Parts Manual. Refer to inside cover for additional serial number information. (from serial number 4551) Part No Rev D October 2006

Transcription

1 Parts Manual Refer to inside cover for additional serial number information Part No.1099 Rev D October 006 (from serial number 551)

2 October 006 Technical Publications Genie Industries 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. Serial Number Information Genie Industries offers the following Parts Manuals for these models: Title Part No. Genie Z-60/ Parts Manual (before serial number 1090) Genie Z-60/ Parts Manual (from serial number 1090 to 000) Genie Z-60/ Parts Manual (from serial number 001 to 550) Contact Us: techsup@genieind.com Copyright 199 by Genie Industries 1099 Rev D October 006 Fourth Edition, Fourth Printing "Genie" and "Z" are registered trademarks of Genie Industries in the USA and many other countries. Printed on recycled paper Printed in U.S.A. ii Z-60/ Part No. 1099

3 October 006 How To Read Your Serial Number Model: Z-60/ Serial number: Z Model year: 006 Manufacture date: 01/05/06 Electrical schematic number: ES0 Machine unladen weight: Rated work load (including occupants): 500 lb / 7 kg Maximum number of platfrm occupants: Maximum allowable side force : 150 lb / 670 N Maximum allowable inclination of the chassis: 0 deg Maximum wind speed : 8 mph/ 1.5 m/s Maximum platform height : 60 ft in/ 18. m Maximum platform reach : Gradeability: N/A Country of manufacture: USA This machine complies with: ANSI A9.5 CAN B.5. ft / 10. m Z Model Model year Sequence number Genie Industries 180 NE 76th Street Redmond, WA 9805 USA Serial label (located on back of tank side bulkhead) Serial number (stamped on chassis) OR PN (located on ground control box) Part No Z-60/ iii

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5 October 006 Table of Contents This manual is updated frequently. Each parts figure listed below has a figure number and a revision letter. If a figure is updated with new information, the revision letter or Rev is updated (example: from Rev A to Rev B). Figure Rev Description B Decals If you have a printed manual, you can keep it up to date by downloading new figures from the Genie website at How To Read Your Serial Number... iii Parts Stocking List... vii How To Order Parts... x Order Form... xi Electronic Version Click on the figure description below to view the figure. 100 Decals F Decals with Words 10.1 G Decals with Symbols 00 Drive Chassis Components 01.1 A Steer Axle Linkage, Oscillate Models (WD, WD) 0.1 A WD Steer Axle Linkage, Non-oscillate Models 0.1 C Non-steer Axle 0.1 B WD Steer Axle - Wheels and Hubs 05.1 B WD Steer Axle - Wheels and Hubs 06.1 B WD Hub - Steer Axle 07.1 A WD and WD Drive Hub 00 Turntable Components 01.1 E Hydraulic and Fuel Tanks - Gasoline/LPG Models 0.1 D Hydraulic and Fuel Tanks - Diesel Models 00 Turntable Components, Continued 0.1 B Function Manifold and Auxiliary Power Unit Installation 0.1 C Turntable Rotation and Hydraulic Rotary Coupler Installation 05.1 D Ground Controls - View C Ground Controls - View 07.1 B Ground Controls - View 08.1 B Turntable Covers 09.1 A Turntable Counterweight 00 Engine Components 01.1 D Perkins 0- Engine - View A Perkins 0C- Engine - View 0.1 A Deutz FL 1011F Engine - View 1 (before serial number 608) 0.1 A Deutz FL 1011F Engine - View (before serial number 608) 05.1 B Deutz FL 1011F Engine - View (before serial number 608) 06.1 B Deutz FL 011F Engine - View 1 (after serial number 607) 07.1 E Deutz FL 011F Engine - View (after serial number 607) 08.1 D Ford LRG-5 EFI Engine - View 1 (before serial number 616) 09.1 D Ford LRG-5 EFI Engine - View (before serial number 616) 10.1 D Ford LRG-5 EFI Engine - View (before serial number 616) 11.1 A Ford DSG- EFI Engine - View 1 (after serial number 615) 1.1 A Ford DSG- EFI Engine - View (after serial number 615) 1.1 A Ford DSG- EFI Engine - View (after serial number 615) 1.1 A Ford DSG- EFI Engine - View (after serial number 615) Table of Contents continues on the next page. Part No Z-60/ v

6 October 006 Table of Contents 500 Boom Components C Secondary Boom - View B Secondary Boom - View 50.1 A Upper Pivot 50.1 A Upper Pivot and Primary Boom Rests C Primary and Extension Booms C Cable Track (before serial number 55) 506. C Cable Track (after serial number 551) C Jib Boom and Platform Rotator 600 Platform Components B Platform Installation - View C Platform Installation - View 60.1 D Platform Controls - View A Platform Controls - View A Joystick Controllers, Single-axis and Multi-axis 700 Hydraulic Components A WD Traction Manifold 70.1 A WD Traction Manifold 70.1 B Two-Speed/Brake Manifold 70.1 D Function Manifold C Jib Select and Platform Rotate Manifolds A Hydraulic Pumps B Oscillate Control Valve (before serial number 580) 707. A Oscillate Control Valve (after serial number 5819) B WD Drive System C WD Drive Oscillate System (before serial number 580) 709. A WD Drive Oscillate System (after serial number 5819) B WD Drive System B WD Drive Oscillate System 700 Hydraulic Components, Continued 71.1 D Hydraulic Hoses and Fittings - Turntable 71.1 B Hydraulic Hoses and Fittings - Boom 71.1 A Hydraulic Hose and Fitting Cross-reference 800 Accessories D Alarm and Beacon Package, Driving Lights 80.1 E Platform Options 80.1 C Ground and Platform Control Box Covers 80.1 C Platform Overload - European Models E Platform Half-mesh and Pipe Cradle A Air Line to Platform B Cold Start Package A Generator Option B Hydraulic Hoses and Fittings - Generator B Hydraulic Oil Cooler A Gauge Option 81.1 B Panel Cradle 81.1 B Welder Option, Chassis Components - View D Welder Option, Platform Components - View B Welder Option, Hoses and Fittings - View B Hydraulic Hoses and Fittings - Arctic Hose Option B Hostile Environment Package - View A Hostile Environment Package - View A Hostile Environment - Engine Air Pre-cleaners 80.1 A Second LPG Carrier Option vi Z-60/ Part No. 1099

