Terex Genie Z-60 DC User manual

Service and Repair Manual
Serial Number Range
Z®-60 DC
from Z60H-2548
from Z60M-
1000
This manual includes:
Repair procedures
Fault Codes
Electrical and
Hydraulic
Schematics
Z®-60 FE
For detailed maintenance
procedures, refer to the
appropriate Maintenance
Manual for your machine.
Original Instructions
Part No. 1307785GT
Rev B
August 2022

Service and Repair Manual August 2022
Introduction
ii Z®-60 DC • Z®-60 FE Part No. 1307785GT
Intro ductio n Intro ductio n
Important
Read, understand and obey the safety rules
and operating instructions in the appropriate
Operator's Manual on your machine before
attempting any maintenance procedure.
This manual provides detailed scheduled
maintenance information for the machine
owner and user. It also 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
1307785GT Rev B, August 2022
Second Edition, Second Printing
Genie and "Z" are registered trademarks of Terex South
Dakota, Inc. in the U.S.A. and many other countries.

August 2022 Service and Repair Manual
Introduction
Part No. 1307785GT Z®-60 DC • Z®-60 FE iii
Revision History
Revision Date Section Procedure / Page / Description
A 9/2021 Initial Release
B 8/2022 Repair 11-1
Fault Codes All Sections
Navigation Menus All Sections
Schematics Electrical schematics
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 August 2022
Introduction
iv Z®-60 DC • Z®-60 FE Part No. 1307785GT
Serial Number Legend
1 Model
2 Facility code
3 Sequence number
4 Serial number (stamped on chassis)
5 Serial label (located under cover)
Z60 H - 12345
1 2 3
45
Model:
Serial number:
Electrical schematic number:
Year of manufacture:
Machine unladen weight:
Rated work load (including occupants):
Maximum number of platform occupants:
Maximum allowable side force:
Maximum allowable inclination of the chassis:
Z60H-12345

August 2022 Service and Repair Manual
Safety Rules
Part No. 1307785GT Z®-60 DC • Z®-60 FE v
Sec ti on 1 Safety 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 modify or alter a MEWP without prior
written permission from the manufacturer.
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 August 2022
Safety Rules
vi Z®-60 DC • Z®-60 FE Part No. 1307785GT
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 pote
ntial
personal 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
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
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
m
ay 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.

August 2022
Table of Contents
Part No. 1307785GT Z®-60 DC • Z®-60 FE vii
Introduction Introduction ......................................................................................................ii
Important Information ......................................................................................... ii
Find a Manual for this Model............................................................................... ii
Revision History ................................................................................................ iii
Serial Number Legend....................................................................................... iv
Section 1 Safety Rules......................................................................................................v
General Safety Rules .........................................................................................v
Section 2 Specifications...................................................................................................1
Machine Specifications .......................................................................................1
Performance Specifications ................................................................................2
Hydraulic Oil Specifications ................................................................................2
Hydraulic Component Specifications...................................................................5
Manifold Component Specifications ....................................................................5
Kubota D1105 Engine Specifications ..................................................................6
Machine Torque Specifications ...........................................................................7
Machine Component Weights.............................................................................7
Hydraulic Hose and Fitting Torque Specifications ...............................................8
Torque Procedure ..............................................................................................9

