Genie Z-80/60 Installation and operating manual

Service and Repair Manual
Serial Number Range
Z-80/60
from Z80134592 to
Z8016H-
6399
from Z80H-
6400
This manual includes:
Repair
procedures
Fault Codes
Electrical and
Hydraulic Schematics
For detailed maintenance
procedures, refer to the
appropriate Maintenance
Manual for your machine.
Part No. 1268556
Rev A3
January 2017

Service and Repair Manual January 2017
Introduction
ii Part No. 1268556
Intr oduct io n Intr oduct io n
Important
Read, understand and obey the safety rules and
operating instructions in the appropriate Operator's
Manual on your machine before attempting any
procedure.
This manual provides troubleshooting and repair
procedures for qualified service professionals.
Basic mechanical, hydraulic and electrical skills are
required to perform most procedures. However,
several procedures require specialized skills, tools,
lifting equipment and a suitable workshop. In these
instances, we strongly recommend that
maintenance and repair be performed at an
authorized Genie dealer service center.
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 this and all other manuals.
Contact Us:
Internet: www.genielift.com
E-mail: [e-mail]
Find a Manual for this Model
Go to http://www.genielift.com
Use the links to locate Service Manuals,
Maintenance Manuals, Service and Repair
Manuals, Parts Manuals and Operator's Manuals.
Copyright © 2015 by Terex Corporation
1268556 Rev A, September 2015
First Edition, First Printing
Genie is a registered trademark of Terex South Dakota, Inc. in
the U.S.A. and many other countries.
“Z” is a trademark of Terex South Dakota, Inc..

January 2017 Service and Repair Manual
Introduction
Part No. 1268556 iii
Revision History
Revision
Date
Section
Procedure / Page / Description
A 9/2015 Initial Release
A1 11/2015 Schematics Added new serial number (from Z8013-4592)
Added Electrical Schematic
(from Z8013-4592 to Z8015-5653)
A2 9/2016 Introduction Serial Number Legend
Specifications GM 3.0L engine
Fault Codes GM 3.0L engine
Schematics GM 3.0L engine; Hydraulic Schematics
A3
1/2017
Repair
Calibrate Steer Sensors
Reference Examples:
Electronic Version
Click on any content or procedure in the Table of Contents to view
the update.
Section – Repair Procedure, 4-2
Section – Fault Codes, All charts
Section – Schematics, Legends and schematics

Service and Repair Manual September 2016
Introduction
iv Part No. 1268556
Serial Number Legend
To August 31, 2016
1 Model
2 Model year
3 Facility code
4 Sequence number
5 Serial number (stamped on chassis)
6 Serial label (located under cover)
From September 1, 2016
1 Model
2 Facility code
3 Sequence number
4 Serial number (stamped on chassis)
5 Serial label (located under cover)

September 2016 Service and Repair Manual
Safety Rules
Part No. 1268556 v
Section 1 Safet y Rul es
Danger
Failure to obey the instructions and safety rules in
this manual and the appropriate Operator's Manual
on your machine will result in death or serious
injury.
Many of the hazards identified in the operator's
manual are also safety hazards when maintenance
and repair procedures are performed.
Do Not Perform Maintenance
Unless:
You are trained and qualified to perform
maintenance on this machine.
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.

Service and Repair Manual September 2016
Safety Rules
vi Part No. 1268556
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 injur
y or death.
Indicates a imminently hazardous
situation which, if not avoided, will
result in death or serious injury.
Indicates a potentially hazardous
situation which, if not avoided,
could result in death or serious
injury.
Indicates a
potentially hazardous
situation which, if not avoided,
may cause minor or moderate
injury.
Indicates a potentially hazardous
situation which, if not avoided,
may result in property damage.
Be sure to wear protective eye wear and
other protective
clothing if the situation
warrants it.
Be aware of potential crushing hazards
such as moving parts, free swinging or
unsecured components when lifting or
placing loads. Always wear approved
steel
-toed shoes.
Workplace 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.
Be sure to keep sparks, flames and
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
are properly maintained and ready for
use. Keep work surfaces clean and free of
debris that could get into machine
com
ponents and cause damage.
Be sure any forklift, overhead crane or
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.
B
e sure that fasteners intended for one
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 to properly dispose of old oil or
other fluids. Use an approved container.
Please
be environmentally safe.
Be sure that your workshop or work area
is properly ventilated and well lit.