7 October 006 Parts Stocking List Required Parts The following parts are required to perform maintenance procedures as outlined in the Genie Z-60/ Service Manual. Perkins 0- Models: Description Part No. Air Filter Element Fuel/water Separator Element... 6 Engine Oil Filter V-belt Deutz FL-1011 Models (before serial number 608): Description Part No. Air Filter Fuel/water Separator Element Engine Oil Filter V-belt Deutz FL-011 Models (after serial number 607): Description Part No. Air Filter Fuel/water Separator Element Engine Oil Filter V-belt Ford LRG-5 EFI Models (before serial number 616): Description Part No. Fuel Pre-Filter Fuel Pressure Regulator/Filter Engine Oil Filter Air Filter Element Serpentine Belt PCV Valve Spark Plug (pack of ) Ford DSG- EFI Models (after serial number 615): Description Part No. Fuel Pre-Filter Fuel Pressure Regulator/Filter Engine Oil Filter Air Filter Element Serpentine Belt PCV Valve Spark Plug Spark Plug (pack of ) Recommended Parts Description Part No. Genie Gray Paint, 1 Ounce (55ml) Aerosol Genie Blue Paint, 1 Ounce (55ml) Aerosol Genie Blue Paint, 1 gallon (.78 liters) Genie Gray Paint, 1 gallon (.78 liters) Parts Stocking List continues on the next page. Part No Z-60/ vii

8 October 006 Parts Stocking List Manuals Genie Industries offers the following support documents for these models: Title Part No. Genie Z-60/ Operator's Manual (before serial number 001) Genie Z-60/ Operator's Manual (from serial number 001 to 5709) Genie Z-60/ Operator's Manual (after serial number 5709) Genie Z-60/ Service Manual (before serial number 1090) Genie Z-60/ Service Manual (from serial number 1090 to 000) Genie Z-60/ Service Manual (after serial number 000) EMI Safety Manual Manual of Responsibilities ANSI A viii Z-60/ Part No. 1099

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10 October 006 How To Order Parts Please be prepared with the following information when ordering replacement parts for your Genie product: Machine model number Machine serial number Genie part number Part description and quantity Purchase order number "Ship to" address Desired method of shipment Name and telephone number of the authorized Genie Distributor in your area Use the Service Parts Fax Order Form on the next page and fax your order to our Parts Department. Genie North America Telephone (5) Toll Free (877) in U.S.A. and Canada Fax (5) Genie UK Parts Telephone () (0) Parts Fax () (0) Genie Australia Parts Telephone (617) Parts Fax (617) Genie France Parts Telephone () (0) Parts Fax () (0) Genie Germany Parts Telephone (9) (0) Parts Fax (9) (0) Machine Information Model Serial Number Date of Purchase Authorized Genie Distributor Phone Number Genie Scandinavia Parts Telephone (6) (1) 0961 Parts Fax (6) (1) 0961 Genie Iberica Parts Telephone () (9) Genie Brazil Parts Telephone (55) (11) Parts Fax (55) (11) Genie Japan Parts Telephone (81) () 5608 Parts Fax (81) () 5608 Genie China Parts Telephone (86) (15) Parts Fax (86) (15) x Z-60/ Part No. 1099

11 Service Parts Fax Order Form Fax to: (5) or Toll Free: International: Please fill out completely Date Account Number Your Name Your Fax Number Your Phone Number Bill To Ship To remove this page and make copies Purchase Order Number Ship Via Model(s) Serial No.(s) Optional Equipment Part Number Description Quantity Price remove this page and make copies All back-ordered parts will be shipped when available via the same ship method as the original order unless Noted below: Ship complete order only - No back orders Ship all available parts and contact customer on disposition of back-ordered parts Other (please specify) FOR GENIE INDUSTRIES USE ONLY Order Number Origin Code Comments Date Scheduled Ship Condition Order Total Terms Code

12

13 October 006 Parts Figures Part No Z-60/

14 100 Decals October 006 Figure Rev Description F Decals with Words 8158 or or Serial plate or or or or or or or 85 Drive Chassis Tank Side Shading indicates decal is hidden from view, i.e. under covers or 89 or Platform 8590 or or 89 Engine Side or or or or 986 or or 9758 or or 986 or Z-60/ Part No. 1099

15 October Decals Decals with Words Rev F Decal Kit - Safety/Instructional (includes items 1-9, 1-1, 16-0,, -1, 8, 9, 1-9) (before serial number 5710) 1111 Decal Kit - Safety/Instructional (includes items 1-9, 1-1, 16-0,, -1, 8, 9, 1-9) (after serial number 5709) 9788 Label - Software, ALC 500 (located inside the platform box) Caution - Component Damage, Hydraulic Valves Arrow - Blue Arrow - Yellow Triangle - Blue Triangle - Yellow Danger - Electrocution Hazard Label - Unleaded Label - Diesel Label - Liquid Petroleum Gas Warning - Crushing Hazard Notice - Maximum Side Force 150 lbs / 667 N (USA / Canada models) (before serial number 5710) Notice - Maximum Side Force 150 lbs / 667 N (USA / Canada models) (after serial number 5709) 986 Notice - Maximum Manual Force 90 lbs / 00 N (Australia models) Notice - Hazardous Materials Notice - Foot Switch Label - No Smoking Label - Power to Platform, 0V AC Caution - Compartment Access Notice - Missing Manuals Warning - Platform Rotate Warning - Shear Point Warning - No Step or Ride Label - Power to Platform, 115V AC Warning - Failure To Read Notice - Max Load 500 lbs / 7 kg Warning - Collision Hazard Danger - Tip-over Hazard, Interlock Danger - General Safety (before serial number 5710) Danger - General Safety (after serial number 5709) 7 78 Label - Generator (option) Danger - Tilt-alarm Notice - Deutz Engine Specifications (before serial number 608) Notice - Deutz Engine Specifications (after serial number 607) Notice - Align Air Hoses Label - Lanyard Anchorage Label - Air Line to Platform Cosmetic - Genie Z-60/ Cosmetic - x Cosmetic - x Cosmetic - Genie Boom Label - Serial Number, Mylar Overlay - Clear 8 89 Notice - Tire Specifications, High flotation Platform Control Panel Clear Protector 0 8 Label - Fault Codes... 1 This list continues on the next page. Part No Z-60/

