relay contact Fuel or RPM normally open solenoid 1 x Starting aid ic 0 0 glow plug or Circuit breaker flame ignitor with amperage Coil Genie 6 14 Z 80 60 Part No 1258748 November 2014 Section 6 Schematics 25 gt 1 7 bar Filter with bypass valve relief setting C Pump fixed displacement 0 S ef bi directional variable displacement Motor bi directional x Motor 2 speed bi directional E Pump prime mover engine or motor Double acting cylinder Accumulator NYE 3 035 0 89 Orifice with size
166. WH 174 Key switch power ground position RD 141 Primary boom angle signal safety WH BK 175 Load sensor signal operational OR 142 Secondary boom angle signal GN WH 176 Secondary extend retract safety BL RD 177 Extend retract lockout BL RD 143 Drive enable left BK 178 Control module status light BL WH 144 Drive enable right GN 179 Drive power relay RD WH 145 Calibrate BK 180 Lift power relay BL 146 Jib bellcrank up FC OR 181 48 Volt alternator field or battery BL BK 147 Jibbellcrank down FC RD 182 24 Volt battery BL WH 148 Jib bellcrank sensor BL 183 Envelope or load sense recovery GR WH 149 Jib Up Down FC WH 184 Program setup enable GR BK 150 Hydraulic generator bypass WH 185 Encode GR 151 Hydraulic EDCoutput BL 186 Encode B BK 152 Injector retard BL 187 Bootstrap or program enable BK 153 Jib extend GR 188 Safety cross check BK WH 154 Jibretract BK 189 Data receive OR RD 155 Pressure comp enable BK WH 190 Data transmit GN WH 156 Jib Up Down WH RD 191 Multi Function pressure relief BK RD 157 Jib Ext Ret WH BK 192 Jib rotate left BL RD 158 Spare WH RD 193 Jib rotate right BL WH 159 Steer joystick signal WH RD 194 Speed select input WH RD 160 Propel joystick signal OR RD 195 Electric brake source WH BK 161 Sec boom joystick signal YL 196 2 5V Sensor power OR 162 Joystick 5 VDC power BR N A Ground or return Genie Part No 1258748 Z 80 60 6 7 Section 6 Schematics November 2014 Limit Switches and Angle Sensors Types of Limi
167. a digital level on top of the primary boom mast on a level part of the tube so it is viewable from the ground controls 8 Startthe engine Raise the boom until the digital level displays 70 10 Loosen the wing nut from threaded rod and move the threaded rod down until the engine turns off 11 Screw threaded rod into clevis yoke Tighten the wing nut to welded bracket Tighten the jam nut to welded bracket Tighten the PBAS fasteners to boom Result The ground control box display should read P9B 8 P11 FAULT 12 Push in the red Emergency Stop button to the off position Wait until display turns off before proceeding 13 Pull out the red Emergency Stop button while holding the enter button 3 or 4 seconds until the endgine symbol appears on the display at the ground control box then release Part No 1258748 Genie Z 80 60 BOOM COMPONENTS 14 Enter sensor calibration mode by pressing the buttons at the ground controls in the following sequence 15 Press the scroll button until PRIMARY BOOM ANGLE 70 is shown on the display 16 Press the plus button to select yes then press the enter button to accept 17 Press the scroll button until Exit is shown on the display Press the plus button to select yes then press the enter button to accept 18 At the ground controls use auxiliary power and lower the boom unti
168. ace a test weight equal to that of the available capacity one of the locations shown Refer to Illustration 1 Result The platform overload indicator lights should be off at both the ground and platform controls and the alarm should not sound Result The platform overload indicator lights are on and the alarm is sounding Calibrate the platform overload system Refer to Repair Procedure 2 4 How to Calibrate the Platform Overload System if equipped Illustration 1 5 Carefully move the test weight to each remaining location Refer to Illustration 1 Result The platform overload indicator lights should be off at both the ground and platform controls and the alarm should not sound Result The platform overload indicator lights are on and the alarm is sounding Calibrate the platform overload system Refer to Repair Procedure 2 4 How to Calibrate the Platform Overload System if equipped A TEREX Part No 1258748 CHECKLIST C PROCEDURES Using a suitable lifting device place an additional 50 Ibs 23 kg of weight onto the platform Result The alarm should sound The platform overload indicator light should be flashing at the platform controls and PLATFORM OVERLOAD should be displayed on the LCD screen at the ground controls Result The alarm is not sounding OR the platform overload indicator light is not flashing OR PLATFORM OVERLOAD is not displayed on the LCD screen at t
169. all the relief valve cap AWARNING hazard Do not adjust the relief valve higher than specified 9 Repeat steps 4 through 8 confirm the relief valve pressure 10 Remove the pressure gauge 11 Remove the wire jumpers from the limit switch connector 12 Securely install the LSP1RO pig tail into the wire harness How to Adjust the Primary Boom Down Relief Valve Note Perform this procedure with the boom in the stowed position 1 Connect a 0 to 5000 psi 0 to 350 bar pressure gauge to the Ls port on the function manifold 2 Startthe engine from the ground controls 3 Press release the rpm select button until the engine changes to high idle 4 Raise the primary boom approximately 5 feet 1 5 m Part No 1258748 October 2014 Section 4 Repair Procedures 5 Place 8 4 x 4 inch 10 x 10 cm block on the primary boom rest pad Lower the primary boom onto the block AWARNING Cushing hazard Keep hands clear of the block when lowering the primary boom 6 Simultaneously push and hold the function enable high speed button and the primary boom down button Observe the pressure reading on the pressure gauge Refer to Section 2 Specifications 7 Turn the engine off Use a wrench to hold the relief valve and remove the cap item E 8 Adjust the internal hex socket Turn it clockwise to increase the pressure or counterclockwise to decrease the pressure Install the relief valve cap
170. alve and loosen the jam nut item CH before SN 1301 or item KH after SN 1300 6 Adjust the stud with a hex wrench Turn it clockwise to increase the pressure or counterclockwise to decrease the pressure Install the relief valve cap AWARNING Tip over hazard Do not adjust the relief valve higher than specified 7 Repeat steps 3 through 4 to confirm relief valve pressure 8 Remove the pressure gauge 9 Install the drive chassis cover Genie 4 88 2 80 60 Part No 1258748 November 2014 Section 4 Repair Procedures eer MANIFOLDS 8 9 Oil Diverter Manifold Components welder option The oil diverter manifold is mounted to the hydraulic generator located in the engine compartment Index Schematic No Description Item Function Torque 1 Pilot Operated Directional valve 2 position Activates 80 90 ft lbs 108 122 Nm 2 Orifice disc 0 031 inch 0 79 Delays shift to drive 35 40 ft lbs 47 54 Nm Solenoid valve 2 position way CBC Pilot valve to diverter 35 40 ft lbs 47 54 Nm 4 Relief valve 280 psi 3 5 19 3 bar 13 2 L rini ies Charge pressure circuit 35 40 ft lbs 47 54 Nm 5 Pressure switch 200 psi 18 6 bar CBE Generator relay switch 16
171. anent ink marker to write the date and number of hours from the hour meter on the oil filter housings 15 Start the engine from the ground controls 16 Inspect the filter housings and related components to be sure that there are no leaks A TEREX CON Part No 1258748 CHECKLIST D PROCEDURES D 7 Perform Engine Maintenance Continental Models Engine specifications require that this procedure be performed every 1000 hours Proper engine maintenance following the engine manufacturer s maintenance schedule is essential to good engine performance and service life Failure to perform the maintenance procedures can lead to poor engine performance and component damage Spark plugs replace O2 sensors replace Required maintenance procedures and additional engine information are available in the Continental TME27 Owner s Manual Continental part number WM10303 Continental TME27 Owner s Manual Genie part number 111901 Section 3 Scheduled Maintenance Procedures November 2014 CHECKLIST D PROCEDURES D 8 Perform Engine Maintenance Deutz Models Engine specifications require that this procedure be performed every 1000 hours Proper engine maintenance following the engine manufacturer s maintenance schedule is essential to good engine performance and service life Failure to perform the maintenance procedures can lead to poor engine performance and component damage All models
172. any drainage Secure the container to the boom 2 Move the platform rotate switch to the left and then to the right through two platform rotation cycles continue holding the switch to the right until the platform is fully rotated to the right Genie PLATFORM COMPONENTS Open the top bleed valve but do not remove it 4 Move the platform rotate switch to the left until the platform is fully rotated to the left Continue holding the switch until air stops coming out of the bleed valve Close the bleed valve AWARNING Crushing hazard Keep clear of the platform during rotation 5 Connect the clear hose to the bottom bleed valve Open the bottom bleed valve but do not remove it 6 Hold the platform rotate switch to the right until the platform is fully rotated to the right Continue holding the switch until air stops coming out of the bleed valve Close the bleed valve AWARNING Crushing hazard Keep clear of the platform during rotation 7 Remove the hose from the bleed valve and clean up any hydraulic oil that may have spilled 8 Rotate the platform full right then full left and inspect the bleed valves for leaks After serial number 228 1 Rotate the platform full right then full left until air is completely out of the rotator Bleeding the valve is not necessary AWARNING Crushing hazard Keep clear of the platform during rotation Part No 1258748 Z 80 60 4 21 Section 4 Repair Procedures
173. arrel end of the primary boom lift cylinder Use the overhead crane to raise the primary boom lift cylinder to a vertical position 4 Remove the pin retaining fastener from the primary boom rod end pivot pin 5 Usea slide hammer to remove the pin Remove the primary boom lift cylinder and linkage arms from the machine Crushing hazard The primary AWARNING boom lift cylinder and linkage arms could become unbalanced and fall if not properly supported when the pin is removed 6 Atthe platform end remove the secondary boom access cover 7 Tag disconnect and plug the hydraulic hoses from the turntable Cap the fittings AWARNING Bodily injury hazard Spraying hydraulic oil can penetrate and burn skin Loosen hydraulic connections very slowly to allow the oil pressure to dissipate gradually Do not allow oil to squirt Genie 2 80 60 8 Tag and disconnect the electrical cables from the turntable 9 Remove the hose protector bracket 10 Working at the platform end place blocks under the barrel end of the secondary boom extension cylinder for support 11 Remove the barrel end retaining fasteners 12 Using a suitable lifting device lift the extension cylinder to clear the saddle blocks 13 Attach a lifting strap from an overhead crane to the secondary extension boom assembly 14 Slide the secondary extension boom assembly out of the secondary boom tube approximately two feet and remove the wear pads from the seco
174. atom Rotator ehe etim ida mente 4 20 2 4 Calibrate the Platform Overload System if equipped 4 232 2 5 Howto Clear the Platform Overload Recovery Message 4 25 Genie 2 80 60 Part No 1258748 November 2014 TABLE OF CONTENTS Section 4 Repair Procedures continued Jib Boom Components 9 1 JID BOOM Gc e e rt ete e D aA 4 26 32 Jib Boom Lift Cylinder 2 2 00 4 28 Boom Components 4 1 Primary Boom Cable 4 30 4 2 Primary BOOM hen neil aet te pd eee lime 4 33 4 3 Primary Boom Lift 4 36 4 4 Primary Boom Extension 4 38 4 5 Primary Boom Angle Sensor 2 0222 4 39 46 Secondary Boom Cable 4 42 4 7 0 44 00 7 4 43 4 8 Secondary Boom Lift Cylinder 2 2002 00 4 45 4 4 Secondary Boom Extension 2 4 47 Engines 5 1 RPM 4 49 5 2 gt aUe medii da i t vates 4 49 5 3 Engine Fault Codes Gasoline LPG 4 55 5 4 Howto Access Perkins 404F Engine Regeneration Service 4 55
175. ause component damage Drive hubs 1 Drive the machine to rotate the hub until one of the plugs is located on top and the other one is at 90 degrees a models with pipe plugs b models with o ring plugs A TEREX COMPANY Remove the plug located at 90 degrees and check the oil level Result The oil level should be even with the bottom of the side plug hole If necessary remove the top plug and add until the oil level is even with the bottom of the side plug hole Models with pipe plugs Apply pipe thread sealant to the plugs and install the plugs Models with O ring plugs Install the plugs into the drive hub Torque to Specification Refer to Section 2 Specifications Check the torque of the drive hub mounting fasteners Refer to Section 2 Specifications Repeat steps 1 through 4 for the other drive hubs Part No 1258748 November 2014 Section 3 Scheduled Maintenance Procedures Pe E CHECKLIST B PROCEDURES Turntable rotate drive hub B 11 1 Remove plug located on the side of the hub Test the Ground Control Override and check the oil level e properly functioning ground control override is Result The oil level should be even with the essential to safe machine operation The ground bottom of the plug hole opening control override function is intended to allow ground personnel to operate the machine from the ground controls
176. b 4 5 kg test weight Repeat this procedure beginning with step 6 Note There may be a 2 second delay before the platform overload indicator light and alarm responds 9 Test all machine functions from the platform controls Result All platform control functions should not operate 10 Turn the key switch to ground control Genie 2 80 60 11 Test all machine functions from the ground controls Result All ground control functions should not operate 12 Using a suitable lifting device lift the test weight off the platform floor Result The alarm should be off The platform overload indicator light should be off at the platform controls and there should be no error message on the LCD display at the ground controls Note There may be a 2 second delay before the overload indicator lights and alarm turn off 13 Test all machine functions from the ground controls Result All ground control functions should operate normally 14 Turn the key switch to platform control 15 Test all machine functions from the platform controls Result All platform control functions should operate normally Part No 1258748 November 2014 Section 4 Repair Procedures 2 5 Platform Overload Recovery Message software V2 04 and later If the ground controls LCD screen displays OVERLOAD RECOVERY the emergency lowering system has been used while the platform was overloaded How to Clear the P
177. b maintenance B 11 Ground control override B 12 Platform self leveling B 13 Engine idle select B 14 Fuel select operation B 15 Drive brakes B 16 Drive speed stowed B 17 Drive speed raised or extended B 18 Alarm and beacon B 19 Hydraulic oil analysis B 20 Safety envelope and circuits B 21 Primary boom self leveling B 22 Primary boom angle sensor B 23 Fuel and hydraulic tank cap venting system A TEREX COMPANY Section 3 Scheduled Maintenance Procedures November 2014 1 MAINTENANCE INSPECTION REPORT Checklist E Engine maintenance Continental models Engine maintenance Deutz models Engine maintenance Perkins models Engine air filter Adjust engine RPM Grease platform overload if equipped Model Checklist C C 1 Serial number Date C 2 Hour meter C 3 Machine owner C 4 ted by print os nspecte rin y p C 6 Inspector signature C 7 Inspector title Test the platform overload if equipped Checklist D Inspector company D 1 Boom wear pads D 2 Free wheel Instructions configuration Make copies of this report to use for each inspection D 3 Turntable rotation bolts D 4 Turntable bearing wear Select the appropriate checklist s for the type of inspection to be performed D 5 Drive hub oil D 6 Replace hydraulic iai id 8 hour filter element
178. be serviced Drive the machine until one of the two plugs is at the lowest point 2 Remove both plugs and drain the oil into a suitable container 3 Drive the machine until one plug is at the top and the other is at 90 degrees a models with pipe plugs b models with o ring plugs Part No 1258748 2014 Section 3 Scheduled Maintenance Procedures 4 Fill the hub with oil from the top hole until the oil level is even with the bottom of the side hole Apply pipe thread sealant to the plugs Install the plugs 5 Models with pipe plugs Apply pipe thread sealant to the plugs and install the plugs Models with O ring plugs Install the plugs into the drive hub 6 Repeat steps 1 through 5 for the other drive hub Turntable Rotate Drive Hub 1 Secure the turntable from rotating with the turntable rotation lock pin 3 4 unlocked locked 2 Remove the motor brake mounting bolts and then remove the motor and brake from the drive 5 hub and set them to the side Component damage hazard Hoses can be damaged if they are 6 kinked or pinched 7 8 Genie A TEREX COMPANY Part No 1258748 CHECKLIST D PROCEDURES 8 motor b motor brake mounting bolts brake Remove the drive hub mounting bolts and use a lifting device to remove the drive hub from the machine Remove the plug from the side of the drive hub Drain the oil from the hub into a container
179. boom bellcrank from the machine AWARNING Crushing hazard The jib boom lift cylinder and jib boom bellcrank could become unbalanced and fall if not properly supported when they are removed from the machine ACAUTION Cushing hazard The platform leveling cylinder may fall if not supported when the rod end pivot pin is removed Section 4 Repair Procedures November 2014 JIB BOOM COMPONENTS 3 2 Jib Boom Lift Cylinder How to Remove the Jib Boom Lift Cylinder Note Perform this procedure with the boom in the stowed position Note When removing a hose assembly or fitting the O ring on the fitting and or hose end must be replaced and then torqued to specification during installation Refer to Section 2 Hydraulic Hose and Fitting Torque Specifications 1 Raise the jib boom slightly and place blocks under the platform mounting weldment Lower the jib boom until the platform is resting on the blocks just enough to support the platform Note Do not rest the entire weight of the boom on the blocks 2 Tag disconnect and plug the jib boom lift cylinder hydraulic hoses Cap the fittings on the cylinder AWARNING Bodily injury hazard Spraying hydraulic oil can penetrate and burn skin Loosen hydraulic connections very slowly to allow the oil pressure to dissipate gradually Do not allow oil to squirt or spray Genie 2 80 60 3 Remove the retaining fasteners from the jib boom lift cylinder rod end
180. cause severe burns 24 Support the drive pump with an appropriate lifting device Remove all of the bell housing to engine fasteners 25 Carefully pull the pump and bell housing assembly away from the engine and secure it from moving Component damage hazard Hoses can be damaged if they are kinked or pinched 23 Remove the flex plate mounting fasteners and remove the flex plate from the engine flywheel Section 4 Repair Procedures November 2014 ENGINES Continental model 27 Tag and disconnect the wire harness from the oxygen sensor 28 Remove the exhaust pipe heat shield fasteners from the top of the muffler ACAUTION Burn Hazard Hot engine parts can cause severe burns 29 Remove the muffler retainer bracket fasteners 30 Remove the muffler fasteners securing the muffler to the exhaust manifold Remove the muffler from the bracket 31 Remove the relay housing from the muffler mount Do not disconnect the relays 32 Disconnect and remove the ECM from the muffler mount 33 Close the shutoff valve on the Liquid Petroleum Gas LPG tank by turning it clockwise if equipped 34 Unbolt the EPR valve from the muffler mount Leave the hoses attached to the EPR valve Genie 2 80 60 35 Remove the muffler mount 36 Support the drive pump with an appropriate lifting device Remove all of pump plate mounting fasteners 37 Carefully pull the pump and bell housing assembly away from the engine and
181. circuits could result in death or serious injury Remove all rings watches and other jewelry Component damage hazard Electrostatic discharge ESD can damage printed circuit board components Maintain firm contact with a metal part of the machine that is grounded at all times when handling printed circuit boards OR use a grounded wrist strap 3 Carefully disconnect the ribbon cable from the LCD display circuit board 4 Remove the LCD display circuit board retaining fasteners 5 Carefully remove the LCD display circuit board from the ground control box lid Section 4 Repair Procedures November 2014 GROUND CONTROLS 6 3 Membrane Decal The membrane decal is a special decal that consists of a decal with an electronic membrane on the backside The membrane contains touch sensitive areas that when pushed activates the machine functions The membrane buttons activate machine functions similar to toggle switches but do not have any moving parts How to Replace the Membrane Decal 1 Turn the key switch at to the off position 2 Push in the red Emergency Stop button to the off position at both the ground and platform controls 3 Remove the ground control box lid fasteners Open the control box lid 4 Tag and disconnect the two ribbon cables from the membrane decal at the ECM circuit board AWARNING Electrocution hazard Contact with electrically charged circuits could result in death or serious injury Rem
182. cond Note Perform this procedure on a firm level surface 1 Turn the key switch to ground control and pull out the red Emergency Stop buttons out to the on position at both the ground and platform controls 2 Push one of the LCD screen buttons shown 4 el until primary boom angle is displayed A TEREX COMPANY Part No 1258748 Z 80 60 3 35 Section 3 Scheduled Maintenance Procedures November 2014 CHECKLIST B PROCEDURES 3 Startthe engine from the ground controls 4 Raise the primary boom The display will begin showing a boom angle of 40 5 Continue raising the primary boom until the display shows 65 O Result The primary boom should stop X Result The primary boom does not stop Immediately release the function enable button and lower the boom Calibrate the limit switch Refer to Repair Procedure 4 7 How to Calibrate the Primary Boom Limit Switch ADANGER Tip over hazard If the boom does not stop at 65 immediately release the function enable button and lower the primary boom Failure to lower the boom could cause the machine to tip over resulting in death or serious injury A TEREX CON B 23 Inspect the Fuel and Hydraulic Tank Cap Venting Systems Genie requires that this procedure be performed every 250 hours or quarterly whichever comes first Perform this procedure more often if dusty conditions exist Free breathing fuel and hydraulic tank caps ar
183. ction 6 Schematic Page Genie Z 80 60 PartNo 1258748 November 2014 INTRODUCTION Serial Number Legend Genie A TEREX COMPANY Model Z 80 60 Serial number 28006 12345 Model year 2014 Manufacture date 01 05 14 Electrical schematic number 50508 Machine unladen weight Rated work load including occupants 500 Ib 227 kg Maximum number of platfrm occupants 2 Maximum allowable side force 150 Ib 670 N Maximum allowable inclination of the chassis 0 deg 280 14 12345 Maximum wind speed 28 mph 12 5 m s Maximum platform height 86 ft 26 38 m m Sequence Maximum platform reach 60 ft 18 28 m number Gradeability N A Country of manufacture USA This machine complies with ANSI A92 5 CAN B 354 4 Model year Terex South Dakota Inc 500 Oakwood Road Serial label PO Box 1150 located under cover Watertown SD 57201 stamped on chassis USA PN 77055 Genie Part No 1258748 Z 80 60 November 2014 This page intentionally left blank Genie M 2 80 60 PartNo 1258748 November 2014 Section 1 Safety Rules Safety Rules Danger Failure to obey the instructions and safety rules in this manual and the Operator s Manual will result in death or serious injury Many of the hazards identified in the operator s manual are also safety hazards when maintenance a
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185. d Do not top off with incompatible hydraulic fluids Hydraulic fluids may be incompatible due to the differences in base additive chemistry When incompatible fluids are mixed insoluble materials may form and deposit in the hydraulic system plugging hydraulic lines filters control valves and may result in componentdamage Note Do not operate the machine when the ambient air temperatue is consistently above 120 F 49 C Hydraulic Fluid Temperature Range 14 32 50 68 86 104 122 F 10 20 30 40 50 40 22 4 40 30 20 10 0 Ambient air temperature 1 Chevron hydraulic oil 5606A 2 Petro Canada Environ MV 46 3 Hydrolube HP 5046D 4 Chevron Rando HD premium oil MV PANY Section 2 Specifications November 2014 SPECIFICATIONS Chevron Rando HD Permium Oil MV Fluid Chevron 5606A Hyraulic Oil Fluid Properties Properties ISO Grade 15 ISO Grade 32 Viscosity index 300 Viscosity index 200 Kinematic Viscosity Kinematic Viscosity cSt 200 F 100 C 5 5 cSt 200 F 100 C 7 5 cST 104 F 40 C 15 cST 104 F 40 C 33 5 cST 40 F 40 C 510 Brookfield Viscosity Flash point 180 F 82 C cSt 4 F 20 C cST 22 F 30 C 1040 3310 Flash point 375 F 190 C Pour point 58 F 50 C Maximum continuous operating temperature 171 F 77 C N
186. d 653 5 570 Injector3 in firing order interruption of 708 5 424 Engine running lamp open load electric connection 703 12 425 Enginerunning lamp 654 3 583 Injector4 in firing order powerstageovertemperature short circuit 729 5 545 Cold start aid relay open load 654 4 589 High side to low side short 729 12 547 Cold start aid relay over circuit in the injector 4 temperature error in firing order ETT 898 9 305 Timeout Error 01 CAN Receive 654 5 571 Injector 4 in firing order Frame TSC1TE Setpoint interruption of electric connection 1079 13 946 Sensor supply voltage monitor 1 error ECU 676 11 543 Cold start aid relay error 1080 13 947 Sensorsupply voltage monitor 676 11 544 Coldstartaid relay open load 2error ECU PartNo 1258748 Z 80 60 5 17 Section 5 Fault Codes m J JP DEUTZ TD 2 9 L4 ENGINE FAULT CODES November 2014 SPN Suspect Parameter Number FMI Failure Mode Identifier KWP Keyword Protocol SPN FMI KWP Description SPN FMI KWP Description 1109 2 121 Engine shut off demand ignored 1180 1 1463 Exhaust gas temperature upstream turbine shut off 116 0 1398 Physikal range check high for threshold exceeded ECU temperature 1180 1067 Sensor error exhaust gas ECU temperature signal range check high 1136 3 1400 SensorerrorECUtemp
187. d and may tip over Refer to Section 6 for limit switch and angle sensor information Secondary Boom 1 Angle Safety Limit Switch LSS2AS 1 Turn the key switch to ground control and pull out the red Emergency Stop buttons out to the on position at both the ground and platform controls 2 Startthe engine from the ground controls 3 Simultaneously push the LCD screen buttons shown to activate status mode 4 Push one of the LCD screen buttons shown until secondary boom 4 length is displayed 5 Fully raise the secondary boom and extend the secondary boom approximately 2 feet 61 cm A TEREX 6 Remove the fasteners from the turntable riser cover at the platform end of the secondary boom Remove the cover 7 Locate the Deutsch connectors from the secondary safety retract switch LSS1RS near the chassis at the platform end of the secondary boom The connection will be marked with yellow zip ties on the wire assembly Disconnect the connectors 8 Locate the Deutsch connectors from the secondary boom 1 retract operational limit switch LSS1RO at the end of the secondary boom The connection will be marked with red zip ties on the wire assembly Disconnect the connectors 9 Install a wire jumper between 1 pin 2 of the Deutsch connector on the wire harness removed in step 8 10 Install a second wire jumper between pin 3 and pin 4 of the Deu