September 2016
Table of Contents
Part No. 1268556 vii
Introduction Introduction ..........................................................................................................ii
Important Information............................................................................................. ii
Find a Manual for this Model.................................................................................. ii
Serial Number Legend .......................................................................................... iv
Section 1 Safety Rules..........................................................................................................v
General Safety Rules.............................................................................................v
Section 2Specifications.......................................................................................................1
Machine Specifications...........................................................................................1
Performance Specifications ...................................................................................1
Hydraulic Specification...........................................................................................2
Hydraulic Component Specifications .....................................................................4
Continental TME27 Engine Specifications.............................................................6
GM 3.0L Engine Specifications..............................................................................7
Deutz TD2011L04i Engine Specifications..............................................................8
Deutz TD 2.9 Engine Specifications.......................................................................9
Perkins 404F-22T Engine Specifications.............................................................10
Perkins 804D-33 Engine Specifications...............................................................11
Machine Torque Specifications............................................................................12
Hydraulic Hose and Fitting Torque Specifications ...............................................13
Torque Procedure ................................................................................................14
SAE and Metric Fasteners Torque Charts...........................................................16

September 2016
Table of Contents
viii Part No. 1268556
Section 3 Repair Procedures.............................................................................................17
Introduction ..........................................................................................................17
Platform Controls...............................................................................................19
Platform Controls .................................................................................................19
1-1 Platform Circuit Board....................................................................................20
How to Remove the LED Circuit Board ..........................................................21
1-2 Joysticks - How to Calibrate a Joystick .........................................................21
How to Reset a Proportional Valve Coil Default.............................................25
How to Set the Function Thresholds and Default Functions Speeds.............25
How to Adjust the Function Speeds ...............................................................27
How to Adjust the Function Ramp Rate Setting .............................................28
Platform Components .......................................................................................28
2-1 Platform..........................................................................................................28
2-2 Platform Leveling Cylinder.............................................................................29
How to Remove the Platform Leveling Cylinder.............................................29
How to Bleed the Platform Leveling Cylinder .................................................30
2-3 Platform Rotator.............................................................................................31
How to Bleed the Platform Rotator.................................................................32
2-4 Platform Overload System (if equipped)........................................................33
2-5 Platform Overload Recovery Message..........................................................36
Jib Boom Components......................................................................................37
3-1 Jib Boom........................................................................................................37
3-2 Jib Boom Lift Cylinder....................................................................................39

September 2016
Table of Contents
Part No. 1268556 ix
Boom Components............................................................................................40
4-1 Primary Boom Cable Track............................................................................41
How to Repair the Primary Boom Cable Track...............................................43
4-2 Primary Boom ................................................................................................44
How to Shim the Primary Boom......................................................................44
How to Disassemble the Primary Boom .........................................................46
4-3 Primary Boom Lift Cylinder ............................................................................47
4-4 Primary Boom Extension Cylinder.................................................................48
4-5 Primary Boom Angle Sensor..........................................................................50
How to Replace the Primary Boom Angle Sensor..........................................50
How to Calibrate the Primary Boom Angle Sensor.........................................51
4-6 Secondary Boom Cable Track.......................................................................53
How to Remove the Secondary Boom Cable Track.......................................53
How to Repair the Secondary Boom Cable Track..........................................53
4-7 Secondary Boom............................................................................................54
4-8 Secondary Boom Lift Cylinder .......................................................................55
4-9 Secondary Boom Extension Cylinder ............................................................57
Engines ...............................................................................................................59
5-1 RPM Adjustment............................................................................................59
5-2 Flex Plate .......................................................................................................59
How to Remove the Flex Plate .......................................................................59
How to Install the Flex Plate ...........................................................................62
How to install the Pump and Bell Housing Assembly.....................................63
5-3 How to Access Perkins 404F Engine Regeneration Service.........................64
Ground Controls.................................................................................................66
6-1 Bypass/Recovery Key Switch ........................................................................66
How to Use the Recovery Mode .....................................................................68
6-2 Circuit Boards.................................................................................................69
6-3 Membrane Decal............................................................................................70
Display Module...................................................................................................71