16 100 Decals October 006 Figure Rev Description F Decals with Words 8158 or or Serial plate or or or or or or or 85 Drive Chassis Tank Side Shading indicates decal is hidden from view, i.e. under covers or 89 or Platform 8590 or or 89 Engine Side or or or or 986 or or 9758 or or 986 or Z-60/ Part No. 1099

17 October Decals Decals with Words Rev F 1 88 Notice - Operating Instructions (before serial number 5710) Notice - Operating Instructions (after serial number 5709) 816 Notice - Tire Specifications Label - Chevron Rykon Label - Wheel Load Notice - Perkins Engine Specifications Ground Control Panel Notice - Ford Engine Specifications (before serial number 61) Notice - Ford Engine Specifications (after serial number 60) Warning - Explosion Hazard Label - Lower Mid-rail Caution - 1 V Electrical, Ford DSG- models (after serial number 615) Label - Transport Diagram... Part No Z-60/

18 100 Decals October 006 Figure Rev Description 10.1 G Decals with Symbols 8158 or Serial plate or or Tank Side or 5967 Drive Chassis Shading indicates decal is hidden from view, i.e. under covers Platform or or or or or Engine Side Z-60/ Part No. 1099

19 October Decals Decals with Symbols 10.1 Rev G Decal Kit - Safety/Instructional (includes items 1-10, 1, 19-6, 9- and 5) 9788 Label - Software, ALC 500 (located inside the platform box) 1 70 Arrow - Blue Arrow - Yellow Triangle - Blue Triangle - Yellow Label - Unleaded Label - Diesel Label - Liquid Petroleum Gas Label - No Smoking Label - Power to Platform, 0V AC Label - Power to Platform, 115V AC Label - Generator (option) Label - Lanyard Anchorage Label - Air Line to Platform Cosmetic - Genie Z-60/ Cosmetic - x Cosmetic - x Cosmetic - Genie Boom Label - Lights Platform Control Panel Clear Protector 0 87 Warning - Crushing Hazard Caution - Compartment Access Label - Read the Manual Danger - Electrocution Hazard Danger - Maximum Capacity, 7 kg Warning - Platform Rotate Ground Control Panel Label - Tire Pressure Label - Wheel Load Notice - Maximum Manual Force, 667 N (Asia / South America) Notice - Maximum Manual Force, 00 N (European models) Warning - Collision Hazard Warning - Shear Point Label - Drive Enable Patch Caution - Shutoff Valves Label - Lower Mid-rail Label - Transport Diagram Label db (European Models)... 1 Part No Z-60/

20 00 Drive Chassis Components October 006 Figure Rev Description 01.1 A Steer Axle Linkage, Oscillate Models (WD, WD) Z-60/ Part No. 1099

21 October Drive Chassis Components Steer Axle Linkage, Oscillate Models (WD, WD) 01.1 Rev A Tie Rod Oscillate Hydraulic Cylinder (includes item ) Seal Kit 7 Counterbalance Valve 5071 Bearing, 1.5 x 1.75 x 1.5 inches Screw - HHC, / -1 x 1.5 inches, GR Lock Washer, 1 / inch Rod End, 0.5 x.75 inches Pivot Pin,.5 x.88 inches Clevis Pin, 1 x.5 inches Steer Cylinder Seal Kit Bearing, 1 x 1.5 x 1 inch Roll Pin, 0.5 x.5 inches Pivot Pin,.76 x 1.5 inches Yoke Assembly, Tank Side (includes items and 10) Low Profile Nylock Nut, 1 / Screw - HHC, / -1 x inches, GR Flat Washer,.5 x x 0.06 inch Thrust Washer,.56 x x 0.18 inch Bearing,.5 x.75 x inches Steer Axle Assembly (includes items 10 and 18) Yoke Assembly, Engine Side (includes items and 10) Rod End, 0.75 x.69 inches Screw - HHC, /8-16 x 1 inch, GR Lock Washer, /8 inch 61 Pivot Pin, 1.5 x 10.5 inches Rue Ring, 1 inch... 6 Part No Z-60/

22 00 Drive Chassis Components October 006 Figure Rev Description 0.1 A WD Steer Axle Linkage, Non-oscillate Models Z-60/ Part No. 1099

23 October Drive Chassis Components WD Steer Axle Linkage, Non-oscillate Models 0.1 Rev A Screw - HHC, / -1 x 1.5 inches, GR 5 60 Lock Washer, 1 / inch 018 Rod End, 0.5 x.75 inches Pivot Pin,.5 x.88 inches Rue Ring, 1 inch Clevis Pin, 1 x.5 inches Steer Cylinder Seal Kit 8 55 Bearing, 1 x 1.5 x 1 inch Roll Pin, 0.5 x.5 inches Pivot Pin,.76 x 1.5 inches Bearing, 1.5 x 1.75 x 1.5 inches Yoke Assembly, Tank Side (includes items 8 and 11) Low Profile Nylock Nut, 1 / Screw - HHC, / -1 x inches, GR Shim, 1 Ga Nylock Nut, 5 / Thrust Washer, 1.51 x.5 x inch Thrust Washer,.56 x x 0.18 inch... as needed Bearing,.5 x.75 x inches Steer Axle Assembly (includes items 8 and 17) Yoke Assembly, Engine Side (includes items 8 and 11) Tie Rod Screw - HHC, /8-11 x inches, GR Non-oscillate Mount Screw - HHC, /8-16 x 1 inch, GR Lock Washer, /8 inch Shim, Ga.... Part No Z-60/

24 00 Drive Chassis Components October 006 Figure Rev Description 0.1 C Non-steer Axle Z-60/ Part No. 1099