188. d on the hydraulic tank 2 Place a suitable container under the hydraulic tank return filter 3 Remove the filter with an oil filter wrench 4 Apply thin layer of fresh oil to the gasket of the new oil filter A TEREX COMI 5 Install the new hydraulic return filter element and tighten it securely by hand Clean up any oil that may have spilled during the installation procedure 6 Use a permanent ink marker to write the date and number of hours from the hour meter on the oil filter Medium and high pressure filters Note The medium pressure filter is for the charge pump One high pressure filter is for all boom and steer functions The other high pressure filter is for the oscillating axle circuit and flattorm manifold 7 Openthe engine side turntable cover and locate the three filters mounted to the bulkhead a high pressure filters b medium pressure filter 8 Place a suitable container under the filters 9 Remove the filter housing by using a wrench on the nut provided on the bottom of the housing Part No 1258748 2014 Section 3 Scheduled Maintenance Procedures 10 Remove the filter element from the housing 11 Inspect the housing seal and replace it if necessary 12 Install the new medium and high pressure filter elements into the housings and tighten them securely 13 Clean up any oil that may have spilled during the installation procedure 14 Use a perm
189. de by pressing the buttons at the ground controls in the following sequence Part No 1258748 Genie Z 80 60 AXLE COMPONENTS 9 Use the button to scroll through the menu until the appropriate steer sensor is displayed Choose from RESET BLUE END BLUE SIDE STEER SENSOR RESET YELLOW END BLUE SIDE STEER SENSOR RESET YELLOW END YELLOW SIDE STEER SENSOR RESET BLUE END YELLOW SIDE STEER SENSOR Press the button to select ves then press the button 10 Exit the sensor calibration mode and turn the keyswitch to the off position 11 Rotate the steer sensor to the opposite limit of travel 12 Using a voltmeter set to DC voltage probe the back of the steer sensor electrical connector at pins B and C 13 Turn the keyswitch on at the ground controls Rotate the sensor slowly until the voltage reading is between 2 4 to 2 5V DC The alarm at the ground control box should sound 14 Turn the keyswitch to platform controls Start the engine from the platform controls 15 Press down the foot switch 16 Rotate the steer sensor cover to adjust the tire alignment Measure the distance between the inside of the tire and the chassis side plate on both sides of the axle 17 Repeat step 14 until the tire is parallel with the chassis 18 Tighten the steer sensor cover fasteners 4 103 Section 4 Repair Procedures November 2014 AXLE COMPONENTS How to Adjust the O
190. dentify discovered symptoms Troubleshoot problem still exists Return to Inspect Perform service problem and test repair solved Section 6 Schematics November 2014 Wire Circuit Legend Circuit numbering Circuit suffix 1 Circuit numbers consist of three parts the circuit Definition Suffix prefix circuit number and circuit suffix The AC Generator GEN circuit prefix indicates the type of circuit The Alternator Field AF circuit number describes the function of the Angle ANG circuit The circuit suffix provides an Auxiliary Boom Valve ABV abbreviation for the number or may be used to Auxiliary Forward Valve AFV further define the function of this portion of the Auxiliary Hydraulic Pump AH circuit It also may be used to indicate the final Auxiliary Platform Valve APV end of the circuit i e LS or limit sw Auxiliary Reverse Valve ARV Ste Auxiliary Steer Drive Valve ASV 2 22 m number may be used more than once Axle Extend Valve AXE Axle Oscillate AXO Axle Retract Valve AXR For Example Axle Front Position FAP C 74 PL This is the circuit for the lockout Axle Rear Position RAP valve 1 C stands for control 74 is the number of the circuit Battery BAT for the primary 1 lock out valve Boom Extended BEX PL stands for Primary Lockout Boom Stowed BST S 62 BST This is the circuit that communicates to the onboard Brake BRK computers of the machine that the boom is fully stowed S Bypass Valves BV
191. dicate the presence of a potentially hazardous situation which if not avoided may result in property damage Note Used to indicate operation or maintenance information Be sure to wear protective eye wear and e other protective clothing if the situation warrants it Be aware of potential crushing hazards F such as moving parts free swinging or unsecured components when lifting or placing loads Always wear approved steel toed shoes Genie vill Z 80 60 Workplace Safety Be sure to keep sparks flames and W lighted tobacco away from flammable and combustible materials like battery gases and engine fuels Always have an approved fire extinguisher within easy reach Be sure that all tools and working areas N are properly maintained and ready for use Keep work surfaces clean and free of debris that could get into machine components and cause damage other lifting or supporting device is 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 time use i e cotter pins and self locking nuts are not reused These components may fail if they are used a second time Be sure any forklift overhead crane or Be sure ie fasteners intended for one Be sure to properly dispose of old oil or 2 other fluids Use approved container Please be environmentally safe sure that your workshop or work area is W pro
192. direction and hold for 5 seconds then return to the center or neutral position Result The alarm at the ground controls should sound for a successful calibration Result If the alarm does not sound repeat calibration procedure November 2014 How to Reset a Proportional Valve Coil Default Note This procedure only needs to be performed if a proportional valve has been replaced Note After the valve coil defaults have been set each machine function threshold and default function speed must be set See How to Set the Function Thresholds and Default Function Speeds 1 2 Genie 2 80 60 Turn the key switch to the off position Press and hold the enter button on the ground control panel while turning the key switch to platform controls Press the minus button twice then press the enter button twice Use the scroll button to scroll through the menu until the function valve that needs to be reset is displayed Press the button to select ves then press the button Part No 1258748 November 2014 Section 4 Repair Procedures How to Set the Function Thresholds and Default Functions Speeds Note Before the threshold and default function speeds can be set the boom function proportional valve coil defaults must be set first See How to Reset a Proportional Valve Coil Default Note If a boom function proportional valve coil has not been replaced and just want to
193. draulic Hose and Fitting Torque Specifications Note The secondary boom extension cylinder must be removed as an assembly with the cable tracks cable track trays and cable track support tubes from the platform end of the secondary boom 1 Raise the primary boom to a horizontal position 2 Remove the access cover from the counterweight end of the secondary boom Section 4 Repair Procedures November 2014 er BOOM COMPONENTS 3 Remove the fasteners securing the cable track 11 Tag disconnect and plug the secondary boom trays and cable track clamps to the secondary extension boom Remove the external snap rings from the extension cylinder rod end pivot pin Use a soft metal drift to remove the pin Remove the access cover from the platform end of the secondary boom extension cylinder hydraulic hoses Cap the fittings on the cylinder AWARNING Bodily injury hazard Spraying hydraulic oil can penetrate and burn skin Loosen hydraulic connections very slowly to allow the oil pressure to dissipate gradually Do not allow oil to squirt 7 Working atthe platform end place blocks under or spray the barrel end of the secondary boom extension cylinder for support 12 Remove the cable track fasteners and cable track support tubes from the extension cylinder Component damage hazard Be careful not to damage the secondary boom retract limit switch when installing the cylinder assembly into the secondary bo
194. dure it conveys the meaning below Indicates that tools will be required to perform this procedure Indicates that new parts will be required to perform this procedure Indicates that a cold engine will be required to perform this procedure Indicates that a warm engine will be required to perform this procedure Indicates that dealer service is required to perform this procedure A TEREX CON Pre delivery Preparation Report The pre delivery preparation report contains checklists for each type of scheduled inspection Make copies of the Pre delivery Preparation report to use for each inspection Store completed forms as required Maintenance Schedule There are five types of maintenance inspections that must be performed according to a schedule daily quarterly six months annual and two years The Scheduled Maintenance Procedures Section and the Maintenance Inspection Report have been divided into five subsections A B C D and E Use the following chart to determine which group s of procedures are required to perform a scheduled inspection Inspection Checklist Daily or every 8 hours A Quarterly or every 250 hours A B Six months or every 500 hours A B C Annual or every 1000 hours A B C D Two years or every 2000 hours A B C D E Maintenance Inspection Report The maintenance inspection report contains checklists for each type of scheduled inspection Make copies of the Maintenanc
195. e ESD can damage printed circuit board components Maintain firm contact with a metal part of the machine that is grounded at all times when handling printed circuit boards OR use a grounded wrist strap 4 Carefully tag and disconnect the connectors from the LED circuit board 5 Remove the LED circuit board retaining fasteners 6 Carefully remove the LED circuit board from the platform control box lid 4 Close the control box lid Part No 1258748 Genie Z 80 60 PLATFORM CONTROLS 1 2 Joysticks How to Calibrate a Joystick The joystick controllers on this machine utilize digital Hall Effect technology for proportional control If a joystick controller is disconnected or replaced it must be calibrated before that particular machine function will operate Note The joystick must be calibrated before the threshold max out or ramping can be set Note After each joystick is calibrated check the display at the ground control box There should be no calibration faults shown on the display If calibration faults exist repeat steps 1 through 8 for that joystick controlled function Note Perform this procedure with the engine off Drive functions 1 Turn the key switch to the off position 2 Press and hold the enter button on the ground control panel while turning the key switch to platform controls 3 Press the minus button twice then press the enter button twice 4 Use the scroll button
196. e LPG tank Disconnect the hose from the tank Move the fuel select switch to the LPG position 6 Have another person crank the engine with the starter motor for 15 seconds wait 15 seconds then crank the engine an additional 15 seconds or until the pressure reaches 320 psi 22 bar 7 Deutz and Perkins models Connect the engine wiring harness to the fuel solenoid GM Ford and Continental models Connect the LPG hose to the LPG tank and open the valve on the tank 8 Start the engine from the ground controls and check for hydraulic leaks Section 4 Repair Procedures October 2014 Manifolds 8 1 Function Manifold View 1 The function manifold is located next to the ground control box Index Schematic No Description Item Function 1 Differential sensing valve Secondary boom up extend and down retract 2 Relief valve 2500 psi 172 bar B Secondary boom up 3 Solenoid valve 2 position 2 way C Secondary boom up circuit 4 Relief valve 2500 psi 172 bar D Secondary boom down 5 Relief valve 1300 psi 89 6 bar E Primary boom down 6 Flow regulator valve 0 1 gpm 0 38 Bleeds off check valves differential sensing circuits to tank 7 Proportional solenoid valve
197. e That would indicate code 531 Note Once a fault code has been retrieved and the repair has been completed the ECM memory must be reset to clear the fault code from the ECM See How to Clear Engine Fault Codes from the ECM How to Clear Engine Fault Codes from the ECM Note Perform this procedure with the engine off and the key switch in the off position 1 Open the engine side turntable cover and locate the battery 2 Disconnect the negative battery cable from the battery for a minimum of 5 minutes AWARNING Electrocution hazard Contact with electrically charged circuits could result in death or serious injury Remove all rings watches and other jewelry 3 Connect the negative battery cable to the battery Section 5 Fault Codes CONTINENTAL TME27 ENGINE FAULT CODES November 2014 9 EIl lelg gt 55 gt 2 System Code Fault Name 515 lt Fault Conditions 108 Pressure High YY MAP pressure gt 16 psi and TPS lt 10 and RPM gt 1800 To Unlatch MAP pressure must be lt 10 psi 107 MAP Voltage Low MAP voltage 0 05 vdc and TPS gt 2 and RPM lt 7000 To Unlatch MAP voltage must be gt 0 5 vdc ECT 118 ECT Voltage High Y ECT voltage gt 4 95 vdc CHT 117 ECT Voltage Low Y ECT voltage lt 0
198. e The ECM also uses signals from the sensors to initiate sequential fuel injection and make constant and instantaneous changes to ignition timing fuel delivery and throttle position to maintain the engine s running condition at its highest efficiency while at the same time keeping exhaust emissions to a minimum When a sensor fails or returns signals that are outside of set parameters the ECM will store a fault code in memory that relates to the appropriate sensor The active fault code will also be displayed on the LCD Screen Note The Perkins 404F 22T is equipped with an engine fault LED located at the platform control box If an engine fault occurs that does not result in an engine shutdown the engine rpm will go into limp home mode resulting in the loss of high rpm A TEREX CON Start the engine from the ground control box and operate various boom functions to verify that an active engine fault occurs and is shown on the display Note All faults are stored in the Previous Fault history menu These faults will not be erased when corrective action has been completed Note Software is available from the engine manufacturer to perform diagnosis through the engine diagnostic port Contact the specific engine manufacturer MPANY Part No 1258748 2014 Deutz TD 2 9 14 Engine Fault Codes Section 5 Fault Codes SPN Suspect Parameter Number FMI Failure Mode Identifier KWP Keyword Pro
199. e essential for good machine performance and service life A dirty or clogged tank cap may cause the machine to perform poorly and continued use may cause component damage Extremely dirty conditions may require that the caps be inspected more often ADANGER Explosion and fire hazard Engine fuels are combustible Perform this procedure in an open well ventilated area away from heaters sparks flames and lighted tobacco Always have an approved fire extinguisher within easy reach Note Perform this procedure with the engine off 1 Remove the cap from the fuel tank Part No 1258748 November 2014 Section 3 Scheduled Maintenance Procedures 4 CHECKLIST PROCEDURES 2 Check for proper venting Result Air passes through the fuel tank cap Proceed to step 4 Result If air does not pass through the clean or replace the cap Proceed to step 3 Note When checking for positive tank cap venting air should pass freely through the cap 3 Using a mild solvent carefully wash the cap venting system Dry using low pressure compressed air Repeat this procedure beginning with step 2 4 Install the fuel tank cap onto the fuel tank 5 Remove the breather cap from the hydraulic tank 6 Check for proper venting Result Air passes through the hydraulic tank cap Proceed to step 8 Result If air does not pass through the clean or replace the cap Proceed to step 7 Note When chec
200. e Inspection Report to use for each inspection Maintain completed forms for a minimum of 4 years or in compliance with employer jobsite and governmental regulations and requirements MPANY Part No 1258748 November 2014 Section 3 Scheduled Maintenance Procedures Pe This page intentionally left blank A TEREX COMPANY Part No 1258748 Z 80 60 3 3 Pre Delivery Preparation Fundamentals It is the responsibility of the dealer to perform the Pre delivery Preparation The Pre delivery Preparation is performed prior to each delivery The inspection is designed to discover if anything is apparently wrong with a machine before it is put into service A damaged or modified machine must never be used If damage or any variation from factory delivered condition is discovered the machine must be tagged and removed from service Repairs to the machine may only be made by a qualified service technician according to the manufacturer s specifications Scheduled maintenance inspections shall be performed by qualified service technicians according to the manufacturer s specifications and the requirements listed in the responsibilities manual Genie A TEREX BRAND Genie Industries USA 18340 NE 76th Street PO Box 97030 Redmond WA 98073 9730 425 881 1800 Genie UK The Maltings Wharf Road Grantham Lincolnshire NG31 6BH England 44 1476 584333 Copyright 2002 by Genie I
201. e Procedures A 11 Perform Engine Maintenance Continental Models Engine specifications require that this procedure be performed every 100 hours Proper engine maintenance following the engine manufacturer s maintenance schedule is essential to good engine performance and service life Failure to perform the maintenance procedures can lead to poor engine performance and component damage Engine oil replace Oil filter replace Required maintenance procedures and additional engine information are available in the Continental TME27 Owner s Manual Continental part number WM10303 Continental TME27 Owner s Manual Genie part number 111901 A TEREX COMI Part No 1258748 CHECKLIST A PROCEDURES A 12 Replace the Drive Hub Oil Manufacturer drive hub specifications require that this one time procedure be performed after the first 150 hours Replacing the drive hub oil is essential for good machine performance and service life Failure to replace the drive hub oil after the first 150 hours of use may cause the machine to perform poorly and continued use may cause component damage Drive Hubs 1 Select the drive hub to be serviced Drive the machine until one of the two plugs is at the lowest point 2 Remove both plugs and drain the oil into a suitable container 3 Drive the machine until one plug is at the top and the other is at 90 degrees models with pipe plugs models with o ring plugs
202. e circuit that directs hot oil out of low pressure side of drive pump 30 35 ft lbs 41 47 Nm 9 Bi directional flow control valve 4 5 17 L MIN El is Equalizes pressure on both sides of divider combiner valve EJ 30 35 ft lbs 41 47 Nm 10 Flow divider combiner valve EJ 6 Controls flow to drive motors in forward and reverse 90 100 ft Ibs 122 136 Nm Genie 4 90 Z 80 60 Part No 1258748 November 2014 Section 4 Repair Procedures MANIFOLDS 4 9 Q CA 9 EG 7 Genie Part No 1258748 Z 80 60 4 91 Section 4 Repair Procedures November 2014 MANIFOLDS 8 11 Valve Adjustments 2WD Traction Manifold How to Adjust the Charge Pressure Relief Valve Note Perform this procedure with the hydraulic oil temperature at 100 F to 150 F 3890 to 65 5 C Note This will take two people to perform this procedure 1 Connect a 0 to 600 psi 0 to 50 bar pressure gauge to the test port on the drive pump 2 Startthe engine from the ground controls 3 Pressthe function enable high rpm select button rabbit symbol position Note the reading on the pressure gauge 4 Turnthe engine off Remove the pressure gauge from the drive pump Connect the gauge to the test port located on the drive manifold 6 Useawrench to hold the charge pressure relief valve and remove the cap item E
203. e internal hex socket Turn it clockwise to increase the pressure or counterclockwise to decrease the pressure Install the relief valve cap AWARNING Tip over hazard Do not adjust the relief valve higher than specified 11 Repeat steps 7 through 8 to confirm relief valve pressure 12 Start the engine and fully retract the primary boom Turn the engine off 13 Install the limit switch and bracket assembly to the primary boom 14 Remove the pressure gauge How to Adjust the Secondary Boom Up Relief Valve 1 Remove the cover retaining fasteners from the secondary boom end cover Remove the cover from the machine 2 Locate the wire connector for secondary boom limit switch 1552 Disconnect the connector Note The secondary boom limit switch 1 552 is the upper limit switch located on the inside of the riser plate at the engine side of the machine 3 Install a jumper wire between pins 3 and 4 of the 552 Deutsch connector on the wire harness end Genie 2 80 60 4 Connect a 0 to 5000 psi 0 to 350 bar pressure gauge to the LS port on the function manifold 5 Startthe engine from the ground controls 6 Simultaneously push and hold the function enable high speed button and the secondary boom up extend button and fully raise the secondary boom 7 Continue holding the function enable high speed button and the secondary boom up extend button while observing the reading on the pressure gauge Refer t
204. e platform to be tucked underneath the mast for transport LSP1AO Limit Switch Primary Boom 1 Angle Operational One side closes when the primary boom is raised from the stowed position disabling the drive motor destroke and limiting the drive speed The other side of the switch closes when the boom is fully lowered allowing the platform to be tucked underneath the mast for transport LSJ1EO Limit Switch Jib Boom 1 Closes when the platform leveling cylinder is fully extended disabling the primary boom down function LSP1EO Limit Switch Primary Boom 1 Extend Operational Switch closes as the primary boom extends the last 6 to 12 inches signaling the computer LSP1RO Limit Switch Primary Boom 1 Retract Operational Switch closes when the primary boom is fully retracted Section 6 Schematics Drive Chassis and Platform Controller Pin Legend November 2014 CONNECTOR J31 BLACK 11 C90PXS RD BK 12 UNUSED 13 UNUSED 14 UNUSED 15 C88PTS RD BK 16 R56PTS RD 17 C56PTS RD 18 S14PLU RD 19 PLATRET BR 20 C84TAY GR BK 21 P85PTS GR 11 UNUSED 12 UNUSED 13 UNUSED 14 UNUSED 15 C470UT WH BK 16 C46HRN WH 17 D81CAN GR 18 D82CAN YL 19 UNUSED 20 UNUSED 21 UNUSED rj 00000000 00
205. e the engine tray from moving could result in death or serious injury A TEREX COMPANY Part No 1258748 Z 80 60 CHECKLIST A PROCEDURES Section 3 Scheduled Maintenance Procedures November 2014 4 CHECKLIST PROCEDURES This page intentionally left blank A TEREX COMPANY 3 16 Z 80 60 Part No 1258748 2014 Section 3 Scheduled Maintenance Procedures Checklist B Procedures B 1 Inspect the Batteries Note Genie specifications require that this procedure be performed every 250 hours or quarterly whichever comes first Proper battery condition is essential to good engine performance and operational safety Improper fluid levels or damaged cables and connections can result in engine component damage and hazardous conditions AWARNING Electrocution burn hazard Contact with hot or live circuits could result in death or serious injury Remove all rings watches and other jewelry AWARNING Bodily injury hazard Batteries contain acid Avoid spilling or contacting battery acid Neutralize battery acid spills with baking soda and water 1 Put on protective clothing and eye wear 2 Be sure that the battery cable connections are free of corrosion Note Adding terminal protectors and a corrosion preventative sealant will help eliminate corrosion on the battery terminals and cables 3 Be sure that the battery hold downs and cable connections are tight A TEREX COMP
206. e the pin retaining fasteners from the primary boom lift cylinder barrel end pivot pin 7 Place blocks under both ends of the primary boom lift cylinder for support 8 Use a soft metal drift to remove the barrel end pivot pin Rest the barrel end of the primary boom cylinder on the blocks AWARNING Crushing hazard The primary boom could become unbalanced and fall if not properly supported when the pivot pin is removed 9 Attach a lifting strap from an overhead crane to the primary boom lift cylinder linkage arm Support the arm 10 Remove the pin retaining fasteners from the primary boom lift cylinder linkage arm where it connects to the primary boom Part No 1258748 November 2014 Section 4 Repair Procedures 11 Use a soft metal drift to remove the upper primary boom lift cylinder linkage arm pivot pin Using a suitable lifting device remove the linkage arm from the machine Crushing hazard The upper ACAUTION primary boom lift cylinder linkage arm will fall if not properly supported when the pivot pin is removed 12 Attach a 5 ton 5000 kg overhead crane to the center point of the primary boom 13 Remove the pin retaining fastener from the primary boom pivot pin 14 Use a soft metal drift to remove the primary boom pivot pin AWARNING Crushing hazard The primary boom could become unbalanced and fall if not properly supported when the pivot pin is removed 15 Carefully remove the primary boo
207. eck the Free wheel Configuration Proper use of the free wheel configuration is essential to safe machine operation The free wheel configuration is used primarily for towing A machine configured to free wheel without operator knowledge may cause death or serious injury and property damage AWARNING Collision hazard Select a work site that is firm and level Component damage hazard If the machine must be towed do not exceed 2 mph 3 2 km h 1 Chockthe steer wheels to prevent the machine from rolling 2 Center a lifting jack of ample capacity 20 000 Ibs 10 000 kg under the drive chassis between the wheels at the non steer end of the machine 3 Liftthe wheels off the ground and place blocks under the drive chassis for support 4 Disengage the drive hubs by turning over the drive hub disconnect caps on each non steer wheel hub disengaged position EAM arg engaged position A TEREX COMI 5 Manually rotate each non steer wheel Result Each non steer wheel should rotate with minimum effort 6 the drive hubs by turning over the hub disconnect caps Rotate each wheel to check for engagement Lift the machine remove the blocks llision h a AWARNING Collision hazard Failure to re engage the drive hubs could result in death or serious injury and property damage 4WD models 7 Chockthe non steering wheels to prevent the machine from roll
208. ect button until the foot Switch activated high idle rabbit and foot switch symbol is selected 4 Press down the foot switch and raise the boom until the engine switches to low idle 5 Choose a point on the machine i e contact patch of a tire as a visual reference for use when crossing the start and finish lines 6 Bring the machine to top drive speed before reaching the start line Begin timing when your reference point on the machine crosses the start line A TEF 7 Continue at full speed and note the time when the machine reference point crosses the finish line Refer to Section 2 Specifications 8 Lower the boom to the stowed position 9 Extend the boom 4 feet 1 2 m 10 Choose a point on the machine i e contact patch of a tire as a visual reference for use when crossing the start and finish lines 11 Bring the machine to top drive speed before reaching the start line Begin timing when your reference point on the machine crosses the start line 12 Continue at top speed and note the time when the machine reference point crosses the finish line Refer to Section 2 Specifications REX COMPANY Part No 1258748 2014 Section 3 Scheduled Maintenance Procedures B 18 Test the Alarm and Optional Flashing Beacon An alarm and optional flashing beacon are installed to alert operators and ground personnel of machine proximity and motion There are four alarm option modes that ca