August 2022
Table of Contents
viii Z®-60 DC • Z®-60 FE Part No. 1307785GT
Section 3 Repair Procedures ......................................................................................... 11
Introduction...................................................................................................... 11
Cailbration Process Steps ................................................................................ 13
Platform Controls........................................................................................... 14
1-1 Platform Controls ....................................................................................... 14
How to Adjust the Joystick Threshold Setting .............................................. 15
How to Adjust the Joystick Max-out Setting ................................................. 16
How to Adjust the Joystick Ramp Rate Setting ............................................ 18
1-2 How to Calibrate Booms Angle Sensors ..................................................... 20
1-3 How to Clear the Fault History.................................................................... 21
Platform Components.................................................................................... 22
2-1 Platform Leveling Slave Cylinder ................................................................ 22
2-2 Platform Rotator......................................................................................... 23
2-3 Platform Overload System.......................................................................... 24
How to Perform a Zero Load Platform Calibration........................................ 24
How to Perform a Full Load Platform Calibration ......................................... 25
How to Replace the Platform Overload Load Cell ........................................ 27
How to Reset Overload Recovery Message ................................................ 28
Jib Boom Components.................................................................................. 29
3-1 Jib Boom.................................................................................................... 29
3-2 Jib Boom Lift Cylinder ................................................................................ 30
Primary Boom Components .......................................................................... 31
4-1 Cable Track ............................................................................................... 31
How to Repair the Cable Track.................................................................... 32
4-2 Primary Boom ............................................................................................ 32
How to Disassemble the Primary Boom....................................................... 33
4-3 Primary Boom Lift Cylinder......................................................................... 34
4-4 Primary Boom Extension Cylinder .............................................................. 35
4-5 Platform Leveling Master Cylinder.............................................................. 36

August 2022
Table of Contents
Part No. 1307785GT Z®-60 DC • Z®-60 FE ix
Secondary Boom Components......................................................................37
5-1 Secondary Boom Lift Cylinder.....................................................................38
Engines...........................................................................................................40
6-1 RPM Adjustment ...................................................................................40
Hydraulic Pumps ............................................................................................41
7-1 Function Pump ...........................................................................................41
How to Check the Function Pump Calibration ..............................................42
Manifolds ........................................................................................................44
8-1 Function Manifold Components ..................................................................44
8-2 Valve Adjustments - Function Manifold .......................................................48
How to Adjust the Proportional Relief Valve and Hydraulic Pressure Sensor 48
How to Adjust the Platform Level Up Relief Valve ........................................49
How to Adjust the Primary Boom Extend Relief Valve ..................................50
8-3 Jib Boom / Platform Rotate Manifold Components ......................................51
8-4 Turntable Rotation Manifold Components ...................................................52
8-5 Oscillate Directional Valve Manifold Components .......................................53
8-6 How to Set Up the Oscillate Directional Valve .............................................54
How to Adjust the Oscillate Reducing Valve.................................................54
How to Test a Coil Diode .............................................................................56
Turntable Rotation Components ...................................................................58
9-1 Turntable Rotation Assembly ......................................................................58
9-2 How to Replace the Universal Tilt Sensor ...................................................60
How to Calibrate the Universal Tilt Sensor ...................................................61
Axle Components...........................................................................................62
10-1 Oscillating Axle Cylinders .........................................................................62
10-2 How to Remove the Steer Cylinder ...........................................................63
How to Calibrate the Steer Angle Sensor.....................................................63
Battery Charger ..............................................................................................65
11-1 Battery Charger ........................................................................................65

August 2022
Table of Contents
x Z®-60 DC • Z®-60 FE Part No. 1307785GT
Section 4 Fault Codes .................................................................................................... 66
Introduction...................................................................................................... 66
Control System Fault Codes.......................................................................... 67
Fault Codes Ground Controls........................................................................... 67
How to Retrieve Control System Fault Codes - Platform Controls ..................... 68
Control System Fault Codes............................................................................. 70
Charger Fault Codes...................................................................................... 91
Battery Charger................................................................................................ 91
Charger Fault Codes................................................................................... 92
Charger Error Codes................................................................................... 93
Pump Control Fault Codes ............................................................................ 97
Pump Controller Fault Handling........................................................................ 97
Drive Control Fault Codes ........................................................................... 106
Drive Controller Fault Handling....................................................................... 106
Section 5 Navigation Menus ........................................................................................ 125
Top Menu ...................................................................................................... 125
Faults Navigation Menu.................................................................................. 126
Options Navigation Menu ............................................................................... 127
Settings Navigation Menu .............................................................................. 128
Advanced and Drive Navigation Menu............................................................ 129