25 October Drive Chassis Components Non-steer Axle 0.1 Rev C 1 Ref. Oscillate Control Valve (refer to 707.1) 915 Screw - HHC, / -1 x.5 inches, GR Hardened Flat Washer, 1 / inch Lock Washer, 1 / inch 5 66 Screw - HHC, / -0 x inches, GR Nylock Nut, 1 / -0 7 Ref. WD Traction Manifold (refer to 701.1) Ref. WD Traction Manifold (refer to 70.1) Screw - HHC, /8-16 x 1 inch, GR Lock Washer, /8 inch Non-steer Axle Assembly (includes item 11) Bearing,.5 x.75 x inches Shim Washer,.5 x x 0.06 inch... as needed Wheel,.5 x 1 inches Wheel, 15 x 19.5 inches Wheel, 19.5 x inches Lug Nut, 5 /8-18, Rough Terrain Tire, SGL, 15 x 19.5, 16 Ply Turf Tire, 1/18 LL x.5, 1 Ply 710 Non-marking Tire, 15 x 19.5, 16 Ply Tire and Wheel Assembly - Air-filled, Right Side Tire and Wheel Assembly - Air-filled, Left Side Tire and Wheel Assembly - Foam-filled, Left Side Tire and Wheel Assembly - Foam-filled, Right Side Tire and Wheel Assembly - High-flotation Tire and Wheel Assembly - Air-filled, Non-marking, Left Side Tire and Wheel Assembly - Air-filled, Non-marking, Right Side Tire and Wheel Assembly - Foam-filled, Non-marking, Right Side Tire and Wheel Assembly - Foam-filled, Non-marking, Left Side Tire and Wheel Assembly - with Sealant, Air Filled Right Side (includes decal) Tire and Wheel Assembly - with Sealant, Air Filled, Left Side (includes decal) Tire and Wheel Assembly - with Sealant, Air Filled, Set of tires (includes decal) Tire and Wheel Assembly - High-flotation Set of tires with Sealant (includes decal) Tire and Wheel Assembly - High-flotation (includes decal) Screw - HHC, 5/8-11 x inches, GR 8 (before serial number 569) Screw - HHC, M16 x 50 inches, GR 10.9 (from serial 569 to 557) Screw - HHC, Flange 5 /8-11 x inches, GR 8 (after serial number 557) Hardened Flat Washer, /8 inch (before serial number 557)... 1 This list continues on the next page. Part No Z-60/

26 00 Drive Chassis Components October 006 Figure Rev Description 0.1 C Non-steer Axle Z-60/ Part No. 1099

27 October Drive Chassis Components Non-steer Axle 0.1 Rev C Motor and Wheel Drive Assembly (WD models)... Ref. Drive Hub (refer to 07.1) 1016 Seal Kit 1011 Disconnect Kit Brake Kit 1016 End Cover Retaining Ring 1016 Cover Ring Nut Bearing Input Shaft Motor and Wheel Drive Assembly (WD models)... Ref. Drive Hub (refer to 07.1) O-ring, Viton, 0.10 x.77, 75D O-ring, Viton, 0.07 x 0.9, 75D Drive Motor, 5cc (WD models) (shown) Drive Shaft Ball Bearing Drive Shaft Seal Tooth Shaft Retaining Ring Piston Ring Seal Kit Drive Motor, 0cc (WD models) Drive Shaft Ball Bearing Drive Shaft Seal Tooth Shaft Retaining Ring Piston Ring Seal Kit 5969 Spring Clip Nut, 1 / P Non-steer Axle cover Screw - HHC, 1/ -0 x 0.75 inch, GR Axle Rotation Stop Shim, 16.1 x 1.5 x 0.0 inch... as needed Pivot Pin,.5 x.88 inches Rod End, 0.5 x.75 inches Screw - HHC, / -1 x 1.5 inches, GR 5 89 Drive Chassis Cover with Decals (circle end) Lock Washer, 1 / inch Flat Washer, 1 / inch 7 896P Axle Rotation Stop Bar (oscillate models) P Axle Rotation Stop Bar (non-oscillate models) Part No Z-60/

28 00 Drive Chassis Components October 006 Figure Rev Description 0.1 B WD Steer Axle - Wheels and Hubs Z-60/ Part No. 1099

29 October Drive Chassis Components WD Steer Axle - Wheels and Hubs 0.1 Rev B Screw - HHC, / -0 x 0.75 inch, GR Lock Washer, 1 / inch 668 Flat Washer, 1 / inch 7586 Drive Chassis Cover with Decals (square end) Spring Clip Nut, 1 / Screw - HHC, /8-11 x inches, GR 8 (before serial number 569) Screw - HHC, M16 x 50 inches, GR 10.9 (from serial 569 to 557) Screw - HHC, Flange 5 /8-11 x inches, GR 8 (after serial number 557) Hardened Flat Washer, /8 inch (before serial number 557) Ref. Wheel (refer to 0.1) 9 Ref. Rough Terrain Tire (refer to 0.1) Tire and Wheel Assembly - Air-filled, Right Side Tire and Wheel Assembly - Air-filled, Left Side Tire and Wheel Assembly - Foam-filled, Right Side Tire and Wheel Assembly - Foam-filled, Left Side Tire and Wheel Assembly - High-flotation Tire and Wheel Assembly - Air-filled, Non-marking, Left Side Tire and Wheel Assembly - Air-filled, Non-marking, Right Side Tire and Wheel Assembly - Foam-filled, Non-marking, Left Side Tire and Wheel Assembly - Foam-filled, Non-marking, Right Side Lug Nut, 5 /8-18, Ref. WD Hub (refer to 06.1) Part No Z-60/

30 00 Drive Chassis Components October 006 Figure Rev Description 05.1 B WD Steer Axle - Wheels and Hubs Z-60/ Part No. 1099

31 October Drive Chassis Components WD Steer Axle - Wheels and Hubs 05.1 Rev B Screw - HHC, / -0 x 0.75 inch, GR Lock Washer, 1 / inch 668 Flat Washer, 1 / inch 7586 Drive Chassis Cover with Decals (square end) Spring Clip Nut, 1 / Wheel,.5 x 1 inches, 9 hole Wheel, 19.5 x inches, 9 hole 7 Ref. Tire (refer to 0.1) Lug Nut, 5 /8-18, Motor and Wheel Drive Assembly... Ref. Drive Hub, 56:1 (refer to 07.1) O-ring, Viton, 0.10 x.77, 75D O-ring, Viton, 0.07 x 0.9, 75D... 1 Ref. Drive Motor (refer to 0.1) Screw - HHC, 5/8-11 x inches, GR 8 (before serial number 569) Screw - HHC, M16 x 50 inches, GR 10.9 (from serial 569 to 557) Screw - HHC, Flange 5/8-11 x inches, GR 8 (after serial number 557) Hardened Flat Washer, 5/8 inch (before serial number 557) Hose Guide Bracket Screw - HHC, /8-16 x 1.5 inches, GR Lock Washer, /8 inch Hardened Flat Washer, 0.1 inch... Part No Z-60/