September 2016
Table of Contents
x Part No. 1268556
Hydraulic Pumps................................................................................................79
7-1 Function Pump...............................................................................................79
7-2 Drive Pump....................................................................................................80
How to Prime the Pump..................................................................................81
Manifolds ............................................................................................................82
8-1 Function Manifold Components - View 1.......................................................82
8-2 Function Manifold Components - View 2.......................................................84
8-3 Valve Adjustments - Function Manifold .........................................................86
How to Adjust the System Relief Valve ..........................................................86
How to Adjust the Primary Boom Down Relief Valve.....................................87
How to Adjust the Primary Boom Extend Relief Valve...................................88
How to Adjust the Secondary Boom Up Relief Valve.....................................89
How to Adjust the Secondary Boom Down Relief Valve ................................90
How to Adjust the Secondary Boom Extend Relief Valve ..............................91
How to Adjust the Platform Manifold Relief Valve..........................................91
8-4 Platform Manifold...........................................................................................92
8-5 Turntable Rotation Manifold...........................................................................94
8-6 Platform Rotate Manifold...............................................................................95
8-7 Two Wheel Steer and Oscillate Manifold.......................................................96
How to Adjust the Oscillate Relief Valve ........................................................98
8-8 Four Wheel Steer and Oscillate Manifold....................................................100
How to Adjust the Oscillate Relief Valve ......................................................104
8-9 Oil Diverter Manifold Components (welder option)......................................105
8-10 Traction Manifold Components, 2WD........................................................106
8-11 Valve Adjustments, 2WD Traction Manifold ..............................................108
8-12 Traction Manifold Components, 4WD........................................................110
8-13 Valve Adjustments, 4WD Traction Manifold ..............................................112
8-14 Valve Coils.................................................................................................113

September 2016
Table of Contents
Part No. 1268556 xi
Turntable Rotation Components....................................................................115
9-1 Turntable Rotation Assembly.......................................................................115
How to Adjust the Turntable Rotation Gear Backlash ..................................116
Axle Components.............................................................................................117
10-1 Steer Sensors ............................................................................................117
How to Measure the Tire Alignment..............................................................117
How to Adjust a Steer Sensor.......................................................................118
How to Calibrate the Steer Sensors..............................................................119
How to Adjust the Oscillate Limit Switches...................................................120
10-2 Oscillating Axle Cylinders ..........................................................................121
Section 4Fault Codes.......................................................................................................122
Introduction.........................................................................................................122
Control System Fault Codes...........................................................................123
How to Read Control System Fault Codes ........................................................123
How to Clear Secondary Boom Safety Switch Faults........................................123
Fault Code Display - Deutz and Perkins Models...........................................131
How to Retrieve Active Engine Fault Codes Deutz D 2.9 L4 and
Perkins 404F-22 Models .......................................................................131
Deutz D 2.9 L4 Engine Fault Codes................................................................132
Perkins 404F-22 Engine Fault Codes.............................................................143
Continental TME27 Engine Fault Codes........................................................145
How to Retrieve Continental Engine Fault Codes ........................................145
How to Clear Engine Fault Codes from the ECM .........................................145
Continental TME27 Engine Fault Codes.......................................................146
GM 3.0L Engine Fault Codes...........................................................................151
GM Fault Code Chart.........................................................................................151

