Terex Genie Z-60/37 DC Installation and operating manual

Service and Repair Manual
Serial Number Range
Z®-60/37 DC
from Z6016N-101 to
Z6016N-
599
from Z60N-
600
This manual includes:
Repair procedures
Fault Codes
Electrical and
Hydraulic Schematics
Z®-60/37 FE
For detailed maintenance
procedures, refer to the
appropriate Maintenance
Manual for your machine.
Part No. 1271125GT
Rev A6
December 2018

Service and Repair Manual December 2018
Introduction
ii Z®-60/37 DC • Z®-60/37 FE Part No. 1271125GT
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 © 2016 by Terex Corporation
1271125GT Rev A, April 2016
First Edition, First Printing
Genie and “Z” are registered trademarks of Terex South Dakota,
Inc. in the U.S.A. and many other countries.

December 2018 Service and Repair Manual
Introduction
Part No. 1271125GT Z®-60/37 DC • Z®-60/37 FE iii
Revision History
Revision
Date
Section
Procedure / Page / Description
A 3/2016 Initial Release
A1 6/2016 Repair Procedures How to Adjust Proportional Relief Valve and Hydraulic
Pressure Sensor / Updated
A2 9/2016 Introduction Serial number Legend
A3 12/2016 Schematic Power Cable Wiring Diagram
A4 11/2017 Specifications Machine Specifications
A5 5/2018 Schematic Corrected Options Schematic
A6 12/2018 Specifications Rotate hub torque value
Reference Examples:
Electronic Version
Click on any content o
r 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 December 2018
Introduction
iv Z®-60/37 DC • Z®-60/37 FE Part No. 1271125GT
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)

December 2018 Service and Repair Manual
Safety Rules
Part No. 1271125GT Z®-60/37 DC • Z®-60/37 FE 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:
RYou are trained and qualified to perform
maintenance on this machine.
RYou read, understand and obey:
•manufacturer's instructions and safety rules
•employer's safety rules and worksite
regulations
•applicable governmental regulations
RYou have the appropriate tools, lifting
equipment and a suitable workshop.

Service and Repair Manual December 2018
Safety Rules
vi Z®-60/37 DC • Z®-60/37 FE Part No. 1271125GT
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 per
sonal
injury hazards. Obey all safety
messages that follow this symbol
to avoid possible injury or death.
Indicates a imminently hazardous
situation which, if not avoided, will
result in death or serious injury.
Indicates a potentially hazardous
situ
ation 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. Alw
ays 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
components 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.
Be 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 t
o 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.

December 2018
Table of Contents
Part No. 1271125GT Z®-60/37 DC • Z®-60/37 FE 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 2 Specifications.......................................................................................................1
Machine Specifications...........................................................................................1
Performance Specifications....................................................................................2
Hydraulic Specification...........................................................................................2
Hydraulic Component Specifications......................................................................5
Manifold Component Specifications.......................................................................6
Kubota D1105 Engine Specifications.....................................................................7
Machine Torque Specifications..............................................................................8
Machine Component Weights................................................................................8
Hydraulic Hose and Fitting Torque Specifications .................................................9
Torque Procedure ................................................................................................10

December 2018
Table of Contents
viii Z®-60/37 DC • Z®-60/37 FE Part No. 1271125GT
Section 3 Repair Procedures.............................................................................................12
Introduction ..........................................................................................................12
Cailbration Process Steps....................................................................................14
Platform Controls...............................................................................................15
1-1 Platform Controls...........................................................................................15
How to Adjust the Joystick Threshold Setting ................................................16
How to Adjust the Joystick Max-out Setting ...................................................17
How to Adjust the Joystick Ramp Rate Setting ..............................................20
1-2 How to Calibrate Booms Angle Sensors .......................................................21
1-3 How to Clear the Fault History.......................................................................22
Platform Components .......................................................................................22
2-1 Platform Leveling Slave Cylinder...................................................................22
2-2 Platform Rotator.............................................................................................24
2-3 Platform Overload System.............................................................................25
2-4 How to Reset Overload Recovery Message..................................................27
Jib Boom Components......................................................................................28
3-1 Jib Boom........................................................................................................28
3-2 Jib Boom Lift Cylinder....................................................................................29
Primary Boom Components .............................................................................30
4-1 Cable Track....................................................................................................30
How to Repair the Cable Track.......................................................................31
4-2 Primary Boom................................................................................................31
How to Disassemble the Primary Boom.........................................................32
4-3 Primary Boom Lift Cylinder............................................................................33
4-4 Primary Boom Extension Cylinder.................................................................34
4-5 Platform Leveling Master Cylinder.................................................................35