32 00 Drive Chassis Components October 006 Figure Rev Description 06.1 B WD Hub - Steer Axle Z-60/ Part No. 1099

33 October Drive Chassis Components WD Hub - Steer Axle 06.1 Rev B 8888 WD Hub, Front 1016 Seal Kit Wheel Stud, 5 / Inner Bearing Oil Seal Hub Cover Ring Seal Shim Outer Bearing... 1 Part No Z-60/

34 00 Drive Chassis Components October 006 Figure Rev Description 07.1 A WD and WD Drive Hub Z-60/ Part No. 1099

35 October Drive Chassis Components WD and WD Drive Hub 07.1 Rev A WD Wheel Drive, 56: WD Wheel Drive, 56: Disconnect Kit End Cover Seal Kit Thrust Bearing Plate Pinion Gear Thrust Bearing External Retaining Ring Internal Retaining Ring Pinion, Half Shaft Half Shaft External Retaining Ring Cylindrical Roller Bearing O-ring, Casting Input Shaft Ball Bearing Wire Seal Retaining Ring Tapered Roller Bearing Internal Retaining Ring Shaft Bearing Spacer Brake Kit, WD Brake Kit, WD Ring Nut Stud Wheel... 9 Part No Z-60/

36 Turntable Components October 006 Figure Rev Description 01.1 E Hydraulic and Fuel Tanks - Gasoline/LPG Models C L Z-60/ Part No. 1099

37 October Turntable Components Hydraulic and Fuel Tanks - Gasoline/LPG Models 01.1 Rev E 1 15 Tank Strap with Rubber Strip, 66 inches Rubber Bumper Strip... inches 597 Flat Washer, 5 /16 inch 88 Nylock Nut, / Hydraulic Tank Assembly with Word Decals, 5 Gallons / 170 liters (includes items 5-7, 10 and 0) Hydraulic Tank Assembly with Symbol Decals, 5 Gallons / 170 liters (includes items 5-7, 10 and 0) Fluid Level Indicator Filler Neck Strainer (before serial number 8) Filler Neck Strainer (after serial number 8) Breather Cap Hydraulic Filter Assembly with Indicator Fiberglass Filter Element 9 89 Fitting (before serial number 8) Fitting (after serial number 8) Strainer Assembly (before serial number 8) Strainer Assembly (after serial number 8) Ball Valve, 16 MPT x 16 FPT (before serial number 8) Ball Valve, 16 MSAE x 16 FSAE (after serial number 8) Adapter - Connector, 16 ORFS x 16 SAE (before serial number 8) Adapter - Connector, 16 ORFS x 16 SAE (after serial number 8) Screw - HHC, / -0 x 0.75 inch Flat Washer, 1 / inch Low Profile Nylock Nut, 1 / Rubber Cushioned Clamp,.75 inches Fuel Pre-filter Hose Clamp, 1 / inch Fuel Hose, 5 /16 inch inches Fuel Pump Fuel Hose, High Pressure, 5 /16 inch inches 6589 Connector Fitting Manual Fuel Shutoff Valve Fuel Hose, 5 /16 inch... 8 inches Screw - HHC, /8-16 x.5 inches Flat Washer, /8 inch S Fuel Tank Assembly with Decal 0 Gallons / 76 liters (includes item 9) Vented Anti-surge Cap, Red Drain Plug, 1 MPT (before serial number 8) Drain Plug, SAE-6 (after serial number 8) Low Profile Nylock Nut, / Screw - HHC, /8-16 x 1 inch, GR S LPG Tank Mount LPG Hose Assembly (before serial number 56) LPG Hose Assembly (after serial number 55) The length listed in the component description is the length of the hose only. Refer to 71.1 to cross-reference Genie part numbers to Parker part numbers. Part No Z-60/

38 C L Turntable Components October 006 Figure Rev Description 0.1 D Hydraulic and Fuel Tanks - Diesel Models Z-60/ Part No. 1099

39 October Turntable Components Hydraulic and Fuel Tanks - Diesel Models 0.1 Rev D 1 15 Tank Strap with Rubber Strip, 66 inches Rubber Bumper Strip... inches 111 Fluid Level Indicator Hydraulic Tank Assembly with Word Decals, 5 Gallons / 170 liters (includes items 5-7, 10 and 0) Hydraulic Tank Assembly with Symbol Decals, 5 Gallons / 170 liters (includes items 5-7, 10 and 0) 1506 Filler Neck Strainer (before serial number 8) Filler Neck Strainer (after serial number 8) Breather Cap Hydraulic Filter Assembly with Indicator Indicator 601 Fiberglass Filter Element 7 89 Fitting (before serial number 8) Fitting (after serial number 8) Strainer Assembly (before serial number 8) Strainer Assembly (after serial number 8) Ball Valve, 16 MPT x 16 FPT (before serial number 8) Ball Valve, 16 MSAE x 16 FSAE (after serial number 8) Adapter - Connector, 16 ORFS x 16 SAE (before serial number 8) Adapter - Connector, 16 ORFS x 16 SAE (after serial number 8) Fuel Hose, 5 /16 inch (before serial number 60) inches 709 Fuel Hose, 5 /16 inch (after serial number 69) inches Hose Clamp, 1 / inch Fitting Manual Fuel Shutoff Valve Fuel Hose, 1 / inch inches Fitting Screw - HHC, /8-16 x.5 inches, GR Flat Washer, /8 inch Flat Washer, 5 /16 inch 0 88 Nylock Nut, / S Fuel Tank Assembly with Decal 0 Gallons / 76 liters (includes item ) Tank Fitting Vented Anti-surge Cap, Green Drain Plug, 1 MPT (before serial number 8) Drain Plug, SAE-6 (after serial number 8) The length listed in the component description is the length of the hose only. Refer to 71.1 to cross-reference Genie part numbers to Parker part numbers. Part No Z-60/