September 2016
Table of Contents
xii Part No. 1268556
Section 5 Schematics .......................................................................................................156
Introduction ........................................................................................................156
Wire Circuit Legend ...........................................................................................157
Wire Color Legend.............................................................................................161
Limit Switches and Angle Sensors.....................................................................166
Drive Chassis and Platform Controller Pin Legend ...........................................168
Turntable Controller Pin Legend........................................................................169
Relay and Fuse Panel Legends.........................................................................170
Electrical Symbol Legend ..................................................................................172
Hydraulic Symbols Legend ................................................................................173
Electrical Schematics......................................................................................174
Electrical Schematic - Engine Options, Deutz TD2.9 Engine............................175
Electrical Schematic - Engine Options, Deutz TD2.9 Engine Harness..............176
Electrical Schematic - Engine Options,Perkins 404F-22T Engine.....................179
Electrical Schematic - Engine Options, Perkins 404F-22T Engine Harness.....180
Electrical Schematic - Engine Options, Perkins 804D Engine...........................183
Electrical Schematic - Engine Options, Continental TME27 Engine .................184
Electrical Schematic - Engine Options, GM 3.0 Engine.....................................187
Electrical Schematic - Safety Circuits................................................................190
Electrical Schematic - Generator Options..........................................................191
Electrical Schematic - Welder Generator Option...............................................194
Electrical Schematic - Hydraulic Generator Options..........................................195
Hydraulic Schematics......................................................................................197
Hydraulic Schematic - 2 Wheel Drive (2 and 4 Wheel Steer)............................198
Hydraulic Schematic - 4 Wheel Drive (2 and 4 Wheel Steer)............................199
Electrical Schematic – (from Z8013-4592 to Z8015-5653)................................201
Electrical Schematic – (from Z8015-5654) ........................................................201

September 2016 Service and Repair Manual
Specifications
Part No. 1268556 1
Section 2 Speci fic ati ons
Machine Specifications
Tires and wheels
Tire size
(foam filled and non
-marking) 18-
625 FF
Tire size
(Hi
-flotation)
445D50/70
Tire ply rating
(foam filled and non
-marking)
16
Tire weight, new foam
-filled (minimum)
(Rough terrain)
622 l
bs
282 k
g
Tire ply rating
(Hi
-flotation)
14
Overall tire diameter
(foam filled and non
-marking) 40.7 i
n
103.3 c
m
Overall tire diameter
(Hi
-flotation) 45.47 i
n
115.5 c
m
Wheel diameter
(foam filled and non
-marking) 24.5 i
n
62.2 c
m
Wheel diameter
(Hi
-flotation) 28 i
n
71.1 c
m
Wheel width
(foam
filled, non-marking and Hi-flotation) 15 i
n
38.1 c
m
Tire Pressure (Hi
-flotation) 80 l
bs
5.5 b
ar
Wheel lugs
11 @ 3/4 -
16
Lug nut torque, dry
420 ft-
lbs
570 Nm
Lug nut torque, lubricated
320 ft-
lbs
434 Nm
Fluid capacities
Fuel tank
35 g
allons
132.5 l
iters
LPG tank
33.5 l
bs
15.2 k
g
Hydraulic tank
45 g
allons
170 l
iters
Hydraulic system (including tank)
80 g
allons
303 l
iters
Drive hubs, 2WD
Drive hubs, 4WD
30.5 f
l oz
902 c
c
23 f
l oz
680 c
c
Turntable rotation drive hub
40 f
l oz
1183 c
c
Drive hub
oil type: SAE 90 multipurpose hypoid gear oil API
service classification GL5
Performance Specifications
Drive speed, maximum
(models with rough terrain tires)
Stowed position
40 ft / 8.7 - 9.3 s
ec
12.2 m / 8.7 - 9.3 s
ec
Raised or extended
40 ft / 40 - 45 s
ec
12.2 m / 40 - 45 s
ec
Drive speed, maximum
(models with Hi
-flotation tires)
Stowed position
40 ft / 13.6 - 14.5 s
ec
12.2 m / 13.6 - 14.5 s
ec
Raised or extended
40 ft / 62 - 70 s
ec
12.2 m / 62 - 70 s
ec
Braking
distance, maximum
High range on paved surface
6 f
t
1.8
m
Gradeability
See Operator's
Manual
Boom function speeds, maximum from platform
controls
Jib boom up
23 to 33 s
econds
Jib boom down
21 to 31 s
econds
Primary boom up, retracted
-
35° to 65° 60 to 70 s
econds
Primary boom down, retracted
-
35° to 65° 75 to 85 s
econds
Secondary boom up
38 to 48 s
econds
Secondary boom down
38 to 48 s
econds
Primary boom extend
48 to 52 s
econds
Primary boom retract
38 to 42 s
econds
Platform Rotate 160°
10 to 14 s
econds
Turntable rotate, 360° boom fully
retracted
114 to 126 s
econds
Turntable rotate, 360° boom
extended
200 to 240 s
econds
For operational specifications, refer to the
Operator's Manual.