August 2022
Table of Contents
Part No. 1307785GT Z®-60 DC • Z®-60 FE xi
Section 6 Schematics ...................................................................................................131
Introduction ....................................................................................................131
Electrical Symbol Legend ...............................................................................132
Hydraulic Symbols Legend .............................................................................133
Electrical Component and Wire Color Legends ...............................................134
Kubota Engine Fuse and Relay Module ..........................................................137
12V DC Charger Wiring (DC Option)...............................................................138
AC Input Wiring (DC Option)...........................................................................139
Limit Switch/Angle Sensor Legend..................................................................140
Electrical Schematics - Options...................................................................141
Wiring Diagrams - Options [from Z60H-2548 to 2999] .....................................142
Wiring Diagram - Options [from Z60H-2548 to 2999].......................................143
Electrical Schematic -Options, 4WD [from Z60H-2548 to 2999] ...................146
Power Cable Wiring Diagram [from Z60H-2548 to 2999] .................................147
Wiring Diagram - FE Models [from Z60H-3000, Z60M-1000] ...........................150
Wiring Diagram - DC Models [from Z60H-3000, Z60M-1000] ..........................151
Electrical Schematics...................................................................................153
Electrical Schematic [from Z60H-2548 to 2999] ..............................................154
Electrical Schematic [from Z60H-2548 to 2999] ..............................................155
Ground Control Box Wiring Diagram [from Z60H-2548 to 2999] ......................158
Ground Control Box Wiring Diagram [from Z60H-2548 to 2999] ......................159
Platform Control Box Wiring Diagram [from Z60H-2548 to 2999].....................162
Platform Control Box Wiring Diagram [from Z60H-2548 to 2999].....................163
Electrical Schematic, PCON [from Z60H-2548 to 2999]...................................166
CAN BUS Wiring Diagram [from Z60H-2548 to 2999] .....................................167

August 2022
Table of Contents
xii Z®-60 DC • Z®-60 FE Part No. 1307785GT
Electrical Schematics .................................................................................. 169
Electrical Schematic, DCON [from Z60H-3000, Z60M-1000]........................... 170
Electrical Schematic, GCON [from Z60H-3000, Z60M-1000]........................... 171
Electrical Schematic, PCON [from Z60H-3000, Z60M-1000] ........................... 174
Electrical Schematic, TCON [from Z60H-3000, Z60M-1000] ........................... 175
Wiring Diagram, CAN BUS [from Z60H-3000, Z60M-1000]............................. 178
Hydraulic Schematics.................................................................................. 179
Hydraulic Schematic ...................................................................................... 180

August 2022 Service and Repair Manual
Specifications
Part No. 1307785GT Z®-60 DC • Z®-60 FE 1
Sec ti on 2 Speci fic ati o ns
Machine Specifications
Tires and Wheels
Rough terrain
Tire size
(Rough terrain)
355/55D625
Tire weight, foam
-filled
(minimum) (Rough terrain)
426 l
bs
193 k
g
Tire weight, foam
-filled
(minimum) (Rough terrain non
marking)
426 l
bs
193 k
g
Tire ply rating
14
Wheel lugs
9 @ 5/8 - 18
Lug nut torque, dry
240 ft-
lbs
325 Nm
Lug nut torque, lubricated
180 ft-
lbs
244 Nm
Overall tire diameter
(Rough terrain, low profile tires)
36.9 i
n
93,7 c
m
Fluid capacities
Fuel
tank 17 g
allons
64,4 l
iters
Hydraulic tank
18 g
allons
68 liters
Hydraulic system (including
tank)
21 g
allons
80 l
iters
Drive hubs
24 f
l oz
710 c
c
Turntable rotation drive hub
43 f
l oz
1262 c
c
Drive hub oil type: SAE 9
0 multipurpose hypoid gear oil
API service classification GL5
Batteries
Type
Lead acid
AGM
L16G-
AC
EV Dry cell
Group
903-L16
Quantity
8
Capacity
Trojan lead acid
Fullriver AGM
Trojan AGM
390 AH
415 AH
370 AH
Reserve capacity @
25A rate
Trojan lead acid
Fullriver AGM
Trojan AGM
789 min
885 m
in
817 m
in
Weight
Refer to
Machine Component Weights
For operational specifications, refer to the
Operator's Manual.