209. ective 2659 12 1526 Exhaust gas recirculation AGS 3699 2 1617 Temperature sensor us and sensor has burn off ds DOC simultaneously defect norpenomiga 3699 14 1615 Maximumstand still duration 2797 4 1337 Injector diagnostics timeout reached oil exchange required error of short circuit to ground 4765 0 1039 Physical range check high for measurement cyl Bank 0 exhaust gas temperature upstream DOC 4765 1 1042 Physical range check low for exhaust gas temperature upstream DOC Part No 1258748 Z 80 60 5 19 Section 5 Fault Codes m J JP DEUTZ TD 2 9 L4 ENGINE FAULT CODES November 2014 SPN Suspect Parameter Number FMI Failure Mode Identifier KWP Keyword Protocol SPN FMI KWP Description SPN FMI KWP Description 4766 1029 Physical range check high for 523008 2 649 Timeouterrorin Manipulation exhaust gas temperature control downstream DOC 523009 9 825 Pressure Relief Valve PRV 4766 1 1032 Physical range check low for reached maximun allowed exhaust gas temperature opening count downstream DOC 523009 10 833 Pressure relief valve PRV 4768 2 1036 Sensor exhaust gas reached maximun allowed temperature upstream DOC open time plausibility error 523212 9 171 TimeoutErrorof CAN Receive 4768 3 1044 Sensor error exhaust gas Frame ComEngPrt temperature u
210. ed LSS1RS Secondary boom fully retracted safety LSJ1EO Platform level fully extended LST10 Drive enable mechanical LSA10S Oscillate axle right side 15 205 Oscillate axle left side Numbering Legend Switch number J Jib boom D Down Primary Boom A Angle S Secondary Boom E Extend T Turntable Retract LS Limit switch y LS P RO Part No 1258748 November 2014 Section 6 Schematics LIMIT SWITCHES AND ANGLE SENSORS Limit Switch and Angle Sensor Legend PRIMARY BOOM ANGLE SENSOR LSP1RO 1552 LSJ1EO SECONDARY BOOM __ BE LSA10S Limit switch Axle 1 Oscillating Operational Activates the axle oscillate circuit on the right side LSA20S Limit switch Axle 2 Oscillating Operational Activates the axle oscillate circuit on the left side LST10O Limit switch Operational Activates the drive enable zone Turntable Angle Sensor Measures the X axis and Y axis of the turntable The alarm sounds at 4 5 degrees Primary Boom Angle Sensor PBS Measures the Y axis angle of the primary boom The operational range shall be 33 degrees to 73 degrees The safety cutouts are set at 70 degrees and will disable boom up and stop the engine Platform Angle Sensor Measures the angle of the platform The range of measurement is 20 degrees The safety cutout is set at
211. eeping exhaust emissions to a minimum When a sensor fails or returns signals that are outside of set parameters the ECM will store a fault code in memory that relates to the appropriate sensor and will turn on the Check Engine Light Note Perform this procedure with the key switch in the off position 1 Open the ground controls side cover and locate the run test toggle switch on the side of the ground control box 2 Pull out the red Emergency Stop button to the on position at both the ground and platform controls 3 Quickly activate and release the start toggle switch button Do not start the engine 4 Move and hold the run test toggle switch to the test position O Result The check engine light should turn on The check engine light should begin to blink Part No 1258748 5 Continue to hold the run test toggle switch in the test position and count the blinks Note Before the fault codes are displayed the check engine light will blink a code 123 three times After the fault codes the check engine light will blink a code 123 three times again indicating the end of the stored codes Note If any fault codes are present the ECM will blink a three digit code three times for each code stored in memory It will blink the first digit of a three digit code pause blink the second digit pause and then blink the third digit For example the check engine light blinks 5 consecutive times blinks 3 times and then 1 tim
212. eners to 57 ft lbs 77 Nm Component damage hazard Do not force the drive pump during installation or the flex plate teeth may become damaged Install the pump coupler onto the pump shaft with the set screw toward the pump Leave the appropriate gap between coupler and pump end plate for your engine Install the pump and pump mounting plate assembly onto the engine Apply Loctite removable thread sealant to the mounting screws 1 Install the pump and bell housing assembly Deutz models Torque the bell housing mounting bolts labeled C in sequence to 28 ft Ibs 38 Nm Then torque the bell housing mounting bolts labeled C in sequence to 40 ft Ibs 54 Nm Section 4 Repair Procedures November 2014 Perkins 804D models Torque the bell housing mounting bolts in sequence to 28 ft lbs 38 Nm and then to 49 ft lbs 66 Nm Perkins 404F models Torque the bell housing mounting bolts labeled B in sequence to 28 ft Ibs 38 Nm and the mounting bolts labeled A to 49 ft lbs 66 Nm Then torque the bell housing mounting bolts labeled B in sequence to 40 ft Ibs 54 Nm and the mounting bolts labeled A to 70 ft lbs 95 Nm Continental model Torque the pump mounting plate fasteners in sequence to 23 ft lbs 31 2 Nm Pele ere Pump Mounting Plate Component damage hazard When installing the pump do not force the pump coupler into the flexplate or damage to the pump shaft seal may occur Componen
213. enetrate and burn skin Loosen hydraulic connections very slowly to allow the oil pressure to dissipate gradually Do not allow oil to squirt or spray 7 Remove the pin retaining fastener from the primary boom lift cylinder rod end pivot pin PartNo 1258748 Genie Section 4 Repair Procedures BOOM COMPONENTS 8 Use a soft metal drift to remove the pin Crushing hazard The primary boom will fall if not properly supported when the pivot pin is removed Crushing hazard The lift cylinder will fall if not properly supported when the pivot pin is removed ACAUTION Crushing hazard The primary boom lift cylinder linkage arms may fall if not properly supported when the pivot pin is removed 9 Remove the primary boom lift cylinder barrel end pivot pin retaining fasteners 10 Use a soft metal drift to remove the barrel end pivot pin Remove the primary boom lift cylinder from the machine Crushing hazard The lift cylinder will become unbalanced and fall if not properly supported when the pin is removed Z 80 60 Section 4 Repair Procedures November 2014 BOOM COMPONENTS 4 4 Primary Boom Extension Cylinder The primary boom extension cylinder extends and retracts the primary boom extension tube The primary boom extension cylinder is equipped with counterbalance valves to prevent movement in the event of a hydraulic line failure How to Remove the Primary Boom Extension Cylinder AW
214. engine off Use a wrench to hold the relief valve and remove the cap item D Part No 1258748 Genie Z 80 60 MANIFOLDS 8 Adjust the internal hex socket Turn it clockwise to increase the pressure or counterclockwise to decrease the pressure Install the relief valve cap AWARNING Tip over hazard Do not adjust the relief valve higher than specified 9 Start the engine and repeat step to confirm relief valve pressure 10 Start the engine and raise the secondary boom approximately 12 inches 30 cm Remove the block and lower the secondary boom to the stowed position 11 Turn the engine off and remove the pressure gauge How to Adjust the Secondary Boom Extend Relief Valve Note Perform this procedure with the secondary boom fully raised 1 Connect 8 0 to 5000 psi 0 to 350 bar pressure gauge to the LS port on the function manifold 2 Start the engine from the ground controls 3 Simultaneously push and hold the function enable high speed button and the secondary boom up extend button with the secondary boom fully raised and extended Observe the pressure reading on the pressure gauge Refer to Section 2 Specifications Section 4 Repair Procedures November 2014 MANIFOLDS 4 Turn the engine off Use a wrench to hold the 4 Turn the engine off Use a wrench to hold the relief valve and remove the cap item Q relief valve and remove the cap item AG 5 Adjust the internal hex socket Turn i
215. enie policy Product specifications are subject to change without notice A TEREX COMPANY 2 12 Z 80 60 Part No 1258748 November 2014 Section 2 Specifications Perkins 804D 33 Engine Displacement Number of cylinders Bore and stroke Horsepower Firing order Compression ratio Compression pressure 201 cu in 3 3 liters 4 3 70 x 4 72 inches 94 x 120 mm 63 2600 rpm 47 kW 2600 rpm 1 3 4 2 22 1 300 to 500 psi 20 7 to 34 5 bar Pressure psi or bar of lowest cylinder must be within 50 psi 3 45 bar of highest cylinder SPECIFICATIONS Oil viscosity requirements Units ship with 15W 40 Extreme operating temperatures my require the use of alternative engine oils For oil requirements refer to the Engine Operator Handbook on your machine Injection system Injection pump make Zexel 10641 3932 Injection pump pressure 1707 to 1849 psi 117 7 to 127 5 bar Injector opening pressure 2000 psi 138 bar Fuel Requirement For fuel requirements refer to the engine Operator s Manual on your machine Low idle 1650 rpm Frequency 335 5 Hz Engine coolant Low idle with generator 1400 rpm Capacity 12 5 quarts Frequency 284 7 Hz 11 8 liters High idle 2300 rpm Batteries Frequency 467 7 Hz Type 12V DC Governor mechanical all speed Group 31 Valve clearance cold 3 Quantity 2 Intake 0 0098 in 0 25 mm Cold cranking ampere 1000A
216. erature 4180 11 1066 Sensor exhaust gas signal range check high temperature upstream turbine 1136 4 1401 SensorerrorECU temperature plausibility error signal range check low 1188 2 1414 Wastegate status message 1176 3 849 Sensorerror pressure sensor from ECU missing upstream turbine signal 118 7 1415 Wastegate actuator blocked range check high 1188 11 1411 Wastegate actuator 1176 4 850 Sensor error pressure sensor internal error downstream turbine signal range check high 1188 11 1412 Wastegate actuator EOL 5 calibration not 1180 0 1193 Physical range check high for performed correctly exhaust gas temperature upstreamturbine 1188 11 1416 Wastegate actuator over temperature 145 C 1180 1460 Turbocharger Wastegate CAN feedback warning threshold 1188 11 1417 Wastegate actuator over exceeded temperature gt 135 C 1180 1462 Exhaust gas temperature 1188 11 1418 Wastegate actuator operating upstream turbine warning voltage error threshold exceeded ES 1188 13 1413 Wastegate actuator calibration 1180 1 1194 Physical range check low for deviation too large exhaust gas temperature recalibration required upstreamturbine 1231 14 85 CAN Bus 1 BusOff Status 1180 1 1461 TurbochargerWastegate exceeded 5 18 Z 80 60 Part No 1258748 2014 Section 5 Fault Codes DEUTZ TD 2 9 L4 ENGINE FAULT CODES SPN Suspect Parameter Number FMI Failure Mode Identifier KWP Keyword Protocol
217. ernal Actuator Y Y fault detection 1177 EPR Internal Circuitry Y Y fault detection 1178 EPR Internal Comm Y Y fault detection Adaptive Learn Key Cycle Continued on next page 5 34 Z 80 60 Part No 1258748 November 2014 Section 5 Fault Codes Pee CONTINENTAL TME27 ENGINE FAULT CODES 9 JABANE Seis sis z System Code Fault Name 515 S Faul Conditions 42 Cam Loss yly pulse 4 cycles and RPM gt Crank 337 Crank Loss Cam pulses without crank activity Sensors gt 6 cam pulses 341 Cam Sync Noise Number of invalid re syncs 1 within a time window of lt 700 ms 336 Crank Sync Noise Number of invalid crank re syncs 1 within a time window of lt 800 ms 16 Never Crank Synced Cranking revs without sync 4 revs at Start and RPM gt 90 rpm Internal 606 COP Failure Y Y Processor 1612 RTI 1 Loss Y Y Diagnostics 1613 RTI 2 Loss Y Y 1614 RTI 3 Loss Y Y 1615 A D Loss Y Y 1616 Invalid Interrupt Y Y 601 Flash Checksum Invalid Y Y 604 RAM Failure Y Y J1939 1625 Shutdown Request Number of shutdown requests gt 1 Network 1626 CAN Tx Failure TX error counter gt 100 1627 CAN Rx Failure Rx error counter gt 100 1628 Address conflict counter gt 5 Adaptive Learn Key Cycle Part No 1258748 Z 80 60 5 35 Sectio
218. essary for a safe operating condition In addition maintaining all of the safety and instructional decals in good condition is mandatory for safe machine operation Decals alert operators and personnel to the many possible hazards associated with using this machine They also provide users with operation and maintenance information An illegible decal will fail to alert personnel of a procedure or hazard and could result in unsafe operating conditions 1 Check to make sure that the operator s and safety manuals are present and complete in the storage container on the platform 2 Examine the pages of each manual to be sure that they are legible and in good condition Result The operator s manual is appropriate for the machine and all manuals are legible and in good condition W Result The operator s manual is not appropriate for the machine or all manuals are not in good condition or is illegible Remove the machine from service until the manual is replaced A TEREX COMI Part No 1258748 3 Open the operator s manual to the decals inspection section Carefully and thoroughly inspect all decals on the machine for legibility and damage Result The machine is equipped with all required decals and all decals are legible and in good condition Result The machine is not equipped with all required decals or one or more decals are illegible or in poor condition Remove the machine from service until the decals a
219. exhaust system is essential to good engine performance and service life Operating the engine with a damaged or leaking exhaust system can cause component damage and unsafe operating conditions AWARNING Bodily injury hazard Do not inspect while the engine is running Remove the key to secure from operation Bodily injury hazard Beware of A CAUTION hot engine components Contact with hot engine components may cause severe burns 1 Remove the engine tray retaining fastener Swing the engine tray out away from the machine a engine tray anchor hole b engine tray retaining fastener Part No 1258748 2014 Section 3 Scheduled Maintenance Procedures 2 Locate the engine tray anchor hole at the pivot end of the engine tray 3 Install the bolt that was just removed into the anchor hole to secure the engine tray from moving AWARNING Crushing hazard Failure to install the bolt into the engine tray to secure it from moving could result in death or serious injury 4 Be sure that all nuts and bolts are tight 5 Inspect all welds for cracks 6 Inspect for exhaust leaks i e carbon buildup around seams and joints 7 Remove the engine tray retaining fastener from the engine tray anchor hole at the pivot end of the engine tray 8 Swing the engine tray in towards the machine Install the bolt that was just removed into the original hole to secure the engine tray ADANGER Crushin
220. following the engine manufacturer s maintenance schedule is essential to good engine performance and service life Failure to perform the maintenance procedures can lead to poor engine performance and component damage Fan belt tension check Battery check Required maintenance procedures and additional engine information are available in the Continental TME27 Owner s Manual Continental part number WM 10303 Continental TME27 Owner s Manual Genie part number 111901 A TEREX A 10 Grease the Turntable Rotation Bearing and Rotate Gear Genie specifications require that this procedure be performed every 100 hours of operation Perform this procedure more often if dusty conditions exist Frequent application of lubrication to the turntable bearing and rotate gear is essential to good machine performance and service life Continued use of an improperly greased bearing and gear will result in component damage 1 Locate the grease fitting next to the ground control box 2 Pump grease into the turntable rotation bearing Rotate the turntable in increments of 4 to 5 inches 10 to 13 cm at a time and repeat this step until the entire bearing has been greased 3 Apply grease to each tooth of the drive gear located under the turntable Grease Specification Chevron Ultra duty grease EP NLGI 2 lithium based or equivalent Part No 1258748 2014 Section 3 Scheduled Maintenanc
221. free of obstructions Note Perform this procedure with the boom in the stowed position 1 Create start and finish lines by marking two lines on the ground 40 feet 12 2 m apart 2 Start the engine from the platform controls 3 Press the engine rpm select button until the foot switch activated high idle rabbit and foot switch symbol is selected 4 Choose a point on the machine i e contact patch of a tire as a visual reference for use when crossing the start and finish lines 5 Bring the machine to top drive speed before reaching the start line Begin timing when your reference point on the machine crosses the start line 6 Continue at full speed and note the time when the machine reference point crosses the finish line Refer to Section 2 Specifications Section 3 Scheduled Maintenance Procedures November 2014 CHECKLIST B PROCEDURES B 17 Test the Drive Speed Raised or Extended Position Proper drive function movement is essential to safe machine operation The drive function should respond quickly and smoothly to operator control Drive performance should also be free of hesitation jerking and unusual noise over the entire proportionally controlled speed range Note Select a test area that is firm level and free of obstructions 1 Create start and finish lines by marking two lines on the ground 40 feet 12 2 m apart 2 Startthe engine from the platform controls 3 Press the engine rpm sel
222. ft cylinder link arm primary boom lift cylinder primary boom primary extension boom platform leveling cylinder upper turntable cover lower turntable cover secondary boom lift cylinder secondary boom secondary extension boom secondary boom hose cover primary boom lift cylinder lever arm primary boom hose cover primary boom link arm pivot pin primary lift cylinder pivot pin rod end primary lift cylinder pivot pin barrel end primary extend cylinder pivot pin rod end platform level cylinder pivot pin barrel end secondary boom pivot pin secondary lift cylinder pivot pin barrel end secondary lift cylinder pivot pin rod end secondary extend cylinder pivot pin rod end secondary boom lever arm pivot pin primary boom pivot pin primary extend cylinder pivot pins barrel end ATT 50 0 n 4 r 5 t u v w x y Part No 1258748 Z 80 60 4 29 Section 4 Repair Procedures November 2014 BOOM COMPONENTS 4 1 Primary Boom Cable Track The primary boom cable track guides the cables and hoses running up the boom It can be repaired link by link without removing the cables and hoses that run through it Removing the entire primary boom cable track is only necessary when performing major repairs that involve removing the primary boom How to Remove
223. g hazard Failure to install the bolt into the engine tray to secure it from moving could result in death or serious injury A TEREX Part No 1258748 CHECKLIST B PROCEDURES B 5 Inspect the Engine Air Filter Genie requires that this procedure be performed every 250 hours or quarterly whichever comes first Perform this procedure more often if dusty conditions exist Note Perform this procedure with the engine off 1 Open the engine side cover Empty the dust discharge valve by pressing together the sides of the discharge slot Clean the discharge slot as needed a retaining clamp b canister end cap c dust discharge valve Disconnect the retaining clamp from the air cleaner canister Remove the filter element 4 Clean the inside of the canister and the gasket with a damp cloth Inspect the air filter element If needed blow from the inside out using low pressure dry compressed air or carefully tap out dust Install the filter element Install the air filter canister end cap and connect the end cap retaining clamp Section 3 Scheduled Maintenance Procedures November 2014 CHECKLIST B PROCEDURES B 6 Perform Engine Maintenance Continental Models Engine specifications require that this procedure be performed every 250 hours Proper engine maintenance following the engine manufacturer s maintenance schedule is essential to good engine performance and service life Fai
224. gh idle rabbit symbol is selected Result The engine should change to high idle a foot switch activated high idle indicator light b low idle indicator light c X high idle indicator light d engine rpm select button 8 Press the engine idle select button until low idle turtle symbol is selected O Result The engine should change to low idle 9 Press the engine idle select button until the foot Switch activated high idle rabbit and foot switch symbol is selected O Result The engine should not change to high idle 10 Press down the foot switch O Result The engine should change to high idle Section 3 Scheduled Maintenance Procedures November 2014 CHECKLIST B PROCEDURES B 14 Test the Fuel Select Operation Gasoline LPG Models The ability to select and switch between gasoline and LPG fuels as needed is essential to safe machine operation A fuel selection can be made whether the engine is running or not Switching malfunctions and or the failure of the engine to start and run properly in both fuel modes and through all idle speeds can indicate fuel system problems that could develop into a hazardous situation Note Perform this test after checking the gasoline and LPG fuel levels and warming the engine to normal operating temperature 1 Turn the key switch to platform controls and pull out the red Emergency Stop buttons out to the on position at both the ground and platform controls
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226. he Jib Boom Note Perform this procedure with the boom in the stowed position Note When removing a hose assembly or fitting the O ring on the fitting and or hose end must be replaced and then torqued to specification during installation Refer to Section 2 Hydraulic Hose and Fitting Torque Specifications 1 Remove the platform mounting weldment and the platform rotator See 2 8 How to the Platform Rotator jib boom platform rotator upper pivot pin platform rotator lower pivot pin jib boom leveling arm jib cylinder pivot pin jib boom cylinder primary boom lower pivot pin primary boom upper pivot pin fasteners from the jib boom Remove the hose a b 2 Remove the hose and cable cover retaining 4 and cable cover from the machine f g h 3 Attach a lifting strap from an overhead crane to the jib boom for support Do not apply lifitng pressure 4 Tag disconnect and plug the jib boom lift cylinder hydraulic hoses Cap the fittings on the cylinder AWARNING Bodily injury hazard Spraying hydraulic oil can penetrate and burn skin Loosen hydraulic connections very slowly to allow the oil pressure to dissipate gradually Do not allow oil to squirt or spray Genie 4 26 2 80 60 Part No 1258748 November 2014 Section 4 Repair Procedures 5 Support the barrel end of the jib boom cylinder with another suitable lifting device 6 Remove the pin retaining fastener from the jib boom
227. he ground controls Calibrate the platform overload system Refer to Repair Procedure 2 4 How to Calibrate the Platform Overload System if equipped Note There may be a 2 second delay before the overload indicator lights flash and the alarm sounds 7 Carefully move the test weights to each remaining location on the platform Refer to Illustration 1 Result The alarm should sound The platform overload indicator lights should be flashing at both the ground and platform controls Result The alarm does not sound and the platform overload indicator lights are not flashing Calibrate the platform overload system Refer to Repair Procedure 2 4 How to Calibrate the Platform Overload System if equipped Note There may be a 2 second delay before the overload indicator lights flash and the alarm sounds 8 Test all machine functions from the platform controls Result All platform control functions should not operate Section 3 Scheduled Maintenance Procedures November 2014 CHECKLIST C PROCEDURES 9 Turn the key switch to ground control 10 Test all machine functions from the ground controls Result All ground control functions should not operate 11 Press and hold the auxiliary power button Note The engine must be shut off to access auxiliary power 12 Using auxiliary power test all machine functions from the ground controls Result All ground control functions should operate
228. he machine which will result in death or serious injury AWARNING Crushing hazard The drive hub could become unbalanced and fall if not properly supported by the overhead crane or lifting device when removed from the machine Note When installing a turntable rotation assembly the rotation gear backlash must be adjusted See 9 1 Adjust the Turntable Rotation Gear Backlash Section 4 Repair Procedures November 2014 TURNTABLE ROTATION COMPONENTS How to Adjust the Turntable 7 Rotation Gear Backlash The turntable rotation drive hub is mounted on an adjustable plate that controls the gap between the rotation motor pinion gear and the turntable 8 bearing ring gear Note Perform this procedure with the platform between the circle end tires and with the machine on a firm level surface 1 Secure the turntable from rotating with the turntable rotation lock pin 2 Loosen the backlash pivot plate mounting fasteners 3 Push the backlash pivot plate towards the turntable as far as possible this will push the rotation gear into the turntable bearing ring gear 4 Loosen the lock nut on the adjustment bolt 5 Turn the adjustment bolt clockwise until it contacts the backlash pivot plate 6 Turn the adjustment bolt 1 2 turn counterclockwise Tighten the lock nut on the adjustment bolt Genie 4 100 Z 80 60 Rotate the backlash pivot plate away from the turntable until it contacts the adjustment bolt Tor
229. he primary boom tube and place it on a structure capable of supporting it AWARNING Crushing hazard The extension boom tube could become unbalanced and fall if not properly supported when removed from the primary boom tube Note During removal the overhead crane strap will need to be adjusted for proper balancing Z 80 60 4 35 Section 4 Repair Procedures November 2014 BOOM COMPONENTS 8 Remove the external snap rings from the extension cylinder rod end pivot pin at the platform end of the extension tube AWARNING Crushing hazard The extension cylinder could become unbalanced and fall if not properly supported when removed from primary boom extension tube 9 Use a soft metal drift to remove the pin Crushing hazard The extension AWARNING cylinder could become unbalanced and fall if not properly supported when removed from primary boom extension tube 10 Attach a lifting strap from an overhead crane to the extension cylinder 11 Working at the end of the extension boom tube opposite the jib boom mount support and slide the extension cylinder out of the extension boom tube Crushing hazard The extension AWARNING cylinder could become unbalanced and fall if not properly supported when removed from primary boom extension tube Note During removal the overhead crane strap will need to be carefully adjusted for proper balancing Genie 2 80 60 4 3 Primary Boom Lift Cylinder The primary boo