Service and Repair Manual September 2016
Specifications
2 Part No. 1268556
Hydraulic Oil Specifications
Hydraulic 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 prevention, corrosion inhibition, seal
conditioning, and foam and aeration suppression
properties.
Cleanliness level,
minimum
ISO 15/13
Water content,
maximum
250 p
pm
Recommended Hydraulic Fluid
Hydraulic oil type
Chevron
Rando HD Premium
Viscosity grade
32
Viscosity index
200
Optional Hydraulic Fluids
Mineral based
Shell Tellus S2 V 32
Shell Tellus S2 V 46
Shell Tellus S4 VX 32 Shell
Shell Donax TG (Dexron III)
Chevron 5606A
Biodegradable
Petro Canada Environ MV
46
Fire resistant
UCON Hydrolube HP-
5046
Note: Genie specifications require additional
equipment and special installation instructions for
the approved optional fluids. Consult Genie Product
Support before use.
Optional fluids may not have the
same hydrau
lic lifespan and
may result in component
damage.
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 required.
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
component damage.
Note: Do not operate the machine when the
ambient air temperature is consistently above
120°F / 49°C.
Hydraulic Fluid Temperature
Range
Ambient air temperature
1 Chevron hydraulic oil 5606A
2 Petro-Canada Environ MV 46
3 UCON Hydrolube HP-5046D
4 Chevron Rando HD premium oil MV

September 2016 Service and Repair Manual
Specifications
Part No. 1268556 3
Chevron Rando HD Premium Oil
MV Fluid Properties
ISO Grade
32
Viscosity index
200
Kinematic Viscosity
cSt @ 200°F / 100°C
cSt @
104°F / 40°C
7.5
33.5
Brookfield Viscosity
cP @
-4°F / -20°C
cP @
-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
Note: A 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 temperature is below -20°F / -29°C with
Rando HD Premium MV.
Chevron 5606A Hydraulic Oil
Fluid Properties
ISO Grade
15
Viscosity index
300
K
inematic Viscosity
cSt @ 200°F / 100°C
cSt @ 104°F / 40°C
cSt @
-40°F / -40°C
5.5
15.0
510
Flash point
180°F / 82°C
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 ambient temperatures
are consistently below 0°F / -17°C unless an oil
heating system is used.
Continued use of Chevron
5606A hydraulic fluid, or
equivalent, when ambient
temperatures are consistently
above 32°F / 0°C may
result in
component damage
Petro-Canada Environ MV 46
Fluid Properties
ISO Grade
46
Viscosity index
154
Kinematic Viscosity
cSt @ 200°F / 100°C
cSt @ 104°F / 40°C
8.0
44.4
Flash point
482°F / 250°C
Pour point
-49°F / -
45°C
Maximum continuous
operating
temperature
180°F / 82°C
Shell Tellus S4 VX Fluid
Properties
ISO Grade
32
Viscosity index
300
Kinematic Viscosity
cSt @ 200°F / 100°C
cSt @ 104°F / 40°C
9
33.8
Brookfield Viscosity
cSt @
-4°F / -20°C
cSt @
-13°F / -25°C
cSt @
-40°F / -40°C
481
702.4
2624
Flash point
>100
Pour point
-76°F / -
60°C
Maximum continuous operating
temperature
103°F / 75°C
UCON Hydrolube HP-5046 Fluid
Properties
ISO Grade
46
Viscosity index
192
Kinematic Viscosity
cSt @ 149°F / 65°C
cSt @ 104°F / 40°C
cSt @
0°F / -18°C
22
46
1300
Flash point
None
Pour point
-81°F / -
63°C
Maximum continuous operating
temperature
189°F / 87°C