40 00 Turntable Components October 006 Figure Rev Description 0.1 B Function Manifold and Auxiliary Power Unit Installation Z-60/ Part No. 1099

41 October Turntable Components Function Manifold and Auxiliary Power Unit Installation 0.1 Rev B Auxiliary Power Unit, 1V DC Motor, 1V DC 668 Pump Check Valve Assembly 719 Motor to Pump Coupler 8998 Positive Battery Cable to Auxiliary Power Unit inches 108 Black Cable Assembly inches 8910 Terminal Cover Boot, Red Red Cable Assembly... 7 inches Screw - HHC, /8-16 x 1 inch, GR Lock Washer, /8 inch Flat Washer, /8 inch 8 Ref. Function Manifold (refer to 70.1) P Manifold Mount Horn, 1V DC Screw - HHC, / - 0 x 1 inch, GR Flat Washer, 5 /16 inch 7569-S Component Tray, Tank Side Spring Clip Nut, / Screw - HHC, 5/8-11 x 1.75 inches, GR Ref. Ground Controls (refer to 06.1 and 07.1) Low Profile Nylock Nut, 1 / Lock Washer, 5 /16 inch Screw - HHC, / -0 x 0.75 inch, GR Level Sensor, P Auxiliary Power Unit Bracket Lock Washer, 1 / inch Flat Washer, 1 / inch Electrical Cord, 1 Ga., Conductor SJO inches Electric Locknut, 1 / inch Squeeze Connector, / inch NPT North American Electrical Plug, 110V AC Pin Electrical Plug (female) 115 British Pin Electrical Plug, 110V AC 6666 European Pin Electrical Plug, 0V AC 588 British Pin Electrical Plug, 0V AC 6577 Fuse, 1A Nylock Nut, 5 / Hardened Flat Washer, 5/8 inch Low Profile Nylock Nut, /8-16 Part No Z-60/

42 00 Turntable Components October 006 Figure Rev Description 0.1 C Turntable Rotation and Hydraulic Rotary Coupler Installation Z-60/ Part No. 1099

43 October Turntable Components Turntable Rotation and Hydraulic Rotary Coupler Installation 0.1 Rev C Screw - HHC, / -1 x 1.5 inches Screw - HHC, 5 /8-11 x inches, GR Hardened Flat Washer, /8 inch Screw - HHC, /8-16 x 1.75 inches, GR Flat Washer, 5 /16 inch 6 88 Nylock Nut, / Port Hydraulic Swivel Seal Kit Screw - SHC, /8-11 x.5 inches, GR Screw - HHC, 1 / x 10 x 0.5 inch Lock Washer, 1 / inch Screw - RHM, 10- x 1.5 inches Flat Washer, No Limit Switch Harness Assembly with Connector Limit Switch 1991 Contact, SPDT Roller Head 9718 Roller Arm P Limit Switch Bracket Nylock Nut, Turntable Rotation Bearing P Hydraulic Swivel Bracket Screw - SHC, 5/8-11 x inches, GR Turntable Rotation Drive Hub, Motor and Brake Assembly (includes items -6) Gear Box Reducer Seal Kit Bearing Kit Pinion Integral Shaft Turntable Rotation Brake Assembly Disc Kit 7568 Spring Kit 666 Brake Seal Kit Turntable Rotation Motor Seal Kit 811 O-ring Turntable Rotation Manifold Counterbalance Valve, 000 psi / 07 bar Seal Kit S Bearing Lubrication Hose Assembly Fitting Fitting (engine side) 1 61 Pin Handle, 0.5 x 6 inches Transport Storage Lock Pin... 1 The length listed in the component description is the length of the hose only. Refer to 71.1 to cross-reference Genie part numbers to Parker part numbers. Part No Z-60/

44 00 Turntable Components October 006 Figure Rev Description 05.1 D Ground Controls - View Z-60/ Part No. 1099

45 October Turntable Components Ground Controls - View Rev D Ref. Platform Overload Module (refer to 80.1) 76 Rubber Boot - Toggle Switch 569 Nylon Spacer, x 0.56 x 0.19 inch Nylon Plug Key Switch, position (includes 1 pair of keys) Key (1 key only) 797 Key (package of 10 keys) 8887 Key Switch Gasket 6681 Red Push Button with Base Base (includes each N.C. contacts) N.C. Contact Hour Meter, 10-80V DC (includes mounting bracket) S Toggle Switch (secondary boom up/down) DPDT, position, Momentary S Toggle Switch (glow plug) (diesel models) SPDT, position, Momentary Plastic Plug (Ford models) S Toggle Switch (engine start) SPDT, position, Momentary S Toggle Switch (function enable) SPDT, position, Momentary Circuit Breaker, 0A (oil cooler option) Circuit Breaker, 15A (engine) Circuit Breaker, 15A (controls) S Toggle Switch (jib boom up/down) SPDT, position, Momentary S Toggle Switch (platform level) SPDT, position, Momentary S Toggle Switch (platform rotate) DPDT, position, Momentary S Toggle Switch (turntable rotate) DPDT, position, Momentary S Toggle Switch (primary boom up/down) DPDT, position, Momentary S Toggle Switch (primary boom extend/retract) SPDT, position, Momentary Toggle Switch (run/test) (Ford models) SPDT, position, Momentary Red LED Indicator Light, 1V DC LED Retainer 58 Plastic Plug S Toggle Switch (gasoline/lpg) (Ford models) DPDT, position, Maintained Plastic Plug S Toggle Switch (auxiliary power) DPDT, position, Momentary Red LED Indicator Light, 1V DC (Ford models) LED Retainer 58 Plastic Plug (diesel models) 6090 Screw - HHC, / -0 x 0.75 inch, GR Lock Washer, 1 / inch Flat Washer, 1 / inch This list continues on the next page. Part No Z-60/

46 00 Turntable Components October 006 Figure Rev Description 05.1 D Ground Controls - View Z-60/ Part No. 1099

47 October Turntable Components Ground Controls - View Rev D Control Box with Decals (before serial number ) Control Box with Decals (from serial number to 95) Control Box with Decals (from serial number 95 to 5175) Control Box with Word Decals Gasoline/LPG Models (after serial number 5175) 1115 Control Box with Word Decals Diesel Models (after serial number 5175) 1116 Control Box with Symbol Decals (after serial number 5175) 078 Gasket 0997 Corrosion Inhibitor Foam 8 88 Nylon Plug, inch... Part No Z-60/