230. he test port on the two wheel steer and oscillate manifold 9 3 Start the engine from the platform controls 4 Press down the foot switch and manually activate one of the oscillate limit switches Hold the switch in the activated position and observe the reading on the pressure gauge Refer to Section 2 Specifications 5 Turn the engine off Use a wrench to hold the relief valve and remove the cap item BE before SN 1291 or JE after SN 1290 Genie 4 82 2 80 60 the relief valve higher than specified Repeat steps 3 through 4 to confirm relief valve pressure Remove the pressure gauge Install the drive chassis cover Part No 1258748 November 2014 Section 4 Repair Procedures n t MANIFOLDS This page intentionally left blank Genie PartNo 1258748 Z 80 60 4 83 Section 4 Repair Procedures November 2014 MANIFOLDS 8 8 Four Wheel Steer and Oscillate Manifold The Four Wheel Steer and Oscillate manifold is mounted inside the drive chassis at the square end of the machine Index Schematic No Description Item 1 Solenoid valve 3 position 4 way KA 2 Solenoid valve 3 position 4 way 3 Check valve KC 4 Check valve 65 psi 4 5 bar KD Solenoid valve 2 position 3 way KE Solenoid valve 2 position way Check valve 65 psi 4 5 bar KG 8 Relief valve
231. hem in a safe and secure location away from the machine Electrocution hazard Contact with AWARNING electrically charged circuits could result in death or serious injury Remove all rings watches and other jewelry Part No 1258748 Genie Z 80 60 BOOM COMPONENTS 3 Remove the retaining fasteners securing the upper and lower turntable covers from the turntable at the platform end Remove the covers 4 Remove the engine tray retaining fastener Swing the engine tray out away from the machine ae _ k dii S J n J 7 C a engine tray anchor hole b engine tray retaining fastener 5 Locate the engine tray anchor hole at the pivot end of the engine tray 6 Install the bolt that was just removed into the anchor hole to secure the engine tray from moving AWARNING Crushing hazard Failure to install the bolt into the engine tray to secure it from moving could result in death or serious injury 7 Remove the fuel tank filler cap Section 4 Repair Procedures November 2014 BOOM COMPONENTS 8 Using an approved hand operated pump drain the fuel tank into a suitable container Refer to Section 2 Specifications Explosion and fire hazard Engine fuels are combustible Perform this procedure in an open well ventilated area away from heaters sparks flames and lighted tobacco Always have an approved fire extinguisher within easy reach Ex
232. hole to secure the engine tray AWARNING Crushing hazard Failure to install the bolt into the engine tray to secure it from moving could result in death or serious injury specification Refer to Section 2 Specifications A TEREX COMPANY Part No 1258748 2014 Section 3 Scheduled Maintenance Procedures D 4 Inspect for Turntable Bearing Wear Periodic inspection of turntable bearing wear is essential to safe machine operation good machine performance and service life Continued use of a worn turntable bearing could create an unsafe operating condition resulting in death or serious injury and component damage Note Perform this procedure with the machine on a firm level surface and the boom in the stowed position 1 Grease the turntable bearing See A 10 Grease the Turntable Bearing and Rotate Gear 2 Torque the turntable bearing bolts to specification See D 3 Check the Turntable Rotation Bearing Bolts 3 Start the machine from the ground controls and fully elevate but do not extend the primary boom and jib The riser should remain in its stowed position 4 Place a dial indicator between the drive chassis and the turntable at a point that is directly under or inline with the boom and no more than 1 inch 2 5 cm from the bearing Note To obtain an accurate measurement place the dial indicator no more than 1 inch 2 5 cm from the turntable rotation bearing A TEREX COM
233. idth or Period High most severe 3 723 10 Engine Speed Sensor 2 168 3 Battery Potential Power Input 1 Abnormal Rate of Change Voltage Above Normal 733 3 Engine Rack Position Sensor 168 4 Battery Potential Power Input 1 Voltage Above Normal Voltage Below Normal 733 4 Engine Rack Position Sensor Voltage Below Normal 5 28 Z 80 60 Part No 1258748 2014 SPN Suspect Parameter Number FMI Failure Mode Identifier Section 5 Fault Codes PERKINS 404F 22TENGINE FAULT CODES SPN FMI Description SPN FMI Description 1485 7 ECU Main Relay 3242 15 Particulate Trap Intake Gas Temp Not Responding Property High least severe 1 2840 11 ECU Instance Other Failure Mode 3242 16 Particulate Trap Intake Gas Temp High moderate severity 2 2840 12 ECU Instance Failure 3251 3 Particulate Trap Differential Pressure 2970 Accelerator Pedal 2 Low Idle Switch 3251 4 Particulate Trap Differential Pressure Voltage Above Normal Voltage Below Normal 29 0 4 Accelerator Pedal 2 Low Idle Switch 3473 7 Aftertreatmert 1 Failed to Ignite Voltage Below Normal Not Responding Properly 3241 1 Exhaust Gas Temperature 1 3473 11 Aftertreatmert 41 Failed to Ignite Low most severe 3 Other Failure Mode 3241 3 Exhaust Gas Temperature 1 3484 O0 Aftertreatmert 1 Ignition 3241 4 Exhaust Gas Temperature 1 3484 3 Aftertreatmert
234. in COUNTERBALANCE VALVE Note alpha callouts refer to 1 RATIO PRESSURE components shown in the A A Ai lA A IA A A 5 3 1 1000 psi 69 bar manifold illustrations 151 2000 psi 138 bar Refer to the Repair Section Al 9l A 31 3800 psi 262 bar E Ife ol 8 1 A 1 2500 psi 172 bar T NH 4 A 3 1 3000 psi 207 bar i ELI Z 1 A 1 3300 psi 227 5 bar 2 4 Hem 11 51 3500 psi 241 3 bar A 3 1 3500 psi 241 3 bar 1 P2 PEXT1 PEXT2 PRET T3 T4 R1 PPR R2 REXT RRET HIGH PRESSURE FILTERS EET t A 1 3800 psi 262 bar FUNCTION 7 MANIFOLD t P 6 Olt PUB rt 2500psi 2600 psi PLATFORM LEVEL JIB BOOM Q EG hnl 172bar 179 PLATFORM ROTATE 1 25 1 00 1 25 1 00 7 i L A r 1 prest 1 1 peris i fi 8 ps gpm 1 14 L min 4 73 L min 3 79 U min 4 75 L min 3 79 L min _ 8 HOF 1300 psi 1300 psi 5 mf 89 6 bar 89 6 bar 3 2 m i 7 L min i 9 T zx 6 SSS SS 3000 psi p 1770 3625 psi 207 0 080 inch 250 8 den X LSTEST 0 762 mm M2
235. ine functions The ground control box also contains two printed circuit boards The LCD Liquid Crystal Display circuit board is mounted to the inside of the control box lid which controls the LCD display screen or CAN Gateway if equipped with a Tier IV engine The TCON circuit board is the main circuit board for the machine There are relays on the ECM circuit board that can be replaced All operating parameters and configuration of options for the machine are stored in the ECM memory Note The ECM circuit board inside the ground control box TCON cannot be replaced by itself If the ECM circuit board is faulty and needs to be replaced contact the Genie Industries Service Department Note When an ECM circuit board is replaced the proportional valves will need to be calibrated See 1 3 How to Calibrate a Joystick Part No 1258748 Genie Z 80 60 GROUND CONTROLS How to Determine the Revision Level 1 Turn the key switch to ground controls and pull out the red Emergency Stop buttons to the on position at both platform and ground controls Result The revision level of the TCON will appear in the LCD display window How to Remove the LCD Display Screen Circuit Board 1 Push in the red Emergency Stop button to the off position at both the ground and platform controls 2 Remove the ground control box lid fasteners Open the control box lid AWARNING Electrocution hazard Contact with electrically charged
236. ing 8 Center a lifting jack with a minimum capacity of 25 000 Ibs 12000 kg under the drive chassis between the steer wheels 9 Liftthe wheels off the ground and then place blocks under the drive chassis for support 10 Disengage the drive hubs by turning over the drive hub disconnect caps on each steer wheel hub TS disengaged position up DEN arg gt engaged position Part No 1258748 2014 Section 3 Scheduled Maintenance Procedures 11 Manually rotate each steer wheel Result Each steer wheel should rotate with minimum effort 12 Re engage the drive hubs by turning over the drive hub disconnect caps Rotate each wheel to check for engagement Lift the machine and remove the blocks llision h Failure t AWARNING Collision hazard Failure to re engage the drive hubs could result in death or serious injury and property damage All models 13 Be sure the free wheel valve on the drive pump is closed clockwise Note The free wheel valve is located on the drive pump and should always remain closed a drive pump b screwdriver lift pump d free wheel valve A TEREX Part No 1258748 CHECKLIST D PROCEDURES D 3 Check the Turntable Rotation Bearing Bolts Maintaining proper torque on the turntable bearing bolts is essential to safe machine operation Improper bolt torque could result in an unsafe operating condition and component damage
237. ir Procedures 8 14 Valve Coils How to Test a Coil A properly functioning coil provides an electromagnetic force which operates the solenoid valve Critical to normal operation is continuity within the coil Zero resistance or infinite resistance indicates the coil has failed Since coil resistance is sensitive to temperature resistance values outside specification can produce erratic operation When coil resistance MANIFOLDS Valve Coil Resistance Specifications Note The following coil resistance specifications are at an ambient temperature of 68 F 20 C As valve coil resistance is sensitive to changes in air temperature the coil resistance will typically increase or decrease by 4 for each 18 F 20 C that your air temperature increases or decreases from 68 F 20 C Valve coil resistance specifications Proportional solenoid valve 12V DC 4 8 Q decreases below specification amperage schematic items G W and AB increases As resistance rises above specification voltage increases Proportional solenoid valve 12V DC 90 schematic items While valves m rate when coil resistance i SIS cols within gt 3 position 4 way solenoid valve 12V DG PA 9 schematic items BB CA CP CQ specification will help ensure proper valve function GB GP and GQ over a wide range of operating temperatures i 3 position 4 way solenoid valve 10V DC 6 3 Q AWARNI
238. itches The main key switch towards the top of the control box is for selection of ground or platform controls The key switch at the bottom of the control box is the Service Bypass Recovery key switch Service Bypass and Recovery modes are only intended for certain circumstances and are not part of normal machine operation If either the Service Bypass or the Recovery function is required this indicates there may be faults with the machine Contact trained personnel immediately Service Bypass is used for a platform out of envelope condition and certain service situations Recovery is only to be used as a last attempt to lower the platform when the operator in the platform is unable to do so system failure or in emergency situations Run o fe d Service Bypass gt AY Recovery 0 Service Bypass Recovery Key Switch Part No 1258748 Genie Z 80 60 Ground Controls How to Use the Service Bypass Mode Tip over hazard Operating the machine outside of the operating envelope while in Service Bypass mode will result in death or serious injury if proper operating procedures and safety precautions are not followed Do not use this mode if you are not trained and familiar with the operating envelope of the machine Note Before using the Service Bypass mode make sure you understand the fault code or issue affecting the operation of the machine to be sure the use
239. k SEC BOOM ANGLE unknown angle Normal function except threshold for one or the other direction is zero Display message on LCD Initiate one second beep of audible warning device Limited speed and direction frozen at zero and neutral alarm sounds Limited speed and direction frozen at zero and neutral alarm sounds Stop all secondary boom functions allow only secondary boom retract Display message on LCD Stop all secondary boom functions allow only secondary boom retract Once the boom is retracted allow secondary boom down Display message on LCD Calibrate thresholds Self clearing transient Power up controller with the problem corrected Power up controller with the problem corrected Power up controller with the problem corrected Power up controller with the problem corrected SEC BOOM UFDOWN Not calibrated Display message OnE GD and allow Perform auto calibrate procedure SPEED operation at default speed Not calibrated SEC BOOM UP DOWN EXT RET FLOW VALVE Fault check SEC EXT SEQ VALVE SEC DWN SEQ VALVE Normal function except threshold for one or the other direction is zero Display message on LCD Limited speed and direction frozen at zero and neutral alarm sounds Limited speed and direction frozen at zero and neutral alarm sounds Part No 1258748 Calibrate thresholds Initiate one second b of audibl Just calibrated di
240. king for positive tank cap venting air should pass freely through the cap 7 Using a mild solvent carefully wash the cap venting system Dry using low pressure compressed air Repeat this procedure beginning with step 6 8 Install the breather cap onto the hydraulic tank TEREX COMPANY Part No 1258748 Z 80 60 3 37 Section 3 Scheduled Maintenance Procedures November 2014 Checklist C Procedures C 1 Perform Engine Maintenance Continental Models Engine specifications require that this procedure be performed every 500 hours Proper engine maintenance following the engine manufacturer s maintenance schedule is essential to good engine performance and service life Failure to perform the maintenance procedures can lead to poor engine performance and component damage Valve tappet clearance adjust Fuel pump check Fuelfilter replace PCV valve check Required maintenance procedures and additional engine information are available in the Continental TME27 Owner s Manual Continental part number WM 10303 Continental TME27 Owner s Manual Genie part number 111901 A TEREX COMI 2 Perform Engine Maintenance Deutz Models Engine specifications require that this procedure be performed every 500 hours Proper engine maintenance following the engine manufacturer s maintenance schedule is essential to good engine performance and service life Failure to perform the maintena
241. kins 800D Series Operation Manual Genie part number 111332 Perkins 404F Series Operation Manual Genie part number 1251562 A TEREX COMI A 7 Check the Hydraulic Filter Condition Indicators Maintaining the hydraulic filters in good condition is essential to good system performance and safe machine operation The filter condition indicators will show when the hydraulic flow is bypassing a clogged filter If the filters are not frequently checked and replaced impurities will remain in the hydraulic system and cause component damage Note There are four hydraulic filters on the machine one tank return filter one medium pressure filter and two high pressure filters All the filters have condition indicators on them except the medium pressure filter 1 Start the engine from the ground controls 2 Press and release the engine idle select button to change the engine rpm to high idle Tank return filter 3 Open the ground control side turntable cover and inspect the filter condition indicator gauge Result The needle on the gauge should be operating in the green area If the needle is in the red area this indicates that the hydraulic filter is being bypassed and the filter needs to be replaced See D 7 Replace the Hyaraulic Filter Elements a filter condition indicator gauge Part No 1258748 2014 Section 3 Scheduled Maintenance Procedures Medium and high pressure fi
242. l level on the turntable rotate bearing plate 5 Startthe engine and level the drive chassis Press down the foot switch and manually activate the oscillate limit switches until the machine is completely level Genie 4 104 Z 80 60 Part No 1258748 November 2014 Section 4 Repair Procedures 10 2 Oscillating Axle Cylinders The oscillating axle cylinders extend and retract between the drive chassis and the oscillating axle The cylinders are equipped with counterbalance valves to prevent movement in the event of a hydraulic line failure The valves are not adjustable How to Remove an Oscillating Axle Cylinder Note Perform this procedure on a firm level surface with the boom in the stowed position Note When removing a hose assembly or fitting the O ring on the fitting and or hose end must be replaced and then torqued to specification during installation Refer to Section 2 Hydraulic Hose and Fitting Torque Specifications 1 Rotate the boom until the turntable counterweight is between the circle end and square end tires PartNo 1258748 Genie Z 80 60 AXLE COMPONENTS 2 Tag disconnect and plug the oscillating axle cylinder hydraulic hoses Cap the fittings on the oscillate cylinder AWARNING Bodily injury hazard Spraying hydraulic oil can penetrate and burn skin Loosen hydraulic connections very slowly to allow the oil pressure to dissipate gradually Do not allow oil to squirt or spray
243. l the faults are no longer shown on the display Result The flashing arrow in the display at the ground controls will turn off Result The flashing arrow in the display at the ground controls does not turn off Repeat this procedure beginning with step 1 19 Start the engine and activate the primary boom down function Release the function enable button when the digital level displays 40 Push in the red Emergency Stop button to the off position 20 Pull out the red Emergency Stop button while holding the enter button 41 3 or 4 seconds until the engine symbol appears on the display at the ground control box then release 21 Enter sensor calibration mode by pressing the buttons at the ground controls in the following sequence 1 Section 4 Repair Procedures November 2014 BOOM COMPONENTS 22 Press the scroll button until PRIMARY BOOM ANGLE 40 is shown on the display 23 Press the plus button to select yes then press the enter button 1 to accept Result The alarm should not sound Result The alarm does sound Repeat this procedure beginning with step 1 24 Press the scroll button until Exit is shown on the display Press the plus button to select yes then press the enter button to accept 25 Start the engine 26 Activate the boom up function until the digital level reads 65 Result The primary boom should stop amp
244. l turn on and the boom will begin the following recovery sequence The primary boom will retract The primary boom will lower Note The key switch must be held in the recovery position until the recovery sequence is complete or until the operator in the platform can safely exit the platform Note If any boom safety limit switches are faulty the boom will only retract and not lower and the operator will need to be recovered from that point Note If the Recovery function has been used this may indicate there may be faults with the machine Tag and remove the machine from service until the fault has been corrected by trained personnel Part No 1258748 November 2014 Section 4 Repair Procedures 6 2 Circuit Boards The ground control box TCON is the communication and operations center for the machine The ground control box contains two key switches The key switch towards the top of the control box is for selection of ground or platform controls The key switch at the bottom of the control box is the Service Bypass key switch It is used to correct an out of level platform If the machine trips an envelope safety switch the operator at the ground controls can turn and hold the Service Bypass key switch in the RECOVER position which will automatically retract the boom and lower the platform to the ground The ground control box contains a replaceable membrane decal with touch sensitive buttons for various mach
245. latform Overload Recovery Message Note This message shall be cleared by a person trained and qualified on the troubleshooting and repair of this machine 1 Turn the key switch to the off position 2 Press and hold the enter button on the ground control panel while turning the key switch to ground controls Hold the enter button for approximately 5 seconds 3 Press the buttons on the ground controls in the following sequence plus minus minus plus PartNo 1258748 Genie Z 80 60 PLATFORM COMPONENTS 4 Press the enter or previous button on the LCD screen until CLEAR OVERLOAD RECOVERY is displayed 5 Press the plus button or the minus button to select YES Then press the buttons in the following sequence plus plus minus and press the enter button to accept Note The passcode buttons plus plus minus mustbe entered in the proper sequence before the enter button is pressed 6 Press the enter previous button on the LCD screen until EXIT is displayed 7 Press the plus button minus button to select YES and then press the enter button 8 Turn the key swith to the off position Section 4 Repair Procedures November 2014 Jib Boom Components 3 1 Jib Boom How to Remove t
246. le Rotate Right CW TRR ac BK RD Black Red Turntable Rotate Signal TRS BK WH Black White Turntable Tilt Alarm TTA BR Brown Turntable Tilt Sensor TTS Test Switch Seen GR BK Green Black GR WH Green White RD Red RD BK Red Black RD WH Red White OR Orange OR BL Orange Blue OR BK Orange Black OR RD Orange Red WH White WH BK White Black WH RD White Red YL Yellow Genio 6 4 Z 80 60 Part No 1258748 2014 Section 6 Schematics Color Circuit and Primary function RD RD BK RD WH WH WH BK WH RD BK BK WH BK RD BL BL BK BL WH BL RD 10 11 12 13 14 15 16 17 18 19 20 21 22 23 24 25 26 27 28 30 Primary boom up drive Primary boom down drive Primary boom up dwn FC proportional valve drive Turntable rotate left valve drive Turntable rotate right valve drive Turntable rotate FC proportional valve drive Primary boom extend Primary boom retract Primary boom Extend Retract proportional valve drive Secondary boom up valve drive Secondary boom down valve drive Secondary boom up dwn FC proportional valve drive Drive enable Platform level up valve Platform level down valve Platform up dwn FC proportional valve drive Platform rotate left valve driver Platform rotate right valve driver Jib select valve driver circuit 12 battery supply 12 ignition supply Keyswitch power to platform ESTOP Power to platform Power to warning senders Po
247. lectrical Schematic Welder Generator Option N M L K J H G F E D lt 12 5 KW HYDRAULIC GENERATOR SX CONTROLLER NEUTRAL BUSS BAR SAUER K23334 A FA 0 NEMA 4 CONTROL BOX TERMINAL CIRCUIT COLOR Al 52 RD WH A2 SENSOR POWER 5V RD L1 L2 L3 Y BATTERY BR 50 AMP 3 POLE CIRCUIT BREAKER V151HG GR WITH INTEGRAL GFI I B2 NC NE V150HG GR BK RED TxD YEL 2 c2 RxD GR WHITE c3 D1 JOYSTICK WH BLACK D2 NC pa Ne BLACK BLACK 12GA GREEN E1 NOT USED GROUND E2 NOT USED GREEN 5 STUD ON NOT USED ee 2 EL FI NOT USED 1 110 VAC GFI 3 F2 C45GEN GR WH BLACK 12GA SILVE 4 L 8GA
248. libration injector 2 5 in firing order 523930 1 116 FuelBalance Control integrator minimum value exceeded injector 2 in firing order minimum value exceeded 523948 0 1160 Zerofuel calibration injector 3 in firing order 523931 0 111 FuelBalance Control integrator maximum value exceeded injector 3 in firing order maximum value exceeded 523948 1 1166 Zerofuel calibration injector 3 in firing order 523931 1 117 FuelBalance Control integrator minimum value exceeded injector 3 in firing order minimum value exceeded 523949 0 1161 Zerofuel calibration injector 4 in firing order 523932 0 112 FuelBalance Control integrator maximum value exceeded injector 4 in firing order maximum value exceeded 523949 1 1167 Zerofuel calibration injector 4 in firing order 523932 1 118 FuelBalance Control integrator minimum value exceeded injector 4 in firing order minimum value exceeded 523960 0 1011 Physical range check high for EGR cooler downstream temp 523935 12 168 TimeoutErrorof CAN Transmit Frame EEC3VOL1 Engine send messages 5 24 Z 80 60 Part No 1258748 2014 Section 5 Fault Codes DEUTZ TD 2 9 L4 ENGINE FAULT CODES SPN Suspect Parameter Number FMI Failure Mode Identifier KWP Keyword Protocol SPN FMI KWP Description SPN FMI KWP Description 523960 0 1458 Highexhaustgastemperature 524
249. low for memory write 639 14 84 CAN Bus 0 BusOff Status 411 4 796 Sensorerrordifferential EE pressure Venturiunit EGR ot E firing order signal range check low 651 4 586 High side to low side short circuit in the injector 1 in firing order 5 16 Z 80 60 Part No 1258748 2014 Section 5 Fault Codes DEUTZ TD 2 9 L4 ENGINE FAULT CODES SPN Suspect Parameter Number FMI Failure Mode Identifier KWP Keyword Protocol SPN FMI KWP Description SPN FMI KWP Description 651 5 568 Injector 1 in firing order 677 3 956 Starter relay high side interruption of electric short circuit to battery connection 677 3 960 Starter relay low side short 652 3 581 Injector 2 in firing order circuit to battery short circuit 677 4 957 Starter relay high side short 652 4 587 High side to low side short circuit to ground circuit in the injector 2 in firing order 677 4 961 Starter relay low side short circuit to ground 652 5 569 Injector 2 in firing order interruption of 677 5 958 Starter relay no load error 677 12 959 Starterrelay powerstage over 653 3 582 Injector 3 firing order temperature shar 703 3 426 Engine running lamp short 653 4 588 High side to low side short circuit to battery circuit in the injector 3 703 4 427 Engine running lamp short order circuit to groun
250. lters Note The medium and high pressure filters are mounted to the engine side bulkhead 4 Inspect the filter condition indicators high pressure filters b filter condition indicators c medium pressure filter O Result The filter condition indicators should be operating with the plungers in the green area Result If any of the indicators display the plunger in the red area this indicates that a hydraulic filter is being bypassed and the filter needs to be replaced See D 7 Replace the Hyaraulic Filter Elements A TEREX CON CHECKLIST A PROCEDURES A 8 Perform 30 Day Service The 30 day maintenance procedure is a one time sequence of procedures to be performed after the first 30 days or 40 hours of usage After this interval refer to the maintenance checklists for continued scheduled maintenance 1 Perform the following maintenance procedures A 8 Grease the Turntable Rotation Bearing and Rotate Gear B 7 Check the Tires Wheels and Lug Nut Torque B 9 Check the Drive Hub Oil Level and Fastener Torque D 3 Check the Turntable Rotation Bearing Bolts D 7 Replace the Hydraulic Filter Elements Part No 1258748 Z 80 60 3 11 Section 3 Scheduled Maintenance Procedures November 2014 CHECKLIST A PROCEDURES A 9 Perform Engine Maintenance Continental Models Engine specifications require that this procedure be performed every 50 hours or weekly Proper engine maintenance
251. lure to perform the maintenance procedures can lead to poor engine performance and component damage Harness connections check Cooling system check Required maintenance procedures and additional engine information are available in the Continental TME27 Owner s Manual Continental part number WM 103093 Continental TME27 Owner s Manual Genie part number 111901 A TEREX COMI B 7 Perform Engine Maintenance Perkins Models Engine specifications require that this procedure be performed every 250 hours Proper engine maintenance following the engine manufacturer s maintenance schedule is essential to good engine performance and service life Failure to perform the maintenance procedures can lead to poor engine performance and component damage Alternator and Fan belts inspect adjust Perkins 800D Series Operation Manual Perkins part number SEBU8324 OR the Perkins 404F Series Operation Manual Perkins part number SEBU8609 Perkins 800D Series Operation Manual Genie part number 111332 Perkins 404F Series Operation Manual Genie part number 1251562 Part No 1258748 November 2014 Section 3 Scheduled Maintenance Procedures CHECKLIST B PROCEDURES B 8 B 9 Check the Tires Wheels Confirm the Proper and Lug Nut Torque Maintaining the tires and wheels in good condition including proper wheel fastener torque is essential to safe operation and good performance Tire and or wheel