Service and Repair Manual September 2016
Specifications
4 Part No. 1268556
Hydraulic Component
Specifications
Drive Pump
Type: bi
-directional variable displacement piston pump
Displacement per revolution
2.8 c
u in
46 c
c
Flow rate @ 230
0 rpm 28 g
pm
106 L/min
Drive pressure, maximum
3625 p
si
250 b
ar
Charge Pump
Type
gerotor
Displacement per revolution
0.85 c
u in
13.9 c
c
Flow rate @ 230
0 rpm 9 g
pm
34 L/min
Charge pressure @ 230
0 rpm
Neutral position
320 p
si
22 b
ar
Function pump
Type: two
-section tandem gear pump
Displacement per revolution
Pump 1 (inner)
1.94 c
u in
31.8 c
c
Flow rate @ 230
0 rpm 17 g
pm
64 L/min
Displacement per revolution
Pump 2
(outer) 0.58 c
u in
9.5 c
c
Flow rate @ 230
0 rpm 5 g
pm
19 L/min
Auxiliary Pump
Type: two
-section fixed displacement gear pump
Displacement per revolution
Section 1 (inner)
0.159 c
u in
2.61 c
c
Flow rate @ 268
7 rpm 1.7 g
pm
6.4 L/min
Displacement per revolution
Section 2 (outer)
0.051 c
u in
0.84 c
c
Flow rate @ 268
7 rpm 0.3 g
pm
1.1 L/min
Function manifold
System relief valve pressure, maximum
(measured at PTEST port)
3200 p
si
220.6 b
ar
Primary boom down relief valve pressure
(measured at LS port)
1300 p
si
89.6 b
ar
Secondary boom down relief pressure
(measured at LS port)
2500 p
si
172 b
ar
Secondary boom up relief pressure
(measured at LS port)
2500 p
si
172 b
ar
Primary boom extend relief pressure
(measured at LS port)
1300 p
si
89.6 b
ar
Secondary boom extend relief pressure
(measured at LS port)
2600 p
si
179 b
ar
Platform manifold relief pressure
3000 p
si
207 b
ar
Platform manifold flow regulator
3 g
pm
11.4 L/min
Oscillate manifold
Oscillate relief pressure (item BE or CH)
800 p
si
55.1 b
ar
Drive manifold
Hot oil relief pressure
280 p
si
19.3 b
ar
Brakes
Brake relief pressure
240 p
si
16.5 b
ar
Hydraulic Filters
High pressure filter:
Beta 3 ≥
200
High pressure filter bypass pressure
102 p
si
7 b
ar
Medium pressure
filter Beta 3 ≥
200
Medium pressure filter bypass pressure
51 p
si
3.5 b
ar
Hydraulic tank return filter
10 micron
with 25 psi / 1.7 b
ar bypass