Service and Repair Manual August 2022
Specifications
2 Z®-60 DC • Z®-60 FE Part No. 1307785GT
Performance Specifications
Drive speed, maximum
Stowed position
2WD/4WD models
Stowed 4.0 m
ph
6.44 k
m/h
40 ft / 6.8 s
ec
12.2 m / 6.8 s
ec
Elevated
0.7 m
ph
1.0 km/h
40 ft / 40 s
ec
12.2 m / 40 s
ec
Gradeability
See Operator's Manual
Braking distance,
high range on paved surface
3 to 6 f
eet
0.9 to 1.8
m
Function speeds,
maximum from platform controls
Jib boom up
13 to 17 s
econds
Jib boom down
13 to 17 s
econds
Primary boom up
54 to 66 s
econds
Primary boom down
54 to 66 s
econds
Primary boom extend
40 to 50 seconds
Primary boom retract
31 to 39 s
econds
Secondary boom up
31 to 39 s
econds
Secondary boom up/down
31 to 39 s
econds
Turntable rotate, per 90°
Stowed
21 to 27 s
econds
Turntable rotate, per 90°
Not stowed
35 to 42 s
econds
For operational specifications, refer to the
Operator's Manual.
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 ra
nge, 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
ISO Grade
32
Viscosity index,
maximum
200
Optional Hydraulic Fluids
Mineral based
Shell Tellus S2 V 32
Shell Tellus S2 V 46
Shell Tellus S4 VX 32
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 hydraulic lifespan and
may result in component
damage.
Note: Extended machine operation can cause the
hydraulic fluid temperature to increase beyond its
maximum allowable range. If the hydraulic fluid
temperature consistently exceeds 200°F / 90°C an
optional oil cooler may be required.

August 2022 Service and Repair Manual
Specifications
Part No. 1307785GT Z®-60 DC • Z®-60 FE 3
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
Chevron Rando HD Premium Oil
MV Fluid Properties
ISO Grade
32
Viscosity index, maximum
200
Kinematic Viscosity, maximum
cSt @ 200°F / 100°C
cSt @ 104°F / 40°C
7.5
33.5
Brookfield Viscosity, maximum
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.

Service and Repair Manual August 2022
Specifications
4 Z®-60 DC • Z®-60 FE Part No. 1307785GT
Chevron 5606A Hydraulic Oil
Fluid Properties
ISO Grade
15
Viscosity index, maximum
300
Kinematic Viscosity, maximum
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, maximum
154
Kinematic Viscosity, maximum
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, maximum
300
Kinematic Viscosity, maximum
cSt @ 200°F / 100°C
cSt @ 104°F / 40°C
9
33.8
Brookfield Viscosity, maximum
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, maximum
192
Kinematic Viscosity, maximum
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