252. lve s at the function manifold to maintain a level primary boom 1 Turn the key switch to ground control and pull out the red Emergency Stop buttons out to the on position at both the ground and platform controls 2 Push one of the LCD screen buttons shown 4 el until primary boom angle is displayed 3 Start the engine and level the platform until the displays shows 0 DEGREES Part No 1258748 November 2014 Section 3 Scheduled Maintenance Procedures CHECKLIST B PROCEDURES 4 Fully raise the secondary boom while watching B 22 the display at the ground controls Stop when the secondary boom just begins to extend Test the Primary Boom Angle Sensor Result The primary boom should remain level at all times to within 2 degrees A properly functioning primary boom angle sensor Note If the platform becomes out of level the tilt PBAS is essential to safe machine operation The alarm will sound and the platform not level primary boom angle udis used to limit the indicator will turn on Level the platform until the angle of the primary boom relative to the angle of indicator light turns off the secondary boom and gravity The ECM at the ground controls TCON monitors the position and angle of the primary boom using the signal from PBAS The PBAS signal is used to control the ramping of the primary boom as well as velocity control limiting the speed of the primary boom to 1 3 feet 0 4 meters per se
253. m from the machine and place it on a structure capable of supporting it AWARNING Crushing hazard The primary boom could become unbalanced and fall if not properly supported when removed from the machine Note When the primary boom is installed the primary boom angle sensor will need to be calibrated Genie Part No 1258748 BOOM COMPONENTS How to Disassemble the Primary Boom Note Complete disassembly of the primary boom is only necessary if the outer or inner primary boom tube must be replaced The extension cylinder can be removed without completely disassembling the boom See 4 4 How to Remove the Primary Boom Extension Cylinder 1 Remove the primary boom See 4 2 How to Remove the Primary Boom 2 Place blocks under the barrel end of the primary boom extension cylinder for support 3 Remove the pin retaining fastener from the extension cylinder barrel end pivot pin at the pivot end of the primary boom 4 Use a soft metal drift to remove the pin Crushing hazard The primary AWARNING boom could become unbalanced and fall if not properly supported when the pivot pin is removed 5 Remove and label the location of the wear pads from the platform end of the primary boom Note Pay careful attention to the location and number of shims used with each wear pad 6 Attach a lifting strap from an overhead crane to the extension boom assembly 7 Support and slide the extension boom assembly out of t
254. m lift cylinder raises and lowers the primary boom The primary boom lift cylinder is equipped with a counterbalance valve to prevent movement in the event of a hydraulic line failure How to Remove the Primary Boom Lift Cylinder AWARNING 2dily injury hazard This procedure requires specific repair skills lifting equipment and a suitable workshop Attempting this procedure without these skills and tools could result in death or serious injury and significant component damage Dealer service is strongly recommended Note When removing a hose assembly or fitting the O ring on the fitting and or hose end must be replaced and then torqued to specification during installation Refer to Section 2 Hydraulic Hose and Fitting Torque Specifications 1 Raise the primary boom to a horizontal position 2 Raise the secondary boom until the primary boom lift cylinder rod end pivot pin is above the counterweight Part No 1258748 November 2014 Attach a 5 ton 5000 kg overhead crane to the platform end of the primary boom Support the boom Do not apply any lifting pressure Support both ends of the primary boom lift cylinder with a second overhead crane or similar lifting device Place blocks under the primary boom lift cylinder linkage arms for support Tag disconnect and plug the primary boom lift cylinder hydraulic hoses Cap the fittings on the cylinder AWARNING Bodily injury hazard Spraying hydraulic oil can p
255. mary Boom Down speed Stowed 12096 max and 50 min switch to the 100 default on position Primary Boom Down speed Stowed 120 max and 50 min Release the 100 default button and press Primary Boom Extend Speed 120 max and 50 min CES EE 100 default Primary Boom Retract Speed 120 max and 50 min 100 default Secondary Boom Up Speed Stowed 12096 max 50 min 100 default Secondary Boom Up Speed Not Stowed 12096 max and 5096 min 100 default Secondary Boom Down Speed Stowed 120 max and 50 min 100 default Secondary Boom Down Speed Not 12096 max 50 min Stowed 100 default Secondary Boom Ext Speed 12096 max and 50 min 100 default Secondary Boom Ret Speed 12096 max and 50 min 100 default TT Rotate speed Retracted 12096 max and 50 min 100 default TT Rotate speed Not Retracted 12096 max and 50 min 100 default Jib Up Down speed 12096 max and 75 min 100 default Genie 4 4 Z 80 60 Part No 1258748 November 2014 Section 4 Repair Procedures S B DISPLAY MODULE Information Displayed With the key Primary Boom Up Down ramp accel 150 max and 50 min switch off 100 default 5 150 50 100 default 5 increment 150 max and 50 min Release the Primary Boom Extend Retract ramp 100 default 5 button 150 50
256. mine which 4 link section needs to be replaced Part No 1258748 November 2014 Section 4 Repair Procedures 3 Carefully remove the snap rings from each end of the damaged section of cable track 4 Remove the retaining fasteners from the upper black rollers from the 4 link section of cable track to be replaced Remove the rollers 5 Lift up the hoses and cables and carefully remove the damaged 4 link section of cable track Component damage hazard Hoses and cables can be damaged if they are kinked or pinched 6 Remove the upper rollers from the replacement section of cable track 7 Lift up the hoses and cables and carefully insert the new 4 link section of cable track Component damage hazard Hoses and cables can be damaged if they are kinked or pinched 8 Connect the ends of the replacement cable track section to the existing cable track using the snap rings 9 Install the rollers onto the new section of cable track 10 Re assemble and install the extension cylinder assembly into the secondary extension boom 11 Operate the boom extend retract function through a full cycle to ensure smooth operation of the cable track Part No 1258748 Genie Z 80 60 BOOM COMPONENTS 4 7 Secondary Boom How to Disassemble the Secondary Boom Note Complete disassembly of the secondary boom is only necessary if the outer or inner secondary boom tube must be replaced The secondary extension boom tube can
257. moved Welder disconnected from the machine if equipped with the weld cable to platform option Wheels chocked All external AC power supply disconnected from the machine A TEREX Fault Codes Before Troubleshooting Read understand and obey the safety rules and operating instructions printed in the Operator s Manual on your machine Be sure that all necessary tools and test equipment are available and ready for use Read each appropriate fault code thoroughly Attempting shortcuts may produce hazardous conditions aware of the following hazards and follow generally accepted safe workshop practices Crushing hazard When testing or replacing any hydraulic component always support the structure and secure it from movement AWARNING Electrocution hazard Contact with electrically charged circuits could result in death or serious injury Remove all rings watches and other jewelry AWARNING Bodily injury hazard Spraying hydraulic oil can penetrate and burn skin Loosen hydraulic connections very slowly to allow the oil pressure to dissipate gradually Do not allow oil to squirt or spray Note Two persons will be required to safely perform some troubleshooting procedures MPANY Part No 1258748 Z 80 60 5 1 Section 5 Fault Codes November 2014 CONTROL SYSTEM FAULT CODES Fault Diagnostics Control System How to Read Control System Fault Codes Note Ini
258. n 5 Fault Codes November 2014 m EH This page intentionally left blank 5 36 Z 80 60 Part No 1258748 November 2014 Section 6 Schematics Observe and Obey Troubleshooting and repair procedures shall be completed by a person trained and qualified on the repair of this machine Immediately tag and remove from service damaged or malfunctioning machine Repair any machine damage or malfunction before operating the machine Before Troubleshooting Read understand and obey the safety rules and operating instructions printed in the Operator s Manual on your machine Be sure that all necessary tools and test equipment are available and ready for use Part No 1258748 Genie Z 80 60 Schematics About This Section There are two groups of schematics in this section Electrical Schematics Electrocution hazard Contact with AWARNING electrically charged circuits could result in death or serious injury Remove all rings watches and other jewelry Hydraulic Schematics Bodily injury hazard Spraying AWARNING hydraulic oil can penetrate and burn skin Loosen hydraulic connections very slowly to allow the oil pressure to dissipate gradually Do not allow oil to squirt or spray General Repair Process Malfunction I
259. n be activated based on user preference or requirement Refer to Display Module in the Repair Section for information 1 Turn the key switch to ground control and pull out the red Emergency Stop button to the on position at both the ground and platform controls Result The alarm should sound twice The flashing beacon if equipped should be on and flashing A TEREX COMI Part No 1258748 CHECKLIST B PROCEDURES B 19 Perform Hydraulic Oil Analysis Replacement or testing of the hydraulic oil is essential for good machine performance and service life Dirty oil and a clogged suction strainer may cause the machine to perform poorly and continued use may cause component damage Extremely dirty conditions may require oil changes to be performed more often Note Before replacing the hydraulic oil the oil may be tested by an oil distributor for specific levels of contamination to verify that changing the oil is necessary If the hydraulic oil is not replaced at the two year inspection test the oil quarterly Replace the oil when it fails the test See E 1 Test or Replace the Hydraulic Oil Section 3 Scheduled Maintenance Procedures November 2014 CHECKLIST B PROCEDURES B 20 Test the Safety Envelope and Circuits Testing the machine safety envelope is critical to safe machine operation If the boom is allowed to operate when a safety switch is not functioning correctly the machine stability is compromise
260. n loosened pu Figure 2 a body hex fitting b reference mark second mark 4 Tighten the hex nut until the mark on the hex nut is aligned with the second mark on the body hex fitting 5 Operate all machine functions and inspect the hoses and fittings and related components to confirm that there are no leaks Section 2 Specifications November 2014 SPECIFICATIONS size THREAD Grades 0 LIE 1 4 SAE FASTENER TORQUE CHART SACER RN NM een i 20 80 9 100 113 10 124 140 158 10 147 28 90 101 120 135 120 135 160 18 140 158 546 L 18 13 176 24 14 19 19 257 20 271 27 366 2 325 s 0321 211 888 38 24 6 352 35 474 37 501 49 664 me 14 1 37 501 49 664 so 678 70 947 1 2 29 a sss ss 745 813 1084 68 s27 143 57 773 75 1016 80 1084 110 149 93 16 s r es js 90 122 120 162 142 _ 946 12 80 1084 Size mm 48 90 122 120 162 130 176 170 230 140 4 34 139 38 T 38 12 389 18 130 176 170 230 180 244 240 325 2 271 10 200 271 270 366 280 379 380 515 320 433 16 220 298 300 406 310 420 420 59 30
261. n the O ring field service kit Genie part number 49612 2 Lubricate the O ring before installation 3 Be sure that the face seal O ring is seated and retained properly 4 Position the tube and nut squarely on the face seal end of the fitting and tighten the nut finger tight 5 Tighten the nut or fitting to the appropriate torque per given size as shown in the table 6 Operate all machine functions and inspect the hoses and fittings and related components to confirm that there are no leaks JIC 37 fittings 1 Align the tube flare hex nut against the nose of the fitting body body hex fitting and tighten the hex nut to the body hex fitting to hand tight approximately 30 in Ibs 3 4 Nm 2 Make areference mark on one of the flats of the hex nut and continue it on to the body hex fitting with a permanent ink marker Refer to Figure 1 A TEREX COMI Part No 1258748 SPECIFICATIONS Figure 1 a hex nut b reference mark body hex fitting 3 Working clockwise on the body hex fitting make a second mark with a permanent ink marker to indicate the proper tightening position Refer to Figure 2 Note Use the JIC 37 Fittings table on the previous page to determine the correct number of flats for the proper tightening position Note The marks indicate that the correct tightening positions have been determined Use the second mark on the body hex fitting to properly tighten the joint after it has bee
262. n unsafe working condition for platform and ground personnel 1 Start the engine from the ground controls 2 Press and hold a function enable speed select button and fully retract the primary boom 3 Push one of the LCD screen buttons shown until 4 platform angle is displayed 4 Press and hold a function enable speed select button and adjust the platform to zero degrees using the platform level up down buttons A TEREX CON 5 Push and hold a function enable speed select button and fully raise the primary boom while observing the platform angle shown on the LCD display Result The platform should remain level at all times to within 2 degrees Note If the platform becomes out of level the tilt alarm will sound and the Platform Not Level Indicator will flash at the ground controls The platform level up down buttons will only work in the direction that will level the platform Level the platform until the indicator light turns off 6 Push and hold a function enable speed select button and fully lower the primary boom Result The platform should remain level at all times to within 2 degrees Note If the platform becomes out of level the tilt alarm will sound and the Platform Not Level Indicator will flash at the ground controls The platform level up down buttons will only work in the direction that will level the platform Level the platform until the indicator light turns off
263. nce procedures can lead to poorengine performance and component damage Engine oil replace Oil filter replace Primary fuel filter replace V belts check Intake air pipes check Cooling system check Required maintenance procedures and additional engine information are available in the Deutz 2011 Series Operation Manual Deutz part number 0312 3547 OR the Deutz 2 9 L4 Series Operation Manual Deutz part number 0312 3893 Deutz 2011 Series Operation Manual Genie part number 139320 Deutz 2 9 L4 Series Operation Manual Genie part number 1251561 Part No 1258748 2014 Section 3 Scheduled Maintenance Procedures C 3 Perform Engine Maintenance Perkins Models Engine specifications require that this procedure be performed every 500 hours Proper engine maintenance following the engine manufacturer s maintenance schedule is essential to good engine performance and service life Failure to perform the maintenance procedures can lead to poor engine performance and component damage Engine oil replace Oil filter replace Fuel filter replace Secondary Fuel filter replace Fan clearance check Cooling system test add Hoses and clamps inspect replace Radiator clean Required maintenance procedures and additional engine information are available in the Perkins 800D Series Operation Manual Perkins part number SEBU8324 OR the Perkins 404F Series
264. nd repair procedures are performed Do Not Perform Maintenance Unless M You are trained and qualified to perform maintenance on this machine M 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 Genie Part No 1258748 Z 80 60 VII Section 1 Safety Rules November 2014 SAFETY RULES 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 symbol used to alert personnel to potential personal injury hazards Obey all safety messages that follow this symbol to avoid possible injury or death A Used to indicate the presence of an imminently hazardous situation which if not avoided will result in death or serious injury Used to indicate the presence of a AWARNING potentially hazardous situation which if not avoided could result in death or serious injury With safety alert symbol used to ACAUTION indicate the presence of a potentially hazardous situation which if not avoided may result in minor or moderate injury Used to in
265. ndary boom tube 15 Support and slide the extension boom assembly out of the secondary boom tube and place it on a structure capable of supporting it AWARNING Crushing hazard The extension boom tube could become unbalanced and fall if not properly supported when removed from the primary boom tube Note During removal the overhead crane strap will need to be adjusted for proper balancing 16 To remove the secondary boom extension cylinder see 4 9 How to Remove the Secondary Boom Extension Cylinder Part No 1258748 November 2014 Section 4 Repair Procedures 4 8 Secondary Boom Lift Cylinder How to Remove the Secondary Boom Lift Cylinder AWARNING 2 dily injury hazard This procedure requires specific repair skills lifting equipment and a suitable workshop Attempting this procedure without these skills and tools could result in death or serious injury and significant component damage Dealer service is strongly recommended Note When removing a hose assembly or fitting the O ring if equipped on the fitting and or the hose end must be replaced All connections must be torqued to specification during installation Refer to Section 2 Hydraulic Hose and Fitting Torque Specifications 1 Lower the secondary boom to the stowed position 2 Tag disconnect secure and remove the battery cables connecting the batteries Remove battery fasteners and hooks from battery tray Remove the batteries and store t
266. ndustries Genie is a registered trademark of Genie Industries Rev B Instructions Use the operators manual on your machine The Pre delivery Preparation consists of completing the Pre operation Inspection the Maintenance items and the Function Tests Use this form to record the results Place a check in the appropriate box after each part is completed Follow the instructions in the operator s manual If any inspection receives an N remove the machine from service repair and re inspect it After repair place a check in the R box Legend Y yes completed N no unable to complete R repaired Comments Pre Delivery Preparation Y N R Pre operation inspection completed Maintenance items completed Function tests completed Model Serial number Date Machine owner Inspected by print Inspector signature Inspector title Inspector company November 2014 Section 3 Scheduled Maintenance Procedures Maintenance Inspection Report Model Serial number Date Hour meter Machine owner Inspected by print Inspector signature Inspector title Inspector company Instructions Make copies of this report to use for each inspection Select the appropriate checklist s for the type of inspection to be performed Daily or 8 hour Inspection A Quarterly or 250 hour Inspection A B Six Month or 500 hour Inspection A B C Annual or 1000 hours Inspection A B C D 2 Year or 2000 ho
267. o poor engine performance and component damage 804D Models Cooling system coolant replace Engine mounts check 404F Models Alternator check Engine mounts check Starter check CHECKLIST E PROCEDURES E 3 Perform Engine Maintenance Deutz Models Engine specifications require that this procedure be performed every 2 years Proper engine maintenance following the engine manufacturer s maintenance schedule is essential to good engine performance and service life Failure to perform the maintenance procedures can lead to poor engine performance and component damage All models Cooling system coolant replace Required maintenance procedures and additional engine information are available in the Deutz 2011 Series Operation Manual Deutz part number 0312 3547 OR the Deutz 2 9 L4 Series Operation Manual Deutz part number 0312 3893 Deutz 2011 Series Operation Manual Required maintenance procedures and additional Genie part number 139320 engine information are available in the Perkins 800D Series Operation Manual Deutz 2 9 L4 Series Operation Manual Perkins part number SEBU8324 OR the Genie part number 1251561 Perkins 404F Series Operation Manual Perkins part number SEBU8609 Perkins 800D Series Operation Manual Genie part number 111332 Perkins 404F Series Operation Manual Genie part number 1251562 Genie Part No 1258748 Z 80 60 3 57 Section 3 Scheduled Maintenance Procedu
268. o Section 2 Specifications 8 Turn the engine off Use a wrench to hold the relief valve and remove the cap item B 9 Adjust the internal hex socket Turn it clockwise to increase the pressure or counterclockwise to decrease the pressure Install the relief valve cap AWARNING Tip over hazard Do not adjust the relief valve higher than specified 10 Repeat steps 5 through 7 to confirm relief valve pressure 11 Remove the pressure gauge 12 Remove the jumper wire from LSS2AO limit switch connector Connect the limit switch to the wire harness 13 Install the secondary boom end cover and tighten the retaining fasteners Part No 1258748 October 2014 Section 4 Repair Procedures How to Adjust the Secondary Boom Down Relief Valve 1 Connect 0 to 5000 psi 0 to 350 bar pressure gauge to the Ls port on the function manifold 2 Start the engine from the ground controls 3 Press and release the rpm select button until the engine changes to high idle 4 Raise the secondary boom approximately 12 inches 30 cm 5 Placea4x4 inch 10 x 10 cm block on the secondary boom rest pad Lower the secondary boom onto the block AWARNING Crushing hazard Keep hands clear of the block when lowering the secondary boom 6 Simultaneously push and hold the function enable high speed button and the secondary boom down button Observe the reading on the pressure gauge Refer to Section 2 Specifications 7 Turn the
269. oft metal drift to remove the pin 19 Remove the secondary boom lift cylinder from the machine by pulling it through the platform end of the secondary boom AWARNING Crushing hazard The secondary boom lift cylinder could become unbalanced and fall if not properly supported when removed from the machine Component damage hazard When removing the secondary boom lift cylinder from the machine be careful not to damage the counterbalance valves at the barrel end of the cylinder Component damage hazard Cables and hoses can be damaged if the cylinder is pulled across them Part No 1258748 Genie Z 80 60 BOOM COMPONENTS 4 9 Secondary Boom Extension Cylinder The secondary boom extension cylinder extends and retracts the secondary boom extension tube The secondary boom extension cylinder is equipped with counterbalance valves to prevent movement in the event of a hydraulic line failure How to Remove the Secondary Boom Extension Cylinder AWARNING 200 injury hazard This procedure requires specific repair skills lifting equipment and a suitable workshop Attempting this procedure without these skills and tools could result in death or serious injury and significant component damage Dealer service is strongly recommended Note When removing a hose assembly or fitting the O ring on the fitting and or hose end must be replaced and then torqued to specification during installation Refer to Section 2 Hy
270. oid valve position 5 HL Platform level up down circuit 19 21 ft Ibs 26 29 Nm 13 Proportional solenoid valve position 5 HM Platform rotate left right circuit 19 21 ft Ibs 26 29 Nm Genie 4 74 Z 80 60 Part No 1258748 Section 4 Repair Procedures November 2014 MANIFOLDS 95 p 71 m S e Y ou 199 On 75 Part No 1258748 Section 4 Repair Procedures November 2014 er MANIFOLDS 8 5 Turntable Rotation Manifold The turntable rotation manifold is mounted to the turntable rotation motor located in the boom storage compartment Index Schematic No Description Item Function Torque 1 Shuttle valve 2 position 3 way KK Turntable rotation brake release 10 13 ft Ibs 14 18 Nm 2 Counterbalance valve LL ius Turntable rotate right 35 40 ft lbs 47 54 Nm 3 Counterbalance valve MM Turntable rotate left 35 40 ft lbs 47 54 Nm Genie Z 80 60 Part No 1258748 November 2014 Section 4 Repair Procedures eer MANIFOLDS 8 6 Platform Rotate Manifold The platform rotate manifold is mounted on the platform rotator Index
271. om Secure the roller arm to the switch body during assembly 8 Remove the barrel end retaining fasteners 9 Using a suitable lifting device lift the extension cylinder to clear the saddle blocks 10 Support and slide the extension cylinder out of the boom extension and place it on a structure capable of supporting it AWARNING Crushing hazard The secondary boom extension cylinder could become unbalanced and fall if not properly supported when removed from the machine Component damage hazard When removing the secondary boom extension cylinder from the machine be careful not to damage the counterbalance valves at the barrel end of the cylinder Component damage hazard Cables and hoses can be damaged if the cylinder is pulled across them Genie 4 48 Z 80 60 Part No 1258748 November 2014 Section 4 Repair Procedures Engines 5 1 5 2 RPM Adjustment Flex Plate Refer to Maintenance Procedure C 5 The flex plate acts as a coupler between the engine Check and Adjust the Engine RPM and the pump It is bolted to the engine flywheel and has a splined center to drive the pump Type B flex plates combines the pump coupler as part of the flex plate which is installed onto the engine flywheel Type flexplate with coupler combined Genie Part No 1258748 Z 80 60 4 49 Section 4 Repair Procedures November 2014 ENGINES How to Remove the Flex Plate Note Perform this proced
272. om the platform if equipped 8 Remove the platform mounting fasteners and remove the platform from the machine Crushing hazard The platform AWARNING could become unbalanced and fall when it is removed from the machine if it is not properly supported Genie 2 80 60 2 2 Platform Leveling Cylinder The platform leveling cylinder maintains platform leveling through the entire range of boom motion This allows the platform to be level with the turntable The ECM at the ground controls compares the difference in readings between the platform angle sensor and the turntable level sensor The ECM at the ground controls sends a signal to the platform controls to open or close the appropriate platform level proportional valve on the platform manifold to maintain a level platform The platform leveling cylinder is equipped with counterbalance valves to prevent movement in the event of a hydraulic line failure How to Remove the Platform Leveling Cylinder Note When removing a hose assembly or fitting the O ring on the fitting and or hose end must be replaced and then torqued to specification during installation Refer to Section 2 Hydraulic Hose and Fitting Torque Specifications 1 Extend the boom until the platform leveling cylinder barrel end pivot pin is accessible 2 Raise the jib boom slightly and place blocks under the platform Part No 1258748 November 2014 Section 4 Repair Procedures 3 Lower the jib