September 2016 Service and Repair Manual
Specifications
Part No. 1268556 5
Manifold Component Specifications
Plug torque
SAE No. 2
36 in-
lbs / 4 Nm
SAE No. 4
10 ft-
lbs / 13 Nm
SAE No. 6
14 ft-
lbs / 19 Nm
SAE No. 8
38 ft-
lbs / 51 Nm
SAE No. 10
41 ft-
lbs / 55 Nm
SAE No. 12
56 ft-
lbs / 76 Nm
Valve coil resistance specifications
Proportional solenoid valve, 12V DC
(schematic items G, W and AB)
4.8
Ω
Proportional solenoid
valve, 12V DC
(schematic items R)
9
Ω
3
position 4 way solenoid valve, 12V DC
(schematic items BA, BB, CA, CB, CP, CQ,
GB, GP and GQ)
9
Ω
3
position 4 way solenoid valve, 10V DC
(schematic items O and S)
6.3
Ω
2
position 2 way solenoid valve, 10V DC
(schem
atic items J) 3.3
Ω
2
position 2 way solenoid valve, 10V DC
(schematic items C and P)
6.3
Ω
2
position 3 way solenoid valve, 10V DC
(schematic items H, V, X, Z, AA, EE and EF)
6.3
Ω
2
position 3 way solenoid valve, 12V DC
(schematic items BC, BD, CE, CF,
FB and FC) 9
Ω
Continuous improvement of our products is a
Genie policy. Product specifications are
subject to change without notice or obligation.

Service and Repair Manual September 2016
Specifications
6 Part No. 1268556
Continental TME27 Engine
Displacement
164 c
u. in
2.68 l
iters
Number of cylinders
4
Bore and Stroke
3.58 x 4.06 i
nches
91 x 103.2 m
m
Horsepower, continuous
@ 250
0 rpm 59 hp / 43.9 k
W
Firing order
1 - 3 - 4 -
2
Standby idle
-computer
controlled Frequency
1000 r
pm
Low function idle-computer
controlled Frequency
1500 r
pm
53.33 Hz
High function idle-computer
controlled Frequency
2500 r
pm
83.33 Hz
Compression ratio
8.2:1
Compression pressure pressure (psi or bar) of the
lowest cylinder must be at least 75% of the highest
cylinder
Governor
electronic
Valve
clearance, warm
Intake
0.014 i
n
0.36 m
m
Exhaust
0.018 i
n
0.45 m
m
Lubrication system
Oil pressure, hot
40 to 60 p
si
2.8 to 4.1 b
ar
Oil capacity (including filter)
7 q
uarts
6.6 l
iters
Oil viscosity requirements
-
22°F to 86°F / -30°C to 30°C 5W-
20
-
4°F to 104°F / -20°C to 40°C 10W-
40
Above 5°F /
-15°C 15W-
40
Unit ships with 15W
-40.
Extreme operating temperatures may require the use of
alternative engine oils. For oil requirements, refer to the
Engine Operator Manual for your engine.
Oil
Pressure switch
Installation torque
8 - 18 ft-lbs
11 - 24 Nm
Pressure switch point
7 p
si
0.55 b
ar
Fuel pump
Fuel pressure
39-40 p
si
2.7 b
ar
Fuel flow rate
0.42 g
pm
1.59 L/min
Fuel requirement
For fuel requirements, refer to the engine Operator
Manual for your engine.
Starter motor
Current draw, normal load
150-
345A
Cranking speed
200 - 250 r
pm
Battery – Engine starting and control system
Type
12V DC, Group 31
Quantity
2
Battery capacity, maximum
1000A
Reserve capacity @ 25A rate
200
Minutes
Engine coolant
Capacity
(engine only)
10.7 q
uarts
10.1 liters
Coolant temperature switch
Installation torque
8 - 18 ft-lbs
11 - 24 Nm
Temperature switch point
230°F
110°C
Alternator output
65A @ 13.8V DC
Fan belt deflection
1/2 i
nch
12 m
m