48 00 Turntable Components October 006 Figure Rev Description 06.1 C Ground Controls - View Z-60/ Part No. 1099

49 October Turntable Components Ground Controls - View 06.1 Rev C Squeeze Connector, / inch NPT (oil cooler option) Electric Locknut, 1 / inch 7717 Receptacle Connector, way Receptacle Connector, 8 way Squeeze Connector Lock Nut, 1 inch Receptacle Connector, way Black Domed Nylon Plug, inches... 1 Part No Z-60/

50 00 Turntable Components October 006 Figure Rev Description 07.1 B Ground Controls - View Z-60/ Part No. 1099

51 October Turntable Components Ground Controls - View 07.1 Rev B Terminal Rail Assembly (includes item ) Terminal Block Mounting Rail, 17 inches 791 End Plate 790 Number Marking Tags, Number Marking Tags, Number Marking Tags, Number Marking Tags, Number Marking Tags, Ignition/Start Module (Diesel models) End Stop Screw - PHM, 10- x 0.5 inch Nylock Nut, SPDT Relay, 1V DC (Ford models) SPDT Relay, 1V DC (Diesel models) SPDT Relay Socket... as needed 05 Relay Socket Terminal, 10-1 Ga. 055 Relay Socket Terminal, 1-16 Ga. 056 Relay Socket Terminal, 18-0 Ga Relay Mount Bracket Nutsert 1 / Screw - HHC, 1 / -0 x 0.75 inch, GR 5 Part No Z-60/

52 00 Turntable Components October 006 Figure Rev Description 08.1 B Turntable Covers Z-60/ Part No. 1099

53 October Turntable Components Turntable Covers 08.1 Rev B Turntable Cover Assembly with Word Decals - Tank Side (includes item 1) (before serial number 710) Turntable Cover Assembly with Word Decals - Tank Side (includes item 1) (after serial number 709) 1050 Turntable Cover Assembly with Symbol Decals - Tank Side (includes item 1) 6019 Screw - HHC, /8-16 x 1.5 inches 597 Flat Washer, 5 /16 inch 88 Nylock Nut, / Screw - HHC, / -0 x 1 inch Fender Washer, 0.5 x 1.5 x 0.06 inch Flat Washer, 1 / inch Nylock Nut, 1 / Turntable Cover Assembly with Word Decals, Engine Side (Ford and Perkins models) (includes items, 11-1) Turntable Cover Assembly with Word Decals, Engine Side (Deutz models) (includes items, 11-1) 105 Turntable Cover Assembly with Symbol Decals, Engine Side (Ford and Perkins models) (includes items, 11-1) 105 Turntable Cover Assembly with Symbol Decals, Engine Side (Deutz models) (includes items, 11-1) P Air Intake Screen (Deutz models) (before serial number 606) P Air Intake Screen (Deutz models) (after serial number 605) 9618-S Air Intake Screen (Ford and Perkins models) Aluminum Rivet, 0.75 x 0.5 inch Turntable Cover Latch (includes mounting fasteners) Key Cover Mounting Hinge Hinge Spacer S Cover Support, Engine Side Gas Strut Retaining Spring Ball Stud Nylock Nut, 5 / P Latch Plate Bulkhead Cover Support, Engine Side Screw - HHC, / -0 x 1.5 inches 178 Bearing Lubrication Hose Assembly Lock Washer, /8 inch 9868 Spring Clip Nut, / Female Bulkhead Adapter, JIC Grease Fitting Rubber Bumper Screw - HHC, /16-18 x 1 inch GR Bulkhead Cover Support, Tank Side S Cover Support, Tank Side... 1 Part No Z-60/

54 00 Turntable Components October 006 Figure Rev Description 09.1 A Turntable Counterweight Z-60/ Part No. 1099

55 October Turntable Components Turntable Counterweight 09.1 Rev A Turntable Counterweight, 5959 lbs Screw - HHC, 1-8 x 17 inches 1775 Flat Washer, 1.06 x x Flat Washer, 1 x.5 x 0.1 inch Lock Washer, 1 inch 6 65 Jam Nut, 1-8 Part No Z-60/

56 00 Engine Components October 006 Figure Rev Description 01.1 D Perkins 0- Engine - View Z-60/ Part No. 1099

57 October Engine Components Perkins 0- Engine - View Rev D 899 Perkins Engine Harness (before serial number 56) Perkins Engine Harness (after serial number 56) 7056 Exhaust Scrubber Option 79 Water Temperature Switch (before serial number 56) Water Temperature Switch (after serial number 56) 77 Oil Pressure Switch (before serial number 56) Oil Pressure Switch (after serial number 56) Coolant Return Tank with Hose Hose Clamp 77 Return Tank Cap Screw - HHC, / -0 x 1 inch 668 Flat Washer, 1 / inch Nylock Nut, 1 / Air Filter Assembly Air Filter Cap 60 Air Filter Element 678 Nut, Nylock, 5 / Flat Washer, 5 /16 inch 6888 Screw - HHC, /16-18 x 1.5 inches Air Cleaner Bracket Hose Clamp,.5 inches Air Cleaner Outlet Hose Exhaust Pipe Exhaust Manifold 7 Exhaust Manifold Gasket 7 Stud, M8 x 1.5 x 5 mm 685 Flanged Nut, M Engine Tray (before serial number 6) Engine Tray (after serial number 6) P Hose Restraint Bracket Clamp,.5 inches Upper Radiator Hose P Radiator Fan Shroud P Fan Guard Screw - PHPM, 10- x 0.5 inch Flat Washer, # Lower Radiator Hose Screw - HHC, M1 x 1.5 x 1.57 inches Lock Washer, M1 911 Flat Washer, M Oil Dipstick Nylock Nut, 1 / Screw - HHC, 1/ -1 x.75 inches Engine Vibration Isolator Flat Washer, 1 / inch P Cast Flat Washer 9 88 Nylock Nut, / Screw - HHC, /8-16 x 1 inch Flat Washer, 5 /16 inch 6090 Screw - HHC, / -0 x 0.75 inch 656 Lock Washer, 1 / inch 509 Wear Pad, x x 0.5 inch P Outboard Engine Mount P Inboard Engine Mount 6 Ref. Function Pump (refer to 706.1) 7 Ref. Drive Pump (refer to 706.1) Lock Washer, /8 inch Fuel Filter Assembly Filter Element 0 78 Lift Pump O-ring Threaded Rod, 1/ -0 x 9.75 inches Wing Nut, 1 / -0 This list continues on the next page. Part No Z-60/