273. on Components 9 1 Turntable Rotation Assembly 2 4 99 Axle Components 10 1 Steer Sensors css iets ETE eae eal 4 101 10 2 Oscillating 4 105 Genie 7 80 60 Part No 1258748 November 2014 TABLE OF CONTENTS Section 5 Fault Codes T dee te 5 1 Fault Diagnostics Control 5 2 How to Clear Secopndary Boom Safety Switch 5 10 Fault Code Display Deutz TD2 9 and Perkins 404F Engines 5 12 Deutz TD2 9 Engine Fault Code Chart 5 13 Perkins 404F 22T Engine Fault Code Chart sss 5 28 Continental Engine ECM Fault Code Chart sss 5 31 Section 6 Schematics laers p E be dete ote dana reese 6 1 Wire Circuit 3000 6 2 Limit Switches and Angle Sensors 2204 10000 6 8 Drive Chassis and Platform Controller Pin 6 10 Turntable Controller Pin Legend 6 11 Engine Relay and Fuse Panel Legend 6 12 Electrical Symbols Legend sssssssseseneeeeeneeneeee nnne nnne 6 14 Hydraulic Symbols 6 15 Electrical Schematic Engine Options Deutz TD2 9 Erigilie
274. orm mounting weldment Index Schematic No Description Item Function Torque 1 Check valve 5 Platform load sense level circuit 12 14 ft Ibs 16 19 Nm 2 Differential sensing valve N C Directs flow to functions 19 21 ft lbs 26 29 Nm 3 Check valve 5 2 Jib load sense up down circuit 12 14 ft Ibs 16 19 Nm 4 Flow control valve Bleeds off differential valve to tank 19 21 ft lbs 26 29 Nm 5 Accumulator 500 psi 34 5 bar Hydraulic dampening 23 ft lbs 31 Nm 6 Proportional solenoid valve 2 position 2 19 21 ft lbs 26 29 Nm 7 Proportional solenoid valve position 5 HG Jib up down circuit 19 21 ft lbs 26 29 Nm 8 Check valve 10 niue LUE 19 21 ft Ibs 26 29 Nm 9 Compensator valve Jib boom differential sensing circuit 33 37 ft lbs 45 50 Nm 10 Compensator valve HJ Platform level diff sensing circuit 33 37 ft lbs 45 50 Nm 11 Pressure compensation valve Platform rotate diff sensing circuit 19 21 ft Ibs 26 29 Nm 12 Proportional solen
275. ory Release the button 8 Atthe ground controls turn the key switch to the off position wait a moment and then turn the key switch to platform controls 9 Check the display at the ground controls to be sure there are no calibration faults Result There should be no calibration faults shown on the display If calibration faults exist repeat this procedure Function speeds Note Be sure the machine is in the stowed position and the platform is rotated between the round end tires 10 Start the engine from the platform controls 11 Select a boom function that needs the function speed set Section 4 Repair Procedures November 2014 PLATFORM CONTROLS 12 Boom up down functions Move the joystick full stroke in the up direction When the alarm sounds move the joystick in the opposite direction full stroke until the alarm sounds again Return the joystick to center Boom extend retract functions Raise the primary boom until it no longer rests on the boom cradle Then move the joystick full stroke How to Adjust the Function Speeds Note Perform this procedure with the boom in the stowed position Refer to Section 2 Specifications 1 Pull out the red Emergency Stop button to the on position at both the ground and platform controls in the extend direction When the alarm sounds move the joystick in the opposite direction full stroke until the alarm sounds again Return the joystick to center
276. ot stowed DCONS Lifting or Driving LORDR Aux Drive OPT YES NO Proximity Kill Switch NONE PROX Platform Overload NONE PLFTS Work Light YES NO Flashing Beacon YES NO Drive Lights YES NO Disable Steer Mode Change while Driving YES NO Rocker Joystick Steering YES NO Chassis Tilt Cutout YES NO Foot Switch Lockout 0 to 30 minutes Genie 30 0 max and 0 0 min 10 0 default 0 to 30 minutes 0 to 10 minutes 10 is the default Only shown when Hydraulic gen is selected Holding or button will cause display to scroll through options or increment number settings automatically 0 2 min inc dec Z 80 60 Part No 1258748 November 2014 Section 4 Repair Procedures Platform Controls The platform controls contains two a printed circuit boards The LED circuit board is mounted to the underside b of the control box lid which contains the LED s The LED circuit board sends the input from the operator to the platform controls ECM circuit board The ECM circuit board PCON sends the data to SS the turntable control box TCON for processing EG eG The platform controls ECM circuit board M GE ALC 1000 communicates with the turntable controls The joystick controllers at the platform controls utilize Hall Effect technology and require no adjustment The operating parameters of the
277. ote An hydraulic oil heating system is recommended when the ambient temperature is consistently below 0 F 18 C Note Do not operate the machine when the ambient temperatue is below 20 F 29 C with Rando HD Premium MV Petro Canada Environ MV 46 Fluid Properties Pour point 81 F 63 C Maximum continuous operating temperature 124 F 51 C Note Use of Chevron 5606A hydraulic fluid or equivalent is required when the ambient temperature is consistently below 0 F 18 C unless an oil heating system is used Continued use of Chevron 5606A hydraulic fluid or equivalent when ambienttemperatures are consistently above 32 F 0 C may result in component damage Note Continued use of Chevron 5606A hydraulic fluid or equivalent when ambient temperatures are ISO Grade 46 consistently above 32 F 0 C may result in Kinematic Viscosity SS ee cSt 200 F 100 C a UCONHydrolube HP 5046 Fluid Properties cST 104 F 40 C 44 4 ISO Grade 46 Flash point 482 250 C Viscosity index 192 Pour point 49 F 45 C Kinematic Viscosity cSt 149 F 65 C 22 Maximum continuous operating cST 104 F 40 C 46 temperature 180 F 82 C cST 0 18 C 1300 Flash point None Pour point 81 F 63 C Maximum continuous operating temperature 189 F 87 C Ganie 2 4 Z 80 60 Part No 1258748 2014 Hydraulic Componen
278. ove all rings watches and other jewelry Component damage hazard Electrostatic discharge ESD can damage printed circuit board components Maintain firm contact with a metal part of the machine that is grounded at all times when handling printed circuit boards OR use a grounded wrist strap 4 60 Z 80 60 Genie Carefully remove the membrane decal from the control box lid while guiding the ribbon cables out of the control box lid Remove any decal adhesive from the control box lid with a mild solvent Component damage hazard Certain solvents can damage LCD display Do not allow any solvent to come in contact with the LCD display screen Install the new membrane decal onto the control box lid while guiding the ribbon cables through the control box lid Connect the ribbon cables to the ECM circuit board Close the control box lid and install the retaining fasteners Part No 1258748 November 2014 Section 4 Repair Procedures Hydraulic Pumps 7 1 2 Tag disconnect and plug the hydraulic hoses at Function Pump the function pump Cap the fittings on the How to Remove the Function AWARNING Podly injury hazard Spraying hydraulic oil can penetrate and Pump burn skin Loosen hydraulic Note When removing a hose assembly or fitting the O ring on the fitting and or hose end must be replaced and then torqued to specification during installation Refer to Section 2 Hydraulic Hose and connections very
279. ow to Remove the Drive Pump Component damage hazard The work area and surfaces where this procedure will be performed must be clean and free of debris that could get into the hydraulic system and cause severe component damage Dealer service is recommended Note When removing a hose assembly or fitting the O ring on the fitting and or hose end must be replaced and then torqued to specification during installation Refer to Section 2 Hydraulic Hose and Fitting Torque Specifications 1 Disconnect the wire harness at the electronic displacement controller EDC located on the drive pump Genie 2 80 60 2 Models without hydraulic tank shutoff valves Remove the drain plug from the hydraulic tank and completely drain the tank into a suitable container Refer to Section 2 Specifications Models with hydraulic tank shutoff valves Close the two hydraulic tank valves located at the hydraulic tank Component damage hazard The engine must not be started with the hydraulic tank shutoff valves in the closed position or component damage will occur If the tank valves are closed remove the key from the key switch and tag the machine to inform personnel of the condition 1 closed 3 Tag disconnect and plug the hydraulic hoses at the drive and function pumps Cap the fittings on the pumps AWARNING Bodily injury hazard Spraying hydraulic oil can penetrate and burn skin Loosen hydraulic connections very
280. pacities Tires and wheels Fuel tank 35 gallons 132 5 liters Tire size foam filled and non marking 18 625 FF LPG tank 33 5 Ibs 15 2 kg Tire size Hi flotation 445D50 70 Hydraulic tank 45 gallons 170 liters Tire ply rating foam filled and non marking 16 Hydraulic system 80 gallons including tank 303 liters Tire weight new foam filled minimum 622 Rough terrain 282 kg Drive hubs 44 fl oz 1 3 liters Tire ply rating Hi flotation 14 Turntable rotation drive hub 40 fl oz 1 2 liters Overall tire diameter 40 7 in foam filled and non marking 103 3 cm Drive hub oil type EP 80 90W gear oil API Service Classification GL5 Overall tire diameter 45 47 in Hi flotation 115 5 cm Wheel diameter 24 5 in foam filled and non marking 62 2 cm Wheel diameter 28 in Hi flotation 71 1 cm Wheel width 15 in foam filled non marking and Hi flotation 38 1 cm Tire Pressure Hi flotation 80 Ibs 5 5 bar Wheel lugs 10 Q 3 4 16 Lug nut torque lubricated 320 ft lbs 434 Nm Lug nut torque dry 420 ft lbs 570 Nm For operational specification refer to the Operator s Manual Continuous improvement of our products is a Genie policy Product specifications are subject to change without notice A TEREX COMPANY Part No 1258748 Z 80 60 2 1 Section 2 Specifications November 2014 SPECIFICATIONS Performance Specifications Drive speed maximum models with rough terrain tires 40 ft 8 7 9 3 sec 12 2
281. pect for Turntable Bearing Wear 3 49 0 5 Replace the Drive Hub 4002444 0 0 0 3 50 D 6 Replace the Hydraulic Filter Elements 24202 3 52 Genie Part No 1258748 Z 80 60 x November 2014 TABLE OF CONTENTS Section 3 Scheduled Maintenance Procedures continued D 7 Perform Engine Maintenance Continental 1006188 3 53 D 8 Perform Engine Maintenance Deutz 3 54 D 9 Perform Engine Maintenance Perkins Models 3 54 Checklist E Procedures E 1 Testor Replace the Hydraulic 3 55 E 2 Perform Engine Maintenance Perkins Models 3 57 E 4 Perform Engine Maintenance Deutz 3 57 E 5 Perform Engine Maintenance Perkins Models 3 58 E 6 Perform Cooling System Maintenance Perkins 404F Models 3 58 Section 4 Repair Procedures ItPOCUCHIOM ionis donde nU 4 1 Display Module 0 ote eed e a hated ems 4 2 Platform Controls 1 1 ALC 1000 Circuit Board sse 4 10 1 3 iJOySliC KS itecto e a e eed 4 11 Platform Components 21 Platformuisicaumteiestus tee ete een ere p e te decem 4 18 2 2 Platform Leveling 00 000 4 198 2 3 P
282. perly ventilated and well lit Part No 1258748 November 2014 Introduction Section 1 Section 2 Section 3 Table of Contents Important Information ete ne Deeper ee ele 0 Serial Number Legend Safety Rules General Safety Rules auae aiet tare nnne trennen nnns Specifications Machine 2 1 Performance Specifications 2 2 Function Speeds 2 2 Hydraulic Specifications sssessessseseseeeeeneeeeneeen nennen 2 93 Hydraulic Component Specifications 2 5 Manifold Component Specifications 0 0 2 6 Valve Coil Resistance 2 6 Continental TME27 Engine sssesssssssseseeeeeeeeennnen nennen nnne nnne nnne nen 2 8 2 20111041 2 9 Deutz TD2 9 E4 Erigirie e RD ERR 2 11 Perkins 8040 33 Engine 80 8 2 13 Perkins404F 22T Englne iE e eh Stc acai 2 14 Machine Torque 2 15 Hydraulic Hose and Fitting Torque Specifications
283. pivot pin Do not remove the pin 4 Use a soft metal drift to tap the jib boom lift cylinder rod end pivot pin half way out and lower one of the leveling arms to the ground Tap the pin the other direction and lower the opposite leveling arm Do not remove the pin ACAUTION Crushing hazard The jib boom lift cylinder may fall if not supported when the rod end pivot pin is removed 5 Support the jib boom lift cylinder with a suitable lifting device 6 Remove the pin retaining fastener from the jib boom lift cylinder barrel end pivot pin Use a soft metal drift to remove the barrel end pivot pin and let the cylinder hang down Crushing hazard The platform AWARNING and jib boom lift cylinder could become unbalanced and fall if not properly supported when the jib boom lift cylinder barrel end lift pivot pin is removed 7 Place blocks under the platform leveling cylinder for support Protect the cylinder from damage 8 Use a soft metal drift to remove the jib boom lift cylinder rod end pivot pin Remove the jib boom lift cylinder from the machine AWARNING Crushing hazard The jib boom lift cylinder could become unbalanced and fall if not properly supported when removed from the machine Part No 1258748 November 2014 Section 4 Repair Procedures Boom Components primary boom li
284. plosion and fire hazard When transferring fuel connect a grounding wire between the machine and pump or container Note Be sure to only use a hand operated pump suitable for use with gasoline and diesel fuels 9 Tag and disconnect the wire harness from the fuel level sending unit 10 Tag disconnect and plug the fuel hoses from the fuel tank 11 Clean up any fuel that may have spilled Genie 2 80 60 12 Remove the fuel tank mounting fasteners Carefully remove the fuel tank from the machine Component damage hazard The fuel tank is plastic and may become damaged if allowed to fall Note Clean the fuel tank and inspect for cracks and other damage before installing it onto the machine 13 Tag disconnect and plug the hydraulic hoses from the secondary boom lift cylinder Cap the fitings on the cylinder AWARNING Bodily injury hazard Spraying hydraulic oil can penetrate and burn skin Loosen hydraulic connections very slowly to allow the oil pressure to dissipate gradually Do not allow oil to squirt or spray 14 Place blocks under each end of the secondary boom lift cylinder for support 15 Remove the pin retaining fasteners from the secondary boom lift cylinder rod end pivot pin 16 Use a soft metal drift to remove the pin 17 Remove the pin retaining fastener from the secondary boom lift cylinder barrel end pivot pin Part No 1258748 November 2014 Section 4 Repair Procedures 18 Use a s
285. pport the platform mounting weldment Do not apply any lifting pressure 10 Remove the eight mounting bolts from the platform mounting weldment 11 Remove the center bolt and slide the platform mounting weldment off of the platform rotator AWARNING Crushing hazard The platform mounting weldment may become unbalanced and fall if it is not properly supported Part No 1258748 November 2014 Section 4 Repair Procedures 12 Support the platform rotator Do not apply any lifting pressure 13 Remove the pin retaining fasteners from the jib boom and jib boom leveling arms to platform rotator pivot pins Do not remove the pins 14 Support the jib boom leveling arms with a suitable lifting device 15 Use a soft metal drift to remove both pins and remove the platform rotator from the machine AWARNING Crushing hazard The jib boom leveling arms may fall if they are not properly supported when the jib boom leveling arm pivot pin is removed Component damage hazard The platform angle sensor is a very sensitive instrument It can be damaged internally if the platform rotator is dropped or sustains any physical shock even if the damage is not visible How to Bleed the Platform Rotator Before serial number 229 Note Do not start the engine Use auxiliary power for all machine functions in this procedure 1 Connecta clear hose to the top bleed valve Place the other end of the hose in a container to collect
286. properly greased platform overload mechanism could result in the system not sensing an overloaded platform condition and will result in component damage 1 Locate the grease fittings on each pivot pin of the platform overload assembly 2 Thoroughly pump grease into each grease fitting using a multi purpose grease Grease Specification Chevron Ultra duty grease EP NLGI 2 lithium based or equivalent A TEREX COMI 7 Test the Platform Overload System if equipped Genie specifications require that this procedure be performed every 500 hours or 6 months whichever comes first Testing the platform overload system regularly is essential to safe machine operation Continued use of an improperly operating platform overload system could result in the system not sensing an overloaded platform condition Machine stability could be compromised resulting in the machine tipping over Note Perform this procedure with the machine on a firm level surface 1 Turn the key switch to platform control Start the engine and level the platform 2 Determine the maximum platform capacity Refer to the machine serial plate 3 Remove all weight tools and accessories from the platform Note Failure to remove all weight tools and accessories from the platform will result in an inaccurate test Part No 1258748 2014 Section 3 Scheduled Maintenance Procedures 4 Using a suitable lifting device pl
287. pstream DOC Engine Protection signal range check high 523216 9 198 TimeoutErrorof CAN Receive 4768 4 1045 Sensor error exhaust gas Frame PrHtEnCmd pre heat temperature upstream DOC command engine command signal range check low 523240 9 179 Timeout CAN message 4769 2 1026 Sensorexhaust gas FunModCtl temperature downstream Function Mode Control DOO plausibility error 523350 4 565 Injectorcylinder bank 1 4769 3 1034 Sensorerror exhaust gas short circuit temperature downstream DOC signal range check high 523352 4 566 Injector cylinder bank 2 short circuit 4769 4 1035 Sensor error exhaust gas temperature downstream 523354 12 567 Injector powerstage output DOC signal range check low defect 523006 34 Controller mode switch short 523470 2 826 Pressure Relief Valve PRV circuit to battery forced to open performed by pressure increase 523006 4 35 Controller mode switch short circuit to ground 523470 2 827 Pressure Relief Valve PRV forced to open performed by 523008 1 648 Manipulation control was pressure shock triggered 5 20 Z 80 60 Part No 1258748 2014 Section 5 Fault Codes 1 DEUTZ TD 2 914 ENGINE FAULT CODES SPN Suspect Parameter Number FMI Failure Mode Identifier KWP Keyword Protocol SPN FMI KWP Description SPN FMI KWP Description 523470 7 876 Maximum rail pressure in limp 523612 1
288. que the mounting fasteners on the backlash pivot plate to specification Refer to Section 2 Specifications Rotate the turntable through an entire rotation Check for tight spots that could cause binding Readjust if necessary Part No 1258748 November 2014 Section 4 Repair Procedures 10 1 Steer Sensors The steer sensor measures steer angle and communicates that information to the ground controls ECM The steer sensor on the ground controls side of the machine at the square end acts as the lead sensor The other three sensors follow the position or steer angle of the lead sensor There is a steer sensor mounted to the top of each upper yoke pivot pin Note If the square end steering function becomes inoperative switch to circle end steer mode and the ground controls side circle end steer sensor will become the lead sensor Note This procedure will require a minimum of two people How to Measure the Tire Alignment 1 Start the engine from the platform controls 2 Press down the foot switch Measure the circle end tires 3 Press the square end steer mode button Measure here 5 1 Y EM PartNo 1258748 Genie Z 80 60 Axle Components 4 Measure the distance between the inside of one circle end tire and the chassis side plate on both sides of the axle Result Both measu
289. r up ee SWITCHES pre on LCD 4 PRIMARY BOOM EXT RET Fault Check both Primary boom extend retract disabled Power up controller with the problem SWITCHES ON TCON buttons pressed display message on LCD corrected PRIMARY BOOM LENGTH Fault check Display message on LCD Power up controller with the problem unknown length corrected PRIMARY BOOM ANGLE Fault check Allow only primary boom retract Power up controller with the problem unknown angle down Display message on LCD corrected PRIMARY UP DOWN SPEED Not calibrated Display message on LCD and allow b re auto calibrate procedure operation at default speed PRIMARY Display message LCD and allow EXTEND RETRACT SPEED Not calibrated operation at default speed Perform auto calibrate procedure Normal function except threshold for Not calibrated one or the other direction is zero Calibrate thresholds Display message on LCD Initiate one second beep of audible PRIMARY BOOM UP DOWN Just calibrated Viana device Self clearing transient FLOW VALVE Value at 5 0 V Value Too High Limited speed and direction frozen at Power up controller with the problem Value Too Low zero and neutral alarm sounds corrected Value at 0 V Continued on next page A TEREX COMPANY Part No 1258748 Z 80 60 5 5 Section 5 Fault Codes November 2014 CONTROL SYSTEM FAULT CODES ErrorSource Error Type Effects Recovery Action
290. re replaced 4 Always return the manuals to the storage container after use Note Contact your authorized Genie distributor or Genie Industries if replacement manuals or decals are needed Section 3 Scheduled Maintenance Procedures November 2014 CHECKLIST A PROCEDURES A 2 Perform Pre operation Inspection Genie specifications require that this procedure be performed daily or every 8 hours whichever comes first Completing a pre operation inspection is essential to safe machine operation The pre operation inspection is a visual inspection performed by the operator prior to each work shift The inspection is designed to discover if anything is apparently wrong with a machine before the operator performs the function tests The pre operation inspection also serves to determine if routine maintenance procedures are required Complete information to perform this procedure is available in the appropriate operator s manual Refer to the Operator s Manual on your machine A TEREX COMI A 3 Perform Function Tests Genie specifications require that this procedure be performed daily or every 8 hours whichever comes first Completing the function tests is essential to safe machine operation Function tests are designed to discover any malfunctions before the machine is put into service A malfunctioning machine must never be used If malfunctions are discovered the machine must be tagged and removed from service
291. rements refer to the Engine Operator Handbook on your machine Standby idle 1000 rpm Oil temperature switch Low idle 1500 rpm Temperature switch point 257 F 125 C Highidle 2500 rpm Oil pressure switch Compression ratio 17 4 1 Oil pressure switch point 20 psi 1 4 bar Compression pressure contact engine manufacturer Enginecoolant Governor electronic Capacity 11 quarts Lubrication system 10 4 liters Oil pressure 40 to 60 psi Fuel injection system 2000 rpm 1 4 to 3 bar Injection pump make Bosch Oil capacity 9 4 quarts Se including filter 9 liters Injection pump pressure maximum 15000 psi 1034 bar Injector opening pressure 3046 psi 210 bar Fuel requirement For fuel requirements refer to the engine Operator s Manual on your machine Continuous improvement of our products is a Genie policy Product specifications are subject to change without notice Genie Part No 1258748 Z 80 60 2 11 Section 2 Specifications November 2014 SPECIFICATIONS Deutz TD 2 9 L4 Engine continued Starter motor Current draw normal load 250A to 400A Brush length new 0 72 in 18 5 mm Brush length minimum 0 27 in 7mm Battery Type 12V DC Size 13 x 613 16 93 8 inches 33 x 17 3 x 23 8 cm Quantity 1 Cold cranking ampere 1000A Reserve capacity 25A rate 200 minutes Alternator output 95A 14V DC Fan belt deflection 3 8 to 1 2 inch 9 to 12 mm Continuous improvement of our products is a G
292. rements should be the same to indicate that the tires are parallel with the chassis Note If the measurements are different or if a tire is not parallel with the chassis the steer sensor of that tire will need to be adjusted See How to Adjust a Steer Sensor 5 Repeat step 4 for the other circle end tire Measure the square end tires 6 Press the circle end steer mode button 7 Measure the distance between the inside of one square end tire and the chassis side plate on both sides of the axle Result Both measurements should be the same to indicate that the tires are parallel with the chassis Note If the measurements are different or if a tire is not parallel with the chassis the steer sensor of that tire will need to be adjusted See How to Adjust a Steer Sensor 8 Repeat step 4 for the other square end tire Measure here _ 63 Square end I 1 D gt Circle end J v 4 101 Section 4 Repair Procedures November 2014 AXLE COMPONENTS How to Adjust a Steer Sensor 1 Start the engine from the platform controls 2 Press down the foot switch and push the engine idle select button until the engine switches to high rpm Square end steer sensors 3 At the platform controls press the circle end steer mode button 4 Locate the steer sensor on top of the yoke pivot pin 5 Loosen the
293. res November 2014 CHECKLIST E PROCEDURES E 4 E 5 Perform Engine Maintenance Perform Cooling Sytem Perkins Models Maintenance Engine specifications require that this procedure be performed every 3000 hours Proper engine maintenance following the engine manufacturer s maintenance schedule is essential to good engine performance and service life Failure to perform the maintenance procedures can lead to poor engine performance and component damage 804D Models Water pump inspect 404F Models Thermostat replace Diesel particulate filter clean e Fuel injectors test replace Flow plugs ARD combustion replace Radiator cap replace Water pump inspect Required maintenance procedures and additional engine information are available in the Perkins 800D Series Operation Manual Perkins part number SEBU8324 OR the Perkins 404F Series Operation Manual Perkins part number SEBU8609 Perkins 800D Series Operation Manual Genie part number 111332 Perkins 404F Series Operation Manual Genie part number 1251562 Genie A TEREX Perkins 404F Models Engine specifications require that this procedure be performed at various intervals Proper engine maintenance following the engine manufacturer s maintenance schedule is essential to good engine performance and service life Failure to perform the maintenance procedures can lead to poor engine performance and component damage
294. rive Speed Raised or Extended Position 3 30 B 18 Test the Alarm and Optional Flashing 3 31 B 19 Perform Hydraulic Oil 3 31 B 20 Test the Safety Envelope and Safety Circuits 3 32 B 21 Test the Primary Boom Self leveling 3 34 B 22 Test the Primary Boom Angle Sensor 3 35 B 23 Inspect the Fuel Tank Cap Venting Systems 3 36 Checklist Procedures C 1 Perform Engine Maintenance Continental Models 3 38 C 2 Perform Engine Maintenance Deutz 3 38 3 Perform Engine Maintenance Perkins Models 3 39 0 4 Replace the Engine Air Filter 022 3 39 C 5 Check and Adjust Engine 3 40 0 6 Grease the Platform Overload Mechanism if equipped 3 42 C 7 Test the Platform Overload System if 0060 60 3 42 Checklist D Procedures D 1 Check the Boom Wear Pads 2 00 0 0 0000 nennen 3 45 D 2 Checkthe Free wheel Configuration 22 0 2 2 0 3 46 D 3 Check the Turntable Rotation Bearing Bolts 3 47 0 4 Ins
295. rj Y37009 5 4 2rnnvudAH NI TE N s fg Lok 5 YO QAH9TTY 1va 9 14 Aviad e RE LL m c ae Tae HM NDITZD or test HM aAHOTTD e Iva MS gis 52 f 28 6 58 5 a z 5 4 1 2 aa 2 dE z i 5 ze 5 6 5 5 az oa 9 x x gt Es aa 5 5 T 25 2na won 5 a HMW IS vSvEH ee A b a 4 N 6 HMWE VSPED ae HS L3HATA MOTD loo co O in 22 5 I 5 9 z un a 2 38 HM 2d3te FEES mz oaa e 0 0 2 2 1009 gt gt T 3AWA B YOLVYANAD 2 Ba WEL SRE S SIXV A 1L 5 2 5 5 Boer 5 5 5 az w dNoLwa XG AERP 5 SIXV 1L 2 5 6 4 NI TIid qr OVIH 67744 5 5 5 L z m VLLASWOUL aa lt lt lt 8 8 5 8 8 8 2a Ne La ra a 5 5 gt YOLVYANAS ov Ta