September 2016 Service and Repair Manual
Specifications
Part No. 1268556 7
GM 3.0L Engine
Displacement
183 c
u. in
3.0 liters
Number of cylinders
4
Bore and Stroke
4.0 x 3.6 i
nches
101.6 x 91.44 m
m
Horsepower @ 250
0 rpm
Horsepower @ 150
0 rpm 70 hp / 52 k
W
40 h
p / 30kW
Firing order
1 - 3 - 4 -
2
Standby idle
-computer
controlled Frequency
1000 r
pm
Low function idle-computer
controlled
1500 rpm
High function idle
-computer
controlled
2500 rpm
Compression ratio
9.25:1
Compression pressure pressure (psi or bar) of the
lowest cylinder must be at
least 75% of the highest
cylinder
Governor
electronic
Lubrication system
Oil pressure, hot
minimum @ 100
0 rpm 6 p
si
0.4 b
ar
Oil capacity (including filter)
5 q
uarts
4.7 liters
Oil viscosity requirements
-
22°F to 86°F / -30°C to 30°C 5W-
20
-
4°F to 104°F / -20°C to 40°C 10W-
40
Above 5°F /
-15°C 15W-
40
Unit ships with 5W
-30.
Extreme operating temperatures may require the use of
alternative engine oils. For oil requirements, refer to the
Engine Operator Manual for your engine.
Fuel requirement
For fuel requirements, refer to the engine Operator
Manual for your engine.
Battery
– Engine starting and control system
Type
12V DC, Group 31
Quantity
2
Battery capacity, maximum
1000A
Reserve capacity @ 25A rate
200 Minutes
Engine coolant
Capacity
12 q
uarts
11.4 l
iters
Alternator output
70A @ 12V DC
Fan belt deflection
1/2 i
nch
12 m
m

Service and Repair Manual September 2016
Specifications
8 Part No. 1268556
Deutz TD2011L04i Engine
Displacement
220.9 c
u. in
3.62 l
iters
Number of cylinders
4
Bore and Stroke
3.78 x 4.92 i
nches
96 x 125 m
m
Horsepower net intermittent @
240
0 rpm 74 h
p
55 k
W
Induction system
turbocharged
Firing order
1 - 3 - 4 -
2
Low idle
1500 r
pm
383 Hz
High idle
2350 r
pm
599 Hz
Compression ratio
17.5:1
Compression pressure pressure (psi or bar)
of the
lowest cylinder must be at least 75% of the highest
cylinder
Governor
centrifugal
mechanical
Valve Clearance, cold
Intake
0.012 i
n
0.3 m
m
Exhaust
0.020 i
n
0.5 m
m
Lubrication system
Oil pressure, hot (@ 200
0 rpm) 40 to 60 p
si
2.8 to 4.1 b
ar
Oil capacity (including filter)
12.8 q
uarts
12.1 l
iters
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
Unit ships with 15W
-40.
Extreme operating temperatures
may require the use of
alternative engine oils. For oil requirements, refer to the
Engine Operator Manual for your engine.
Oil temperature switch
Installation torque
8 - 18 ft-lbs
11 - 24 Nm
Temperature switch point
275°F
135°C
Oil Pressure switch
Installation torque
8 - 18 ft-lbs
11 - 24 Nm
Pressure switch point
22 p
si
1.5 b
ar
Fuel injection system
Motorpal
Injection pump pressure, maximum
15,000 p
si
1034 b
ar
Injector opening pressure
3046 p
si
210 b
ar
Fuel requirement
For fuel
requirements, refer to the engine Operator
Manual for your engine.
Starter motor
Current draw, normal load
140 -
200A
Cranking speed
250 - 350 r
pm
Battery
– Engine starting and control system
Type
12V DC, Group 31
Quantity
2
Battery capacity,
maximum
1000A
Reserve capacity @ 25A rate
200 Minutes
Alternator output
80A @ 14V DC
Fan belt deflection
3/8 to 1/2 inch
9 to 12 m
m