December 2018
Table of Contents
Part No. 1271125GT Z®-60/37 DC • Z®-60/37 FE ix
Secondary Boom Components.........................................................................36
5-1 Secondary Boom Lift Cylinder........................................................................37
Engines................................................................................................................39
6-1 RPM Adjustment ............................................................................................39
How to Replace the Motor Tach Sensor.........................................................39
Hydraulic Pumps................................................................................................40
7-1 Function Pump...............................................................................................40
How to Check the Function Pump Calibration ................................................41
Manifolds.............................................................................................................42
8-1 Function Manifold Components .....................................................................42
8-2 Valve Adjustments - Function Manifold..........................................................47
How to Adjust the Proportional Relief Valve and Hydraulic Pressure Sensor 47
How to Adjust the Platform Level Up Relief Valve..........................................48
How to Adjust the Primary Boom Extend Relief Valve....................................49
8-3 Jib Boom / Platform Rotate Manifold Components........................................50
8-4 Turntable Rotation Manifold Components .....................................................51
8-5 Oscillate Directional Valve Manifold Components.........................................52
8-6 How to Set Up the Oscillate Directional Valve...............................................53
How to Adjust the Oscillate Reducing Valve...................................................53
How to Test a Coil Diode ................................................................................55
Turntable Rotation Components ......................................................................56
9-1 Turntable Rotation Assembly.........................................................................56
9-2 How to Replace the Universal Tilt Sensor .....................................................58
How to Calibrate the Universal Tilt Sensor .....................................................59
Axle Components...............................................................................................60
10-1 Oscillating Axle Cylinders.............................................................................60
10-2 How to Remove the Steer Cylinder..............................................................61
How to Calibrate the Steer Angle Sensor .......................................................61

December 2018
Table of Contents
x Z®-60/37 DC • Z®-60/37 FE Part No. 1271125GT
Section 4 Fault Codes.........................................................................................................63
Introduction ..........................................................................................................63
Control System Fault Codes.............................................................................64
Fault Codes Ground Controls..............................................................................64
How to Retrieve Control System Fault Codes - Platform Controls......................65
Control System Fault Codes................................................................................66
Section 5 Navigation Menus ..............................................................................................81
Faults Navigation Menu .......................................................................................82
Options Navigation Menu.....................................................................................83
Settings Navigation Menu....................................................................................84
Section 6 Schematics.........................................................................................................85
Introduction ..........................................................................................................85
Electrical Symbol Legend ....................................................................................86
Hydraulic Symbols Legend ..................................................................................87
Electrical Component and Wire Color Legends...................................................88
Kubota Engine Fuse and Relay Module ..............................................................91
12V DC Charger Wiring (DC Option)...................................................................92
AC Input Wiring (DC Option)................................................................................93
CAN BUS Wiring Diagram - DC Models..............................................................94
Limit Switch/Angle Sensor Legend......................................................................95
Electrical Schematics – Options ......................................................................97
Wiring Diagram -Options....................................................................................98
Schematics - Options, 4WD, DC, and FE Models ...............................................99
Power Cable Wiring Diagram.............................................................................102
Hydraulic Schematics......................................................................................103
Hydraulic Schematic - DC and FE Models ........................................................104
Electrical Schematics...................................................................................... 105
Electrical Schematics, DC/FE Models ...............................................................106
Ground Control Box Terminal Strip Wiring Diagram..........................................112
Platform Control Box Wiring Diagram................................................................113