296. rning device Value at5 0V at 5 0 V Value too oe Limited speed and direction frozen at Power up controller with problem Value too low zero and neutral alarm sounds corrected PROPEL JOYSTICK ValueatOV ValueatOV V zero and neutral Just Calibrated Initiate one second beep of audible warning device Normal function except threshold for Not calibrated one or the other direction is zero Display message on LCD PROPEL VALVES FWD J Initiate one second beep of audible PROPEL VALVES REV ust calibrated davio Self clearing transient PROPEL EDC FWD Value at 5 0 V PROPEL EDC REV Q 6 Value Too High Limited speed and direction frozen at Power up controller with the problem Value Too Low zero and neutral alarm sounds corrected Value at 0 V A TEREX COMPANY 5 8 Z 80 60 Part No 1258748 November 2014 Section 5 Fault Codes CONTROL SYSTEM FAULT CODES ErrorSource Error Type Effects Recovery Actions Limited d and direction frozen at Power up controller with the problem Faull cheek pes DN corrected 2 contacts closed message on LCD corrected Value at 5 0 V Value too high Limited speed and direction frozen at Power up controller with problem Value too low zero and neutral alarm sounds corrected STEERING JOYSTICK Value at 0 V Not calibrated Joystick speed and direction frozen at Calibrate joystick zero and neutral Just calibrated Initiate
297. rom moving AWARNING Crushing hazard Failure to install the bolt into the engine tray to secure it from moving could result in death or serious injury 5 Inspect the following areas for burnt chafed corroded pinched and loose wires Engine wiring harness Battery area wiring 6 Open the ground controls side turntable cover 7 Inspect the following areas for burnt chafed corroded pinched and loose wires Inside of the ground control box Hydraulic manifold wiring Hydraulic oil cooler wiring 8 Inspect for a liberal coating of dielectric grease atthe following location All wire harness connectors to the ground control box Hydraulic manifold wiring 9 Start the engine from the ground controls and raise the secondary boom above the turntable covers 10 Inspect the turntable area for burnt chafed and pinched cables A TEREX CON Part No 1258748 CHECKLIST B PROCEDURES 11 Lower the secondary boom to the stowed position and turn the engine off 12 Inspect the following areas for burnt chafed corroded pinched and loose wires Cable track on the boom Cables on the boom and jib boom Jib boom platform rotate manifold Inside of the platform control box 13 Remove the engine tray retaining fastener from the engine tray anchor hole at the pivot end of the engine tray 14 Inspect for a liberal coating of dielectric grease at the following location All wire harness connectors to
298. s Indicates that an incorrect result has occurred after performing a series of steps Section 4 Repair Procedures November 2014 Display Module This table lists the various screens and menu options of the operating software Some display menus are for informational purpose only while others can be used to change the machine operating parameters The key switch must be in the off position before entering the programming mode Always exitthe programming mode before turning the red Emergency Stop button to the off position Screen Information Displayed Boom Type Z80 4WS ETC Engine Type Software Version Default Hour meter On power up Engine Speed amp Engine Oil Pressure PSI English amp Engine Oil Pressure kPa metric amp Engine Temperature F English Engine temperature is not Engine Temperature C metric displayed until engine is Primary Boom Angle Sensor above 100 F 38 C TT Level Sensor X TT Level Sensor Y Platform Angle Battery Volts With the key Hydraulic Pressure PSI 0 4500 PSI Hydraulic Pressure kPa 0 31000 kPa DPF Soot 0 150 Force DPF Regeneration No Yes Inhibit DPF Regeneration No Yes Primary Boom Zone lt 0 DEG gt 0 DEG 65 DEG Primary Boom Length 0 gt 0 gt 22 Secondary Boom Length gt Secondary Angle 0 DEG gt 0 DEG 65 DEG Genie 4 2 Z 80 60 Part No 1258748 November 2014 Section
299. s 4 Place a suitable container underneath the hydraulic tank A TEREX COMI Part No 1258748 5 Remove the drain plug from the hydraulic tank and completely drain the tank into a suitable container Refer to Section 2 Specifications 6 Tag disconnect and plug the two suction hoses and supply hose for the auxiliary pump from the hydraulic tank Cap the fittings on the tank Note The hoses can be accessed through the access hole under the turntable 7 Tag disconnect and plug the return filter hydraulic hose at the return filter Cap the fitting on the filter housing 8 Remove the ground controls side turntable cover 9 Support the hydraulic tank with an appropriate lifting device 10 Remove the hydraulic tank mounting fasteners 11 Remove the hydraulic tank from the machine AWARNING Cushing hazard The hydraulic tank could become unbalanced and fall if not properly supported when removed from the machine 12 Remove the hydraulic return filter housing mounting fasteners Remove the hydraulic return filter housing from the hydraulic tank 13 Remove the suction strainers from the tank and clean them using a mild solvent 14 Rinse out the inside of the tank using a mild solvent Section 3 Scheduled Maintenance Procedures November 2014 CHECKLIST E PROCEDURES 15 Install the suction strainers using a thread sealant on the threads 16 Install the drain plug using a thread sealant on the threads
300. s eT UR SAFETY SWITCH P6R1 SAFETY SWITCH P6R2 SAFETY SWITCH P10 Fault check Powerup We problem aum PEE E Gee TUM SAFETY SWITCH P22R SENSOR EE OVERLOAD Fault check if active Display message on LCD FORK BOOM DOWN OVERLOAD SHUT DOWN MODE A TEREX COMPANY 5 6 Z 80 60 Part No 1258748 November 2014 Section 5 Fault Codes CONTROL SYSTEM FAULT CODES Error Source Error Type Effects Recovery Actions Value at 5 0 V Value too high Limited speed and direction frozen at Power up controller with problem Value too low zero and neutral alarm sounds corrected TURNTABLE ROTATE VaueatoV ato V JOYSTICK Joystick speed and direction frozen at Not calibrated y P Calibrate joystick zero and neutral Just calibrated second beep Qf audible Self clearing transient warning device TURNTABLE ROTATE Fault Check both Turntable rotate disabled display Power up controller with the problem BUTTONS buttons pressed message on LCD corrected TURNTABLE ROTATE Display message LCD and allow 7 SPEED Not calibrated ogerattomatidatault aped Perform auto calibrate procedure Normal function except threshold for Not calibrated one or the other direction is zero Calibrate thresholds Display message on LCD Initiate second beep of audible TURNTABLE ROTATE FLOW Just calibrated Self clearing transient VALVE Value at 5 0 V
301. s ene D 7 Engine maintenance Quarterly or 250 hour Continental models Inspection ATB D 8 Engine maintenance Six Month or 500 hour Deutz models Inspection A B C D 9 Engine maintenance Annual or 1000 hours Perkins models Inspection A B C D 2 Year or 2000 hour comments Inspection A B C D E Place a check in the appropriate box after each inspection procedure is completed Use the step by step procedures in this section to learn how to perform these inspections If any inspection receives an tag and remove the machine from service repair and re inspect it After repair place a check in the R box Legend Y yes acceptable N no remove from service R repaired E 1 Replace hydraulic oil E 2 Engine maintenance Perkins models E 3 Engine maintenance Deutz models Perform every 3000 hours E 4 Engine maintenance Perkins models Perform at various intervals E 5 Cooling system Perkins 404F models A TEREX COMPANY Part No 1258748 2014 Section 3 Scheduled Maintenance Procedures Checklist A Procedures A 1 Inspect the Manuals and Decals Maintaining the operator s and safety manuals in good condition is essential to safe machine operation Manuals are included with each machine and should be stored in the container provided in the platform An illegible or missing manual will not provide safety and operational information nec
302. s press the four wheel steer mode button Measure the distance between the inside of the tire and the chassis side plate on both sides of the axle on each tire 18 If any tire is not parallel repeat the process beginning with step 3 Part No 1258748 November 2014 Section 4 Repair Procedures How to Calibrate the Steer Sensors If a steer sensor reaches the limit of travel before a tire is adjusted parallel to the chassis the steer sensor must be calibrated This procedure will re establish a center position on the steer sensor Note Perform this procedure with the machine in the stowed position Note This procedure will require two people 1 Start the engine from the platform controls 2 Press down the foot switch 3 Choose a steer mode based on the tire that needs alignment Note If a circle end tire cannot be aligned press the square end steer mode button If a square end tire cannot be aligned press the circle end steer mode button 4 Loosen the steer sensor cover retaining fasteners Do not remove them 5 Rotate the steer sensor cover either clockwise or counterclockwise to bring the tire as close to alignment as possible 6 Turn off the engine 7 Press and hold the enter button on the ground control panel while pulling out the ground controls red Emergency Stop button to the on position Hold the enter button for approximately 5 seconds and then release it 8 Enter sensor calibration mo
303. s and check the rpm Refer to Section 2 Specifications Skip to step 3 if the low idle rpm is correct 2 Loosen the low idle lock nut Turn the low idle adjustment screw clockwise to increase the rpm or counterclockwise to decrease the rpm Tighten the low idle lock nut and confirm the rpm Perkins models solenoid boot yoke lock nut low idle adjustment screw low idle lock nut yoke high idle adjustment nut 0 A TEREX COMPANY CHECKLIST C PROCEDURES 3 Move the function enable rpm select toggle switch to the high idle rabbit symbol position Refer to Section 2 Specifications If high idle rpm is correct disregard adjustment step 4 4 Loosen the yoke lock nut Turn the high idle adjustment nut and solenoid boot counterclockwise to increase the rpm or clockwise to decrease the rpm Tighten the yoke lock nut and recheck the rpm Note Be sure the solenoid fully retracts when activating high idle Part No 1258748 Z 80 60 3 41 Section 3 Scheduled Maintenance Procedures November 2014 CHECKLIST C PROCEDURES C 6 Grease the Platform Overload Mechanism if equipped Genie specifications require that this procedure be performed every 500 hours or 6 months whichever comes first Perform this procedure more often if dusty conditions exist Application of lubrication to the platform overload mechanism is essential to safe machine operation Continued use of an im
304. s injury Remove all rings watches and other jewelry 1 Test the coil for resistance See 8 14 How to Test a Coil 2 Connect a 100 resistor to the negative terminal of a known good 9V DC battery Connect the other end of the resistor to a terminal on the coil Resistor 10Q Genie part number 27287 Note The battery should read 9V DC or more when measured across the terminals Genie 2 80 60 COIL mac IVI t b 100 9V RESISTOR BATTERY 1 1 cc Ben DXX f eee J e i c e1 f Xd NJ Toe bo T L i f per i multimeter 9V DC battery 100 resistor coil om 0 Note Dotted lines in illustration indicate reversed connection as specified in step 6 3 Seta multimeter to read DC current Note The multimeter when set to read DC current should be capable of reading up to 800 mA 4 Connect the negative lead to the other terminal on the coil 5 Momentarily connect the positive lead from the multimeter to the positive terminal on the 9V DC battery Note and record the current reading 6 At the battery or coil terminals reverse the connections Note and record the current reading Result Both current readings are greater than 0 mA and are different by a minimum of 20 The coil is good W Result If one or both of the current readings 0 mA or if the two current readings do
305. scillate Limit 6 Loosely install the limit switches Using a feeler gauge establish a gap of 0 015 0 030 inches Switches 0 381 0 762 mm between the limit switch Tip over hazard Failure to plunger and the top of the axle perform this procedure on a firm 7 Carefully hold the position of each limit switch level surface could compromise and tighten the limit switch mounting fasteners the stability of the machine and could cause the machine to tip over which will result in death or serious injury 8 Verify the gap is 0 015 0 030 inches 0 381 0 762 mm between the limit switch plunger and the top of the axle 9 Measure the distance between the drive chassis and the axle on both sides from the inside of the drive chassis Note Perform this procedure with the machine on a firm level surface that is free of obstructions Use a digital level to confirm O Result The measurements should be equal Note This procedure will require two people Note If the distance is not equal and the 1 Lower the boom to the stowed position adjustment to the limit switches was completed 2 Remove the drive chassis cover from the with the ground and drive chassis level consult circle end of the machine Genie Industries Service Department 3 Remove the oscillate axle limit switch mounting fasteners Remove the limit switches Note The oscillate axle limit switches are located inside the drive chassis above the axle 4 Place a digita
306. secure it from moving Component damage hazard Hoses can be damaged if they are kinked or pinched 38 Remove the flex plate mounting fasteners Remove the flex plate from the engine flywheel Part No 1258748 November 2014 Section 4 Repair Procedures How to Install the Flex Plate 1 Install the flex plate onto the engine flywheel with the raised spline towards the pump Apply Loctite removable thread sealant to the mounting screws Note Torque the flex plate mounting bolts in two stages Continental model Torque the flex plate mounting bolts in sequence to 20 8 ft lbs 28 Nm Deutz models Torque the flex plate mounting bolts in sequence to 28 ft lbs 38 Nm Then torque the flex plate mounting bolts in sequence to 40 ft Ibs 54 Nm Perkins models Torque the flex plate mounting bolts in sequence to 28 ft lbs 38 Nm Then torque the flex plate mounting bolts in sequence to 40 ft Ibs 54 Nm Perkins Deutz and Continental Flex Plate Part No 1258748 Z 80 60 Genie Install the pump coupler onto the pump shaft with the set screw toward the pump Leave the appropriate gap between coupler and pump end plate for your engine Apply Loctite removable thread sealant to the pump coupler set screw Torque the set screw to 61 ft lbs 83 Nm Install the pump onto the pump mounting plate Apply Loctite removable thread sealant to the pump retaining fasteners Torque the pump retaining fast
307. si 4 5 bar KU Prevents steer cylinder from moving when not steering 22 Flow regulator valve 1 5 5 7 L min Square end yellow side steer cylinder extend circuit 23 Flow regulator valve 1 0 3 8 L min Square end yellow side steer cylinder retract 24 Flow regulator valve 1 5 5 7 L min KX Square end blue side steer cylinder extend circuit 25 Check valve KY ius Load sensing circuit square end yellow side steer cylinder retract 26 Check valve 65 psi 4 5 bar KZ uk Prevents steer cylinder from moving when not steering 27 Check valve 65 psi 4 5 bar KAA Prevents steer cylinder from moving when not steering 28 Check valve Load sensing circuit square end yellow side steer cylinder extend 29 Check valve Load sensing circuit square end blue side steer cylinder extend 30 Check valve 65 psi 4 5 bar Prevents steer cylinder from moving when not steering 31 Check valve 65 psi 4 5 bar KAE Prevents steer cylinder from
308. si of lowest cylinder must Injection pressure 2133 psi be within 50 psi 3 45 bar of highest cylinder 147 bar Governor electronic Fuel requirement Valve clearance cold For fuel requirements refer to the engine Operator s Intake 0 008 in Manual on your machine 0 2mm Alternator output 85A 12V DC Exhaust 0 008 in Fan belt deflection 9 8 in 0 2 mm 10 mm Starter motor Current draw normal load 140A 200A Brush length new 0 7480 in 19 mm Brush length minimum 0 5 in 12 7 mm Ganie 2 14 Z 80 60 Part No 1258748 November 2014 Section 2 Specifications Perkins 404F 22T Engine continued SPECIFICATIONS Machine Torque Specifications Battery Platform rotator Type 12V DC 14 8 center bolt GR 5 dry 640 ft lbs Size 13 x 613 16 93 8 inches Ber Nm 33 x 17 3 x 23 8 cm 3 8 16 bolts GR 8 35 ft Ibs Quantity 1 use blue thread locking compound 47 5 Nm Cold cranking ampere 1000 Turntable rotate assembly Reserve capacity 25A rate 200 minutes Rotate bearing mounting bolts lubricated 180 ft lbs 244 Nm Engine coolant Rotate drive hub mounting bolts lubricated 80 ft lbs Capacity 14 quarts 108 4 Nm Backlash plate mounting bolts lubricated 280 ft lbs Coolant temperature sending unit 379 Nm Temperature switch point 221 F Drive motor and hubs ee Drive hub mounting bolts lubricated 160 ft Ibs use blue thread locking compound 217 Nm Drive hub mounting bolts dry
309. slowly to allow the oil pressure to dissipate gradually Do not allow oil to squirt or spray Part No 1258748 November 2014 Section 4 Repair Procedures 4 Support the pumps with a suitable lifting device and remove the two drive pump mounting fasteners 5 Carefully pull the drive pump out until the pump coupler separates from the flex plate 6 Remove the drive pump assembly from the machine Component damage hazard Be sure to open the two hydraulic tank valves and prime the pump after installing the pump Note Before installing the pump verify proper pump coupler spacing See 5 2 Flex Plate How to Prime the Pump 1 Connect a 0 to 600 psi 0 to 50 bar pressure gauge to the test port on the drive pump 2 Remove the engine tray retaining fastener Swing the engine tray out away from the machine a engine tray anchor hole b engine tray retaining fastener 3 Locate the engine tray anchor hole at the pivot end of the engine tray PartNo 1258748 Genie Z 80 60 HYDRAULIC PUMPS 4 Install the bolt removed in step 4 into the anchor hole to secure the engine tray from moving AWARNING Crushing hazard Failure to install the bolt into the engine tray to secure it from moving could result in death or serious injury 5 Deutz and Perkins models Tag and disconnect the engine wiring harness from the fuel shutoff solenoid at the injector pump GM and Ford models Close the valve on th
310. stands for safety 62 is the number of the circuit for boom Calibrate CAL stowed and BST stands for Boom Stowed CAN Signal CAN P 48 LP P stands for power 48 is the circuit number for work CAN Shield SHD lamps and LP stands for Lamp CATS Module CAT R 48 LP R stands for relay In this case it is the wire that Chain Break CNK feeds the relay coil for the work lamp All other numbers remain Data High DTH the same Data Low DTL Drive Chassis Controller DCN Circuit prefix Drive Enable DE Control Drive Enable Left DEL D Data Drive Enable Right DER Electrical Displacement Control EDC E Engine Envelope Light ENV Gauges Engine Speed Select ESP N Neutral Engine Status Lamp ESL CP ed Envelope Lockout ENL Pa Extend retract Lockout ERL R Relay Output Filter Restricted FLR S Safety Filter Switch FLT V Valve Flashing Beacon FB Float Switch FS Footswitch Signal FTS Forward FWD Fuel Pump FP Fuel Select gas LP FL Fuel Solenoid FSL Genie 6 2 Z 80 60 Part No 1258748 2014 Definition Function Enable Ground Control Ground Horn High RPM Hydraulic Generator Ignition Jib Bellcrank Down Jib Bellcrank Up Jib Sensor Jib U D Control Jib Down Jib Up Down Flow Control Jib Select Valve Jib Up Jib E R Control Jib Ext Jib Ret Jib Rotate Left CCW Jib Rotate Right CW Joystick 5 VDC Power Lamps Left Front Left Front Steer
311. steer cylinder from moving when not steering 20 25 ft lbs 27 34 Nm 14 Check valve 65 psi 4 5 bar Prevents steer cylinder from moving when not steering 20 25 ft lbs 27 34 Nm 15 Check valve Load sensing circuit yellow side steer cylinder retract 8 10 ft lbs 11 14 Nm 16 Gheck valve ne JP us Load sensing circuit yellow side steer cylinder extend 8 10 ft lbs 11 14 Nm 17 606 ets Load sensing circuit blue side steer cylinder extend 8 10 ft lbs 11 14 Nm Genie 4 80 Z 80 60 Part No 1258748 November 2014 Section 4 Repair Procedures MANIFOLDS JJ 00 9 Genie Part No 1258748 Z 80 60 4 81 Section 4 Repair Procedures November 2014 MANIFOLDS How to Adjust the Oscillate 6 Relief Valve Note Perform this procedure with the boom in the Adjust the internal hex socket Turn it clockwise to increase the pressure or counterclockwise to decrease the pressure Install the relief valve cap stowed position ip j p AWARNING Tip over hazard Do not adjust Note Perform this procedure with the engine running at high RPM 7 Note This procedure will require two people 1 Remove the drive chassis cover from the 8 square end of the machine 2 Connect 8 0 to 5000 psi 0 to 350 bar pressure gauge to t
312. t Section 2 Specifications SSS Qr SPECIFICATIONS Specifications Auxiliary pump Drive pump Type two section fixed displacement gear pump Type bi directional variable displacement piston pump Displacement Section 1 inner 0 159 cu in 2 61 cc Displacement 2 81 cu in 46 cc Flow rate 2687 rpm 1 7 gpm 6 4 L min Flow rate 2300 rpm 28 gpm 106 L min Displacement Section 2 outer 0 051 cu in 0 84 cc Drive pressure maximum 3625 psi 250 bar Flow rate 2687 rpm 0 3 gpm 1 1 L min Charge pump Function manifold Type gerotor System relief pressure 3200 psi Displacement 0 85 cuin measured at Presr port 220 6 bar 13 9 cc Primary boom down relief pressure 1300 psi Flow rate 2300 rpm 9 gpm measured at Ls port 89 6 bar 34 L min Secondary boom down relief pressure 2500 psi Charge pressure 2300 rpm measured at Ls port 172 bar 320 psi Neutral position 22 bar Secondary boom up relief pressure 2500 psi measured at Ls port 172 bar Function pumps Primary boom extend relief pressure 1300 psi Type two section tandem gear pump measured at Ls port 89 6 bar Displacement Pump 1 inner 1 94 cu in Secondary boom extend relief pressure 2600 psi 31 8 measured at Ls port 179 bar Flow rate 2300 rpm 17 gpm Platform manifold relief pressure 3000 psi 64 4 L min 207 bar Displacement Pump 2 outer 0 58 cu in Platform manifold flow regulator 3
313. t 04 10813 e 58 5 8 5 8 5 E N N co PartNo 1258748 6 6 18 November 2014 Section 6 Schematics Ss Electrical Schematic Engine Options Deutz TD2 9 Engine Wiring N M L K J D C B A SRR 3 a 6 x lt oc 52 T g 99 DETAIL C DUETZ 2 9L TURBO TIERIV ENGINE 85 538 gt 8 c ki 5 5 1 o 2 E J232 D2 2 92PIN __ __ __ __ __ __ __ 131 021 0PIN ECU PWR ENGINE ECU INJECTOR 35021 2 INJ3 AO2 BK GND BR D2 2 24j ECU GND INJECTOR 25021 23 gt 2 A03 OR 3 P20PWR RD gt 22 30 ECU PWR MPROP 5021 4 MPROP A04 WH GND BR D2 2 44 ECU GND MPROP DD2 1 5 gt MPROP A05 WH BK P20PWR RD gt D2 2 54 ECU PWR RAIL PRES 502 1 7 RAILP AO7 RD GND BR 7022 62 ECU GND INJECTOR 1 021 16 A16 GR C26LVL WH RD D2 2 13d COOLANT LEVEL 1 INJECTOR 4 021 18 4 A18 BL COOLANT LEVEL CLSWJPR OR D2 2 154 CLUTCH EGR SOL PWR D2 1 19 EGRSOLPWR OR RD S C135RET WH 022 260 FUEL PUMP RELAY GND EGR SOL GND 5D2 1 20 EGRSOLGND BR PTIORETABK LL P33RET BK 02 2 284 STARTER RELAY GND START ASSIST DD2 1 235 R34SA RD 4 UBAT WH WH 62 2 292 COOLANT PWR M SENS PWR 5D2 1 24 gt MSENPWR GR WH WH gt 02 2 3 AUX ENGINE STOP RAIL PRES D2 1 25 gt RAILP A25 RD WH BK D2 2 354 ENGINE START RAIL PRES D2 1
314. t Switches There are two types of limit switches found in various locations throughout the machine mechanical type operational or safety switches As in aircraft which features redundant safety Systems each mechanical operational switch is backed up with a separate independently functioning safety switch The mechanical type operational or safety Switches are used to sense a positive displacement or movement of the limit switch actuator or arm as the machine moves through its range of operational functions Included in this group are envelope limit switches which sense the extended length and angle of the booms and rotational position of the turntable For example when the secondary boom is fully raised and the operational switch is activated it tells the ECM at the ground controls to start extending the secondary boom Another example is the drive enable limit switch which disables the drive function anytime the boom is rotated past the rear axles indicated by the circle end of the drive chassis In some cases the engine will be stopped if safety parameters are exceeded Genie 2 80 60 Limit Switch Numbering LSP1AO Primary boom angle stowed LSP1RO Primary boom length retracted LSP1EO Primary boom length fully extended LSS1AO Secondary boom angle fully stowed LSS2AO Secondary boom angle fully raised LSS3AO Secondary boom angle 25 to 30 LSS2AS Secondary boom angle safety LSS1RO Secondary boom fully retract
315. t be reset in software or through the use of the TCON LCD They will not clear by re powering the machine Note There are two methods to reset the faults by using Web GPI or through the menu available onthe TCONLCD Using Web GPI 1 Connect the device containing the WEB GPI software to the TCON with an RS 232 cable Select the Secondary Boom then the Safety Switch Status Flags screen Change any safety switch drop down menus displaying FAULT to Press SEND Exit Web GPI A TEREX COMPANY Using the TCONLCD Note Take care when using this method to avoid resetting threshold defaults 1 With the key switch off press and hold the button and turn the key switch to the on position Release the button after five seconds and press the buttons Press the button until CLEAR ALL SAFETY SWITCH FAULTS appears 3 Select ves then press the button 4 Press the button until exit appears 5 Select ves then press the 4 button Note This clears all latching faults not standard faults Part No 1258748 November 2014 Section 5 Fault Codes Pee es CONTROL SYSTEM FAULT CODES A TEREX COMPANY Part No 1258748 Z 80 60 5 11 Section 5 Fault Codes November 2014 Fault Code Display Deutz TD 2 9 L4 and Perkins 404F 22T Models How to Retrieve Active Engine Fault Codes The ECM constantly monitors the engine by the use of sensors on the engin
316. t calibrated Joystick speed and direction frozen at Calibrate joystick zero and neutral Just calibrated second beep praudipig Self clearing transient warning device Value at 5 0 V Value too high Limited speed and direction frozen at Power up controller with problem PRIMARY Value too low zero and neutral alarm sounds corrected EXTEND RETRACT Value at 0 V JOYSTICK Not calibrated Joystick speed and direction frozen at Calibrate joystick zero and neutral Just calibrated Second been ot audible Self clearing transient warning device SECONDARY BOOM JOYSTICK A TEREX COMPANY 5 4 Z 80 60 Part No 1258748 2014 Section 5 Fault Codes CONTROL SYSTEM FAULT CODES Error Source Error Type __ Effects Recovery Actions Value at 5 0 V Value too high Limited speed and direction frozen at Power up controller with problem Value too low zero and neutral alarm sounds corrected STEER JOYSTICK Value at 0 V Not calibrated Joystick speed and direction frozen at Calibrate joystick zero and neutral Just calibrated Ine ode second beep t audible Self clearing transient warning device PRIMARY BOOM UP DOWN Fault Check both Primary boom up down disabled Power up controller with the problem SWITCHES ON TCON buttons pressed display message on LCD corrected SEC BOOM Secondary boom up extend and UP EXT DWN RET down retract disabled display message Pows