August 2022 Service and Repair Manual
Specifications
Part No. 1307785GT Z®-60 DC • Z®-60 FE 5
Hydraulic Component
Specifications
Function Pump
Type
2
s
ection tandem gear
pump
Displacement per
revolution
(inner pump)
(outer pump)
.40 cu in / 6.6 c
c
.20 cu in / 3.3 cc
Max flow rate
L/min(inner pump)
L/min(outer pump)
6.8 g
pm / 25.74
3.4 g
pm / 12.87
Auxiliary Pump
Type
Fixed displacement
gear pump
Displacement per revolution
1.7 g
pm
6.44 L/min
Function manifold
Proportional relief valve
pressure, variable
50 to 3000 p
si
3.4 to 207 b
ar
Platform level relief valve
pressure
2800 p
si
193 bar
Primary boom extend relief valve
pressure
1250 p
si
86 b
ar
Oscillate reducing valve
pressure 400 p
si
28 b
ar
Platform level flow regulator
Variable
1 to 1.5 g
pm
3.8 t
o 5.7 L/min
Hydraulic Filters
High pressure filter:
Beta 5 ˆ 1000
Hydraulic tank return filter
Beta 10 ˆ 200
Manifold Component
Specifications
Plug torque
SAE No. 4
13 ft-
lbs / 18 Nm
SAE No. 6
18 ft-lbs / 24 Nm
SAE No. 8
50 ft-
lbs / 68 Nm
SAE No.10
55 ft-
lbs / 75 Nm
SAE No. 12
56 ft-
lbs / 75.9 Nm
Valve coil resistance
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 / 10°C that your air temperature
increases or decr
eases from 68°F / 20°C.
Description
Specification
Proportional solenoid relief valve, 24V
DC (schematic item AA)
22
Ω
Proportional solenoid valve, 3 position
4
way, 20V DC (schematic items B, G,
and S
19
Ω
Proportional solenoid valve, 3 position
4
way, 20V DC (schematic items AE, E, I,
O, R, and Z)
24
Ω
Solenoid valve, 2 position 3way, 12V DC
(schematic item JA)
9
Ω

Service and Repair Manual August 2022
Specifications
6 Z®-60 DC • Z®-60 FE Part No. 1307785GT
Kubota D1105 Engine
Displacement
68.53 c
u in
1.123 liters
Number of cylinders
3
Bore and Stroke
3.07 x 3.09 i
nches
78 x 78.4 m
m
Horsepower, gross
intermittent
24.8 @ 3000 r
pm
18.5 kW @ 3000 r
pm
Combustion system
Indirect injection
Firing order
1 - 2 -
3
Low idle
2150 r
pm
208 Hz
High idle
3000 r
pm
500 Hz
Compression ratio
24:1
Compression pressure
412 to 469 p
si
28.4 to 32.3 b
ar
Governor
mechanical
Valve clearance, cold
0.00571 to 0.00728 i
n
0,145 to 0,185 m
m
Lubrication system
Oil pressure
28 to 64 p
si
1.9 to 4.4 bar
Oil
capacity
(including filter)
5.4 q
uarts
5.1 l
iters
Oil viscosity requirements
Below -10°C (14° F)
SAE 10W-
30/
SAE 10W-
40
-
10 to 25° C (14° to 77° F) SAE 10W-
30/
SAE 10W-
40/
SAE 15W-40
Above 25° C (77° F)
SAE 10W-
30/
SAE 10W-
40/
SAE 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.
Engine coolant
Capacity
3.3 q
uarts
3.1 l
iters
Fuel injection system
Injection pump make
Bosch MD
Injection pump pressure,
maximum
1991 p
si
137 bar
Injection timing
16.5° BTDC
Fuel requirement
For fuel requirements, refer to the engine Operator
Manual for your engine.
Starter motor
Cranking speed
200 -
300 RPM
Current draw, normal load
155A
Battery
Type
12V DC
Group
70
Quantity
1
Ampere hour
75AH
Cold cranking ampere
450A
Reserve capacity @ 25A rate
70 m
inutes
Alternator output
40A @ 12V DC
Fan belt deflection
0.28 to 0.35 i
nch
7 to 9 m
m
Electric clutch
1.6A @ 48 V DC
29.22 Ω+/-
5%