58 00 Engine Components October 006 Figure Rev Description 01.1 D Perkins 0C- Engine - View Z-60/ Part No. 1099

59 October Engine Components Perkins 0C- Engine - View Rev D 01 Battery Hold-down Battery, 1V DC, 1000 CCA Positive Battery Cable, 78 inches 8156 Negative Battery Cable, 8 inches 9869 Corrosion Inhibitor 1011P Radiator Baffle Air Cleaner Inlet Hose Radiator Radiator Cap P Upper Radiator Support Bracket... 1 Part No Z-60/

60 00 Engine Components October 006 Figure Rev Description 0.1 A Perkins 0C- Engine - View Z-60/ Part No. 1099

61 October Engine Components Perkins 0C- Engine - View 0.1 Rev A Vibration Isolator, M Oil Cap Thermostat Housing Exhaust tailpipe P Muffler Mount Muffler Muffler (scrubber option) 7085 Clamp, inches Muffler Strap Starter Solenoid Starter Alternator Bracket Alternator, 1V DC, 55 A... 1 (before serial number 56) Alternator, 1V DC, 65 A (after serial number 56) Screw - HHC, M1 x 1.5 x 0 mm, GR Lock Washer, M Flat Washer, M Nylock Nut, 1 / Screw, HHC, / -1 x.75 inches Vibration Isolator P Cast Flat Washer Nylock Nut, / Screw - HHC, /8-16 x 1 inch Flat Washer, 5 /16 inch 778 Fan Fan Spacer Shutoff Solenoid Oil Pressure Switch Screw - HHC, /16-18 x 1 inch Flat Washer, 5 /16 inch Low Profile Nylock Nut, 5 / Throttle Linkage Clevis Yoke, 1 / Hex Nut, 1 / Oil Filter Screw - HHC, 1 / -0 x 1 inch 668 Flat Washer, 1 / inch 6091 Nylock Nut, 1 / Throttle Solenoid Screw - HHC, / -0 x 1.5 inches 7 978P Fuel/Water Separator Bracket Fuel/Water Separator Fuel/Water Separator Element Medium Pressure Filter Assembly Filter Element Screw - HHC, /8-16 x 1.5 inches P Medium Pressure Filter Bracket Bell Housing Kit Pump Coupler, 15 Tooth Pump Mount Housing 8977 Coupler Flex Plate 8977 Hardware Kit 057 Screw - HHC, M8 x 1.5 x 0 mm 908 Lock Washer, M Flat Washer, /8 inch P Muffler Support Bracket Radiator Isolators Clamp, 1.88 inches V-belt Water Pump Water Pump Pulley Water Pump Hose Water Temperature Switch... 1 Part No Z-60/

62 00 Engine Components October 006 Figure Rev Description 0.1 A Deutz FL 1011F Engine - View 1 (before serial number 608) Z-60/ Part No. 1099

63 October Engine Components Deutz FL 1011F Engine - View 1 (before serial number 608) 0.1 Rev A 59 Manual - Workshop Deutz, FL-1011F 895 Engine Wire Harness Air Intake Gasket P Air Intake Baffle Screw - HHC, M8-1.5 x 60 mm, GR Flat Washer, M Screw - HHC, M8-1.5 x 0 mm, GR Engine Pulley Cover V-belt Starter Solenoid Starter Screw - HHC, M1 - x 55 mm, GR Lock Washer, M Rear Engine Mount Screw - HHC, 5/8-11 x.5 inches, GR Inboard Engine Mount Outboard Engine Mount Screw - HHC, M8-1.5 x 100 mm, GR Plate Washer, /8 x.5 x 0.15 inch Vibration Isolator, Red and White (pair) P Hose Restraint Bracket Nylock Nut, 1 / Flat Washer, 1 / inch Screw - HHC, / -0 x 1 inch, GR S Engine Tray Battery, 1V DC, 1000 CCA Corrosion Inhibitor Grease 01 Battery Hold Down Threaded Rod, / -0 x 9.75 inches Wing Nut, 1 / -0 Part No Z-60/

64 00 Engine Components October 006 Figure Rev Description 0.1 A Deutz FL 1011F Engine - View (before serial number 608) Z-60/ Part No. 1099

65 October Engine Components Deutz FL 1011F Engine - View (before serial number 608) 0.1 Rev A 1 09 Exhaust Pipe Screw - HHC, M x 0 mm, GR Lock Washer, M Flat Washer, /8 inch Nut, 5 / Lock Washer, 5 /16 inch Flat Washer, 1 / inch U-bolt, 5 /16-18 x.5 inches 9 79P Exhaust Support Bracket Clamp -.5 inches Muffler Muffler Gasket Engine Side Cover (includes mounting fasteners) Fuel Injector (Non-EPA models) Fuel Injector (EPA models) Fuel Line Injector Pump (Non-EPA models) Injector Pump (EPA models) Fitting S Hose Assembly - Components: Genie part numbers 881, 8819 and inches Wear Pad, x x 0.5 inch Screw - HHC, / -0 x 0.75 inch, GR Mount Plate Screw - HHC, / -1 x 1.5 inches, GR Lock Washer, 1 / inch 1 Ref. O-ring (refer to 706.1) Screw - HHC, /8-16 x 1 inch, GR Lock Washer, /8 inch Ref. Function Pump (Non-oscillating models) (refer to 706.1) 5 Ref. Drive Pump (refer to 706.1) Lock Washer, 1 / inch 988 Screw - HHC, 5 /8-11 x 1.75 inches, GR Lock Washer, 5 /8 inch 106 Hardened Flat Washer, 5 /8 inch Pump Coupler Ring Gear Flex Plate... 1 The length listed in the component description is the length of the hose only. Refer to 71.1 to cross-reference Genie part numbers to Parker part numbers. Part No Z-60/