317. t clockwise 5 Adjust the internal hex socket Turn it clockwise to increase the pressure or counterclockwise to decrease the pressure Install the relief valve cap to increase the pressure or counterclockwise to decrease the pressure Install the relief valve cap AWARNING Tip over hazard Do not adjust AWARNING Tip over hazard Do not adjust the relief valve higher than specified 6 Repeat steps 2 through 5 to confirm relief valve 6 pressure the relief valve higher than specified Repeat steps 2 through 3 to confirm relief valve pressure 7 Remove the pressure gauge 7 Remove the pressure gauge How to Adjust the Platform Manifold Relief Valve Note Perform this procedure with the boom in the stowed position 1 Connect 0 to 5000 psi 0 to 350 bar pressure gauge to the ptest 2 port on the function manifold 2 Startthe engine from the ground controls 3 Simultaneously push and hold the function enable high speed button and the jib boom down button with the jib boom fully lowered Observe the reading on the pressure gauge Refer to Section 2 Specifications 4 72 Z 80 60 Genie Part No 1258748 November 2014 Section 4 Repair Procedures n t MANIFOLDS This page intentionally left blank Genie PartNo 1258748 Z 80 60 4 73 Section 4 Repair Procedures November 2014 P m t MANIFOLDS 8 4 Platform Manifold The platform Manifold is mounted to the platf
318. t damage hazard Do not force the drive pump during installation or the flex plate teeth may become damaged Perkins 404F 22T Pump Mounting Plate Deutz Pump Mounting Plate Continental Pump Mounting Plate Genie 4 54 Z 80 60 Part No 1258748 November 2014 Section 4 Repair Procedures 5 3 Engine Fault Codes Refer to Repair Section 5 Fault Codes Genie Part No 1258748 ENGINES 5 4 How to Access Perkins 404F Engine Regeneration Service Machines equipped with Perkins 404F 22T Diesel engines will have a regeneration mode that should run automatically when soot levels in the Diesel Particulate Filter DPF reach specified levels How to Check the DPF Soot Percentage 1 Turn the key switch to the on position 2 Press the plus button and the minus button at the same time to access the Operator Status menu Press the enter button twice to display DPF SOOT PCT 0 150 How to Force or Inhibit DPF Regeneration There are three modes available for DPF regeneration The default AUTOMATIC MODE allows for ECU controlled regeneration The machine powers up in this mode INHIBIT DPF REGENERATION will disable regeneration In this mode the exhaust temperatures will not raise due to regeneration The mode will remain active until an ignition key cycle power cycle or FORCE DPF REGENERATION is selected This mode will be indication by an LCD message while active
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320. take two people to perform this procedure 1 Connect a 0 to 600 psi 0 to 50 bar pressure gauge to the test port on the drive pump 2 Startthe engine from the ground controls 3 Pressthe function enable high rpm select button rabbit symbol position Note the reading on the pressure gauge 4 Turnthe engine off Remove the pressure gauge from the drive pump Connect the gauge to the test port located on the drive manifold 6 Useawrench to hold the charge pressure relief valve and remove the cap item FF 7 Startthe engine from the platform controls 8 Move rpm select switch to high rpm rabbit symbol Genie Z 80 60 9 Begin driving the machine forward at a medium speed while one person monitors the pressure gauge Continue driving until the pressure stabilizes Note The pressure reading should be approximately 40 psi 2 8 bar less than the pressure reading taken in step 3 10 If it is not stop the machine and adjust the internal hex socket on the pressure relief valve item FF either up or down Turn it clockwise to increase the pressure or counterclockwise to decrease the pressure 11 Drive the machine forward and check the pressure 12 Continue making small adjustments until the pressure reading on the gauge is approximately 40 psi 2 8 bar less than the pressure reading taken in step 3 13 Turn the engine off and remove the pressure gauge Part No 1258748 November 2014 Section 4 Repa
321. the Cable Track Component damage hazard The boom cable track can be damaged if it is twisted Note A cable track repair kit is available through the Genie Industries Service Parts Department 1 Visually inspect the cable track and determine which 4 link section needs to be replaced 2 Carefully remove the snap rings from each end of the damaged section of cable track 3 Remove the retaining fasteners from the upper black rollers from the 4 link section of cable track to be replaced Remove the rollers 4 Lift up the hoses and cables and carefully remove the damaged 4 link section of cable track Component damage hazard Hoses and cables can be damaged if they are kinked or pinched 4 32 Z 80 60 Genie Remove the upper rollers from the replacement section of cable track Lift up the hoses and cables and carefully insert the new 4 link section of cable track Component damage hazard Hoses and cables can be damaged if they are kinked or pinched Connect the ends of the replacement cable track section to the existing cable track using the snap rings Install the rollers onto the new section of cable track Operate the boom extend retract function through a full cycle to ensure smooth operation of the cable track Part No 1258748 November 2014 4 2 How to Shim the Boom 1 Measure each wear pad Result Each wear pad meets minimum specification Proceed
322. the Cable Track Note When removing a hose assembly or fitting the O ring on the fitting and or hose end must be replaced and then torqued to specification during installation Refer to Section 2 Hydraulic Hose and Fitting Torque Specifications 1 Tag and disconnect the wire connectors from the platform control box 2 Tag disconnect and plug the hydraulic hoses from the counterbalance valve manifold located on the platform rotator Cap the fittings on the manifold AWARNING Bodily injury hazard Spraying hydraulic oil can penetrate and burn skin Loosen hydraulic connections very slowly to allow the oil pressure to dissipate gradually Do not allow oil to squirt or spray Genie 2 80 60 3 Remove the mounting fasteners from the power to platform outlet box Remove the outlet box and lay to the side 4 Remove the hose clamp from the platform support 5 Tag and disconnect the electrical connector from the platform angle sensor Note The platform angle sensor is mounted to the platform rotator 6 Tag and disconnect the electrical connectors for the foot switch and jib boom limit switch 7 Remove the platform manifold mounting fasteners Remove the manifold and lay to the side Component damage hazard Cables and hoses can be damaged if they are kinked or pinched 8 Remove the hose and cable cover retaining fasteners from the jib boom Remove the hose and cable cover from the machine 9 Remove the hose and
323. the main key switch and start the engine from the ground controls 16 Re connect the Deutsch connector from the secondary safety retract switch LSS1RS removed in step 7 Secondary Boom 1 Retracted Safety Limit Switch LSS1RS 17 Simultaneously push the LCD screen buttons shown to activate status mode 18 Push one of the LCD screen buttons shown 4 until secondary boom angle is displayed 19 Raise the secondary boom until the display shows lt 35 DEGREES 20 Locate the Deutsch connectors from the secondary boom 2 angle safety limit switch LSS2AS on the inside of the turntable riser The connection will be marked with purple zip ties on the wire assembly Disconnect the connectors 21 Locate the Deutsch connectors from the secondary boom 2 angle operational limit switch LSS2AO on the inside of the turntable riser The connection will be marked with green zip ties on the wire assembly Disconnect the connectors Section 3 Scheduled Maintenance Procedures November 2014 CHECKLIST B PROCEDURES 22 Install a wire jumper between pins 1 and 2 of the Deutsch connector on the wire harness removed in step 21 Result The display should show 65 DEGREES 23 Press and hold the low speed function enable button and extend the secondary boom O Result The secondary boom should extend no more than 12 inches 30 5 cm and stop The engine should stop
324. the platform control box Hydraulic manifold wiring 15 Swing the engine tray in towards the machine 16 Install the bolt that was just removed into the original hole to secure the engine tray AWARNING Crushing hazard Failure to install the bolt into the engine tray to secure it from moving could result in death or serious injury Section 3 Scheduled Maintenance Procedures November 2014 CHECKLIST B PROCEDURES B 3 Test the Key Switch Proper key switch action and response is essential to safe machine operation The machine can be operated from the ground or platform controls and the activation of one or the other is accomplished with the key switch Failure of the key switch to activate the appropriate control panel could cause a hazardous operating situation 1 Pull out the red Emergency Stop button to the on position at both the ground and platform controls 2 Turn the key switch to ground control start the engine and then turn the key switch to platform control 3 Check all machine function from the ground controls Result All machine functions should not operate 4 Turn the key switch to ground control 5 Check all machine function from the platform controls Result All machine functions should not operate 6 Turn the key switch to the off position O Result The engine should stop and no functions should operate A TEREX CON B 4 Check the Exhaust System Maintaining the
325. this and all other manuals Contact Us http www genielift com e mail awp techpub terex com Z 80 60 Genie Serial Number Information Genie offers the following Service Manuals for these models Title Part No Genie Z 80 Service Manual from serial number 101 to 4591 88619 Copyright O 2014 Terex Corporation 1258748 Rev November 2014 Second Edition First Printing Genie and S is a registered trademark of Terex South Dakota Inc in the USA and many other countries 4 Printed recycled paper Printed in U S A Part No 1258748 November 2014 Revision History Revision Date Section Procedure Schematic Page Description mum m sse 000000000 2 1 Section 2 Specifications Page Electronic Version 3 3 Section3 Maintenance Procedure Page 4 48 Section 4 Repair Procedure Page Click on any procedure or page number Fault Codes Section 5 highlighted in blue to view the update 6 5 Section 6 Schematic Page Genie Part No 1258748 Z 80 60 lii November 2014 REVISION HISTORY CONTINUED Procedure Schematic Page Description 2 1_Section 2 Specifications Page Electronic Version 3 3 Section3 Maintenance Procedure Page 4 48 Section 4 Repair Procedure Page Click on any procedure or page number Fault Codes Section 5 highlighted in blue to view the update 6 5 Se
326. tial fault testing occurs at power up Faults are abnormal conditions that exist due to component failure or System misuse CPU memory LCD LED limited joystick and limited operator switch testing is done on power up If an operator switch is depressed on power up the display should show and error and not allow any machine functions Releasing the switch will clear the error and allow all machine functions The joystick operates similarly All other fault testing is done continuously 1 When a fualt is diagnosed the PCON fault indicator will flash and a fault message will be displayed on the TCON LCD The message will contain the fault source and type 2 Additional information including the occurrence counter and a time stamp is available with a PC connected to one of the RS232 ports Up to 30 unique fault messages can be saved Each fault is saved with the device identity fault type engine hour time stamp and an 8 bit occurrence counter 3 The fault code table on the following pages lists the functions or components monitored by the system and recovery actions A TEREX COMPANY REV Part No 1258748 November 2014 Section 5 Fault Codes REV CONTROL SYSTEM FAULT CODES ErrorSource Error Type _ Recovery Actions Not calibrated Just calibrated PRIMARY BOOM EXT RET FLOW VALVE Value at 5 0 V SEC BOOM LENGTH Fault check Fault check unknown length Fault chec
327. tocol SPN FMI KWP Description SPN FMI KWP Description 51 3 1019 EGR Valve short 51 6 1022 Actuator error EGR Valve circuit to battery signal range check high 51 3 1024 Position sensor error of 51 6 1224 Actuator EGR Valve actuator EGR Valve over current signal range check high 51 6 1230 Actuatorerror EGR Valve 51 3 1226 EGR Valve short Overload by short circuit circuit to battery A02 51 7 1016 Actuator position for EGR 51 3 1227 EGR Valve short circuit to Valve not plausible battery A67 51 11 1231 Actuatorerror EGR Valve 51 4 1020 EGR Valve short circuit Power stage over temp to ground due to high current 51 4 1025 Position sensorerroractuator 51 12 1018 Actuator EGR Valve EGR Valve signal range powerstage overtemperature check low 51 12 1021 Mechanical actuator defect 51 4 1228 EGR Valve short circuit to EGR Valve ground A02 51 12 1225 Actuator EGR Valve 51 4 1229 EGR Valve short circuit to overtemperature ground A67 94 1 474 Lowfuelpressure warning 51 4 1232 Actuatorerror EGR Valve threshold exceeded Voltage below threshold 94 1 475 Low fuel pressure shut off 51 5 1015 Actuatorerror EGR Valve threshold exceeded signal range check low 94 3 472 Sensor error low fuel pressure 51 5 1017 Actuator EGR Valve open load signal range check high 51 5 1023 Actuator error EGR Valve 94 4 473 Sensor error low fuel pressure signal range
328. trols Repeat this procedure beginning with step 5 Note The platform will need to be moved up and down and allowed to settle between each adjustment Note There may be a 2 second delay before the platform overload indicator lights and alarm responds Section 4 Repair Procedures November 2014 PLATFORM COMPONENTS 7 Move the platform up and down by hand so it bounces approximately 2 5 to 5 cm 1 to 2 inches Allow the platform to settle O Result The alarm should be off The platform overload indicator light should be off at the platform controls and there should be no error message on the LCD display at the ground controls Proceed to step 8 Result The overload indicator lights are flashing at the platform and ground controls and the alarm is sounding Repeat this procedure beginning with step 5 Note There may be a 2 second delay before the platform overload indicator light and alarm responds 8 Addan additional 10 Ib 4 5 kg test weight to the platform Result The alarm should be sounding The platform overload indicator light should be flashing at the platform controls and PLATFORM OVERLOAD should be displayed on the LCD screen at the ground controls Proceed to step 9 Result The alarm should be off The platform overload indicator light should be off at the platform controls and there should be no error message on the LCD display at the ground controls Remove the additional 10 I
329. tsch connector on the wire harness Result The display should show Part No 1258748 2014 Section 3 Scheduled Maintenance Procedures 11 Press and hold the high speed function enable button and lower the secondary boom Result The secondary boom should lower to 60 and the engine should stop Result If the engine does not stop at 60 and the secondary boom continues to lower the secondary boom 2 angle safety limit switch LSS2AS is out of adjustment or the wiring circuit is faulty and will need to be replaced or repaired Immediately remove the machine from service until repairs are made Bodily injury hazard If the secondary boom lowers to less than 60 without stopping the engine stop immediately and raise the secondary boom above 60 Failure to raise the secondary boom could result in death or serious injury 12 Remove the key from the main key switch insert it into the service bypass recovery key switch turn the key to Service Bypass mode and raise the scondary boom above 60 using auxiliary power 13 Remove the wire jumpers installed in steps 9 and 10 and connect the wire harness to LSS1RO removed in step 8 14 Fully raise the secondary boom and extend the secondary boom approximately 1 foot 30 5 cm A TEREX COMI Part No 1258748 CHECKLIST B PROCEDURES 15 Turn the service bypass recovery key switch back to run return the key to
330. ur Inspection A B C D E Place a check in the appropriate box after each inspection procedure is completed Use the step by step procedures in this section to learn how to perform these inspections If any inspection receives an N tag and remove the machine from service repair and re inspect it After repair place a check in the R box Legend Y yes acceptable N no remove from service R repaired Checklist A Y NR Checklist B N R 1 Inspect the manuals B 1 Batteries and decals 2 Pre operation inspection A 3 Function tests A 4 Engine maintenance Continental models A 5 Engine maintenance Perkins models A 6 Engine maintenance Deutz models A 7 Hydraulic filter condition indicators Perform after 40 hours A 8 30 Day Service Perform every 50 hours A 9 Engine maintenance Perkins and Continental models Perform every 100 hours A 10 Rotation bearing A 11 Engine maintenance Continental models Perform after 150 hours A 12 Replace drive hub oil Perform every 200 hours A 13 Engine maintenance Perkins models Comments Part No 1258748 B 2 Electrical wiring B 3 Key switch B 4 Exhaust system B 5 Engine Air Filter B 6 Engine maintenance Continental models B 7 Engine maintenance Perkins models B 8 Lug nut torque B 9 Brake configuration B 10 Drive hu
331. ure with the engine off and cool to the touch 1 Open the engine side turntable cover 2 Tag and disconnect the battery cables from the battery s AWARNING Electrocution bu m hazard Contact with electrically charged circuits could result in death or serious injury Remove all rings watches and other jewelry 3 Tag and disconnect the wiring plug at the electronic displacement controller EDC located on the drive pump Genie 2 80 60 Deutz TD2011L04i models 4 Tagand disconnect the wiring from the bell housing 5 Remove the U bolt from the exhaust flex pipe at the muffler ACAUTION Burn hazard Hot engine parts can cause severe burns 6 Remove the muffler bracket retaining fasteners from bell housing Remove the muffler and bracket assembly from the engine 7 Supportthe drive pump with an appropriate lifting device Remove all of the remaining bell housing engine fasteners 8 Carefully pull the pump and bell housing assembly away from the engine and secure it from moving Component damage hazard Hoses can be damaged if they are kinked orpinched 9 Remove the flex plate mounting fasteners and remove the flex plate from the engine flywheel Deutz TD 2 9 models 10 Tag and disconnect the wiring from the bell housing 11 Supportthe drive pump with an appropriate lifting device Remove all of the bell housing engine fasteners Part No 1258748 November 2014 Section 4 Repair Procedures
332. ut error of CAN ComRxDPFBrnAirPmpCtl Transmit Frame A1DOC 524103 1675 Timeouterrorof CAN Receive 524115 1660 Timeouterror of CAN Frame ComRxDPFBrnAirPmp Transmit Frame AT1S 524104 1676 Timeouterrorof CAN Receive 524116 1661 Timeouterror of CAN Frame ComRxDPFCtl Transmit Frame SCR2 524105 1668 Timeouterror of CAN Transmit 524117 1662 Timeouterror of CAN Frame ComEGRMsFlw Transmit Frame SCR3 524106 1677 Timeout error of CAN 524118 1672 Timeout error of CAN Receive Frame Receive Frame ComRxCM1 ComRxEGRMsFlw1 524119 1673 Timeout error of CAN 524107 1678 Timeout error of CAN Receive Frame Receive Frame ComRxCustSCR3 ComRxEGRMsFlw2 5 26 Z 80 60 Part No 1258748 2014 SPN Suspect Parameter Number FMI Failure Mode Identifier KWP Keyword Protocol Description SPN FMI KWP 524120 9 1682 Timeout error of CAN Receive Frame ComRxSCRHiDiag 524121 9 1683 Timeout error of CAN Receive Frame ComRxTrbChActr 524122 9 1684 Timeout error of CAN Receive Frame ComRxUQSens 524123 9 1685 Timeout error of CAN Receive Frame ComSCRHtCtl 524124 9 1686 Timeout error of CAN Receive Frame ComTxAT1IMG 524125 9 1687 Timeout error of CAN Receive Frame ComTxTrbChActr Part No 1258748 A TEREX COMPANY Section 5 Fault Codes DEUTZ TD 2 9 L4 ENGINE FAULT CODES Section 5 Fault Codes November 2014 rr D
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334. vel cylinder rod end pivot pin half way out and lower one of the leveling arms to the ground Tap the pin the other direction and lower the opposite leveling arm Do not remove the pin 11 Use a soft metal drift to remove the platform level cylinder rod end pivot pin 12 Carefully pull the platform leveling cylinder out of the boom Crushing hazard The jib boom ACAUTION cylinder will fall if not properly supported when the platform level cylinder rod end pivot pin is removed How to Bleed the Platform Leveling Cylinder Note Do not start the engine Use auxiliary power for all machine functions in this procedure 1 Raise the jib boom to a horizontal position 2 Push the platform level up and down buttons through two complete platform leveling cycles to remove any air that might be in the system Section 4 Repair Procedures November 2014 PLATFORM COMPONENTS 2 3 Platform Rotator The platform rotator is a hydraulically activated helical gear assembly used to rotate the platform 160 degrees How to Remove the Platform Rotator Component damage hazard Mark the platform mounting weldment and the rotator flange before removing the platform mounting weldment The platform mounting weldment must be replaced in the exact same position on the rotator flange as it was before removal If a new rotator is installed or the rotator is disassembled proper alignment can be achieved by rotating the rotator all the wa
335. wer to oil pressure sender Power to temp sender Auxiliary power Platform level alarm Drive motor shift speed Forward EDC A Part No 1258748 Genie Z 80 60 WIRE CIRCUIT LEGEND Color Circuit and Primary function WH BK WH RD BK BK WH BK RD BL BL BK BL WH BL RD OR OR BK OR RD GR GR BK GR WH WH WH BK WH RD WH BK BL BL WH BL RD WH BK BK WH GR BK RD RD WH RD BK GR WH GR WH Reverse EDC B Brake Start Start aid glow plug or choke High engine speed select Steer clockwise Steer counterclockwise Gas LP Limit switch signal stowed RPM signal Boom retracted signal Jib up Jib down AC Generator Drive horn Output power enable Work lamp Motion lamp Auxiliary boom Auxiliary steer Auxiliary platform Boom envelope safety valve cutoff Power to safety interlock switches engine Axle oscillation Foot switch TCON estop power Boom down safety interlock Safety interlock to engine Chain break circuit Axle extend Axle retract Boom stowed safety Power to boom envelope safety switch This list continues on the next page Section 6 Schematics rm PH WIRE CIRCUIT LEGEND Color Circuit and Primary function November 2014 Color Circuit and Primary function 99 100 101 102 103 104 105 106 107 108 109 110 111 112 113 114 115 116 117
336. y of 1 277 or greater The battery is fully charged Proceed to step 13 Result The difference in specific gravity readings between cells is greater than 0 1 OR the specific gravity of one or more cells is less than 1 177 Replace the battery Check the battery acid level If needed replenish with distilled water to 1 8 inch 3 mm below the bottom of the battery fill tube Do not overfill 12 Install the vent caps and neutralize any electrolyte that may have spilled A TEREX COMI B 2 Inspect the Electrical Wiring Maintaining electrical wiring in good condition is essential to safe operation and good machine performance Failure to find and replace burnt chafed corroded or pinched wires could result in unsafe operating conditions and may cause component damage AWARNING Electrocution hazard Contact with hot or live circuits could result in death or serious injury Remove all rings watches and other jewelry 1 Open the engine side turntable cover 2 Remove the engine tray retaining fastener Swing the engine tray out away from the machine ES a a engine tray anchor hole b engine tray retaining fastener 3 Locate the engine tray anchor hole at the pivot end of the engine tray Part No 1258748 2014 Section 3 Scheduled Maintenance Procedures 4 Install the bolt that was just removed into the anchor hole to secure the engine tray f
337. y at the ground controls to be sure there are no calibration faults Note There should be no calibration faults shown on the display If calibration faults exist repeat this procedure Genie Z 80 60 Part No 1258748 November 2014 How to Adjust the Function Ramp Rate Setting The ramp rate setting of a joystick controls the time at which it takes for the joystick to reach maximum output when moved out of the neutral position The ramp rate settings of a joystick can be changed to compensate for hydraulic pump wear to maintain peak performance from the machine Refer to Section 2 Specifications Note Perform this procedure with the boom in the stowed position 1 Pull out the red Emergency Stop button to the on position at both the ground and platform controls 2 Press and hold the enter button on the ground control panel while turning the key Switch to ground controls 3 Press the plus button twice then press the scroll button twice 4 Press the scroll button until be adjusted is displayed the function to 5 Press the plus button to increase the ramp rate or press the minus button the ramp rate 6 Press the enter button to save the setting in memory 98 7 Perform this procedure until the machine function speed meets specification Genie Part No 1258748 Section 4 Repair Procedures m
338. y if the rpm is incorrect and continued use may cause component damage Not applicable to these models Continental TME27 Deutz TD 2 9 L4 Models Perkins 404F 22T Models Note The engine rpm is controlled by the ECM and can only be adjusted by re programming the ECM If rom adjustment or service is required please contact Genie Product Support Deutz TD2011L04i models 1 Connect a tachometer to the engine Start the engine from the ground controls and check the rpm Refer to Section 2 Specifications A TEREX COMI a Deutz models a high idle adjustment b low idle adjustment Skip to step 4 if the low idle rpm is correct 2 Loosenthe locknut on the low idle adjustment Screw 3 Adjust the low idle adjustment screw until low idle meets specification Tighten the locknut 4 Push and hold the function enable high speed button Note the engine rpm on the display Refer to Section 2 Specifications If the high idle is correct disregard adjustment step 5 5 Loosen the yoke lock nut Turn the high idle adjustment nut and solenoid boot counterclockwise to increase the rpm or clockwise to decrease the rpm Tighten the yoke lock nut and recheck the rpm Note Be sure the solenoid fully retracts when activating high idle Part No 1258748 2014 Section 3 Scheduled Maintenance Procedures Perkins 804D models 1 Connecta tachometer to the engine Start the engine from the ground control
339. y to the left and then installing the platform mounting weldment all the way in the left position Note When removing a hose assembly or fitting the O ring on the fitting and or hose end must be replaced and then torqued to specification during installation Refer to Section 2 Hydraulic Hose and Fitting Torque Specifications 1 Remove the platform See 2 1 How to Remove the Platform 2 Disconnect the wire harness from the platform angle sensor Genie 2 80 60 3 disconnect and plug the hydraulic hoses from the platform rotator manifold Cap the fittings on the manifold AWARNING Bodily injury hazard Spraying hydraulic oil can penetrate and burn skin Loosen hydraulic connections very slowly to allow the oil pressure to dissipate gradually Do not allow oil to squirt or spray 4 Remove the hose and cable clamp from the platform support 5 Remove the platform manifold mounting fasteners Lay the platform manifold to the side Component damage hazard Cables can be damaged if they are kinked or pinched 6 Remove the power to platform electrical outlet box bracket mounting fasteners 7 Remove the power to platform electrical outlet box from the platform and lay it to the side 8 Remove the weld cable from the platform if equipped AWARNING Electrocution hazard Contact with electrically charged circuits could result in death or serious injury Remove all rings watches and other jewelry 9 Su
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88619 Z-80/60 Service Manual Rev E

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