August 2022 Service and Repair Manual
Specifications
Part No. 1307785GT Z®-60 DC • Z®-60 FE 7
Machine Torque Specifications
Platform Rotator
1
-8 center bolt, GR 5
Lubricated
480 ft-
lbs
650 Nm
Dry
640 ft-lbs
867 Nm
3/8
-16 bolts, GR 8
Lubricated
33 ft-
lbs
45 Nm
Dry
44 ft-
lbs
60 Nm
Turntable rotate assembly
Rotate bearing mounting bolts, lubricated
160 ft-
lbs
217 Nm
Rotate drive hub mounting bolts,
lubricated
80 ft-
lbs
108.4 Nm
Drive motors and hubs
Drive hub mounting bolts, dry
93 ft-
lbs
126 Nm
Drive
motor leads square nuts (requires
1
2 point socket)
9 f
t lbs
12 Nm
Machine Component Weights
Tire and wheel assembly
429 l
bs
195 kg
Drive motor and hub
160 l
bs
73 k
g
Engine assembly
724 l
bs
328 k
g
Primary boom
1277 l
bs
579 k
g
Primary boom lift cylinder
283 l
bs
128 k
g
Primary boom extend cylinder
234 l
bs
106 k
g
Secondary boom linkage
3017 l
bs
1368 k
g
Secondary boom lift cylinder
180 l
bs
82 k
g
Jib boom assembly
247lbs
112kg
Jib boom cylinder
47 lbs
22 k
g
Oscillate cylinder
50 l
bs
23 k
g
6
ft / 1.8 m platform 275 l
bs
125 kg
8
ft / 2.4 m platform 315 l
bs
143 k
g
Battery box assembly with counterweight
(without batteries)
612 l
bs
278 k
g
Battery 6volt (wet)
106 l
bs
48 k
g
Battery
6 volt (maintenance free) 123 l
bs
56 k
g

Service and Repair Manual August 2022
Specifications
8 Z®-60 DC • Z®-60 FE Part No. 1307785GT
Hydraulic Hose and Fitting
Torque Specifications
Your machine is equipped with Parker Seal-Lok™
ORFS or 37° JIC 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 18 ft-lbs / 25 Nm
-6 30 ft-lbs / 41 Nm
-8
40 ft-lbs / 55 Nm
-10 60 ft-lbs / 81 Nm
-12 85 ft-lbs / 115 Nm
-16 110 ft-lbs / 150 Nm
-20 150 ft-lbs / 205 Nm
-24 230 ft-lbs / 315 Nm
JIC 37° Fittings
(swivel nut or hose connection)
SAE Dash Size
Thread Size
Flats
-4 7/16-20 2
-6 9/16-18 1 1/2
-8 3/4-16 1 1/2
-10 7/8-14 1 1/2
-12 1 1/16-12 1 1/4
-16
1 5/16-12
1
-20 1 5/8-12 1
-24 1 7/8-12 1
SAE O-ring Boss Port
(tube fitting - installed into Aluminum)
(all types)
SAE Dash Size
Torque
-4 14 ft-lbs / 19 Nm
-6 23 ft-lbs / 31,2 Nm
-8
36 ft-lbs / 49 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
Adjustable Fitting Non-adjustable fitting
1 jam nut
SAE O-ring Boss Port
(tube fitting - installed into Steel)
SAE Dash Size Torque
-4
ORFS / 37° (Adj)
ORFS (Non-adj)
37° (Non-adj)
15 ft-lbs / 20,3 Nm
26 ft-lbs / 35,3 Nm
22 ft-lbs / 30 Nm
-6
ORFS (Adj / Non-adj)
37° (Adj / Non-adj)
35 ft-lbs / 47,5 Nm
29 ft-lbs / 39,3 Nm
-8 ORFS (Adj / Non-adj)
37° (Adj / Non-adj)
60 ft-lbs / 81,3 Nm
52 ft-lbs / 70,5 Nm
-10
ORFS (Adj / Non-adj)
37° (Adj / Non-adj)
100 ft-lbs / 135,6 Nm
85 ft-lbs / 115,3 Nm
-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