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Terex Genie Z-80/60 Articulated Boom Lift Service Manual

215 pages · Publication 1268556

$69.81
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Models
Genie Z-80/60
Serial coverage
from Z8013-4592 to Z8016H-6399, from Z80H-6400
Manual type
Service Manual
Pages
215
Publication
1268556
Condition
Brand new
Terex Genie Z-80/60 Articulated Boom Lift Service Manual, publication 1268556

What's inside

From the manual's own table of contents: 114 sections, 151 entries. See sample pages (PDF, 576 KB)

Introduction Introduction
Important Information
Find a Manual for this Model
Serial Number Legend
Section 1 Safety Rules
General Safety Rules
Section 2 Specifications
Machine Specifications
Performance Specifications
Hydraulic Oil Specifications
Hydraulic Component Specifications
Continental TME27 Engine Specifications
GM 3.0L Engine Specifications
Deutz TD2011L04i Engine Specifications
Deutz TD 2.9 Engine Specifications
Perkins 404D-22 Engine Specifications
Perkins 404F-22T Engine Specifications
Perkins 804D-33 Engine Specifications
Machine Torque Specifications
Hydraulic Hose and Fitting Torque Specifications
Torque Procedure
Section 3 Repair Procedures
Introduction
Platform Controls
Show all 114 sections
Platform Circuit Board1 topic
  • How to Remove the LED Circuit Board
Joysticks - How to Calibrate a Joystick4 topics
  • How to Reset a Proportional Valve Coil Default
  • How to Set the Function Thresholds and Default Functions Speeds
  • How to Adjust the Function Speeds
  • How to Adjust the Function Ramp Rate Setting
Platform Components
Platform
Platform Leveling Cylinder2 topics
  • How to Remove the Platform Leveling Cylinder
  • How to Bleed the Platform Leveling Cylinder
Platform Rotator1 topic
  • How to Bleed the Platform Rotator
Platform Overload System (if equipped)
Platform Overload Recovery Message
Jib Boom Components
Jib Boom
Jib Boom Lift Cylinder
Boom Components
Primary Boom Cable Track1 topic
  • How to Repair the Primary Boom Cable Track
Primary Boom2 topics
  • How to Shim the Primary Boom
  • How to Disassemble the Primary Boom
Primary Boom Lift Cylinder
Primary Boom Extension Cylinder
Primary Boom Angle Sensor2 topics
  • How to Replace the Primary Boom Angle Sensor
  • How to Calibrate the Primary Boom Angle Sensor
Secondary Boom Cable Track2 topics
  • How to Remove the Secondary Boom Cable Track
  • How to Repair the Secondary Boom Cable Track
Secondary Boom
Secondary Boom Lift Cylinder
Secondary Boom Extension Cylinder
Engines
RPM Adjustment
Flex Plate3 topics
  • How to Remove the Flex Plate
  • How to Install the Flex Plate
  • How to install the Pump and Bell Housing Assembly
How to Access Perkins 404F Engine Regeneration Service
Ground Controls
Bypass/Recovery Key Switch1 topic
  • How to Use the Recovery Mode
Circuit Boards
Membrane Decal
Display Module
Hydraulic Pumps
Function Pump
Drive Pump1 topic
  • How to Prime the Drive Pump
Manifolds
Function Manifold Components - View 1
Function Manifold Components - View 2
Valve Adjustments - Function Manifold7 topics
  • How to Adjust the System Relief Valve
  • How to Adjust the Primary Boom Down Relief Valve
  • How to Adjust the Primary Boom Extend Relief Valve
  • How to Adjust the Secondary Boom Up Relief Valve
  • How to Adjust the Secondary Boom Down Relief Valve
  • How to Adjust the Secondary Boom Extend Relief Valve
  • How to Adjust the Platform Manifold Relief Valve
Platform Manifold
Turntable Rotation Manifold
Platform Rotate Manifold
Two Wheel Steer and Oscillate Manifold1 topic
  • How to Adjust the Oscillate Relief Valve
Four Wheel Steer and Oscillate Manifold
Oil Diverter Manifold Components (welder option)
Traction Manifold Components, 2WD
Valve Adjustments, 2WD Traction Manifold
Traction Manifold Components, 4WD
Valve Adjustments, 4WD Traction Manifold
Valve Coils
Turntable Rotation Components
Turntable Rotation Assembly1 topic
  • How to Adjust the Turntable Rotation Gear Backlash
Axle Components
Steer Sensors4 topics
  • How to Measure the Tire Alignment
  • How to Adjust a Steer Sensor
  • How to Calibrate the Steer Sensors
  • How to Adjust the Oscillate Limit Switches
Oscillating Axle Cylinders
Section 4 Fault Codes
Control System Fault Codes
How to Read Control System Fault Codes
How to Clear Secondary Boom Safety Switch Faults
Fault Code Source
Fault Code Display - Deutz and Perkins Models1 topic
  • Models
Deutz D 2.9 L4 Engine Fault Codes
Perkins 404 Engine Fault Codes
Continental TME27 Engine Fault Codes3 topics
  • How to Retrieve Continental Engine Fault Codes
  • How to Clear Engine Fault Codes from the ECM
  • Continental TME27 Engine Fault Codes
GM 3.0L Engine Fault Codes
GM Fault Code Chart
Section 5 Schematics
Wire Circuit Legend
Wire Color Legend
Limit Switches and Angle Sensors
Drive Chassis and Platform Controller Pin Legend
Turntable Controller Pin Legend
Relay and Fuse Panel Legends
Electrical Symbol Legend
Hydraulic Symbols Legend
Electrical Schematics
Electrical Schematic - Engine Options, Deutz TD2.9 Engine
Electrical Schematic - Engine Options, Deutz TD2.9 Engine Harness
Electrical Schematic - Engine Options,Perkins 404F-22T Engine
Electrical Schematic - Engine Options, Perkins 404F-22T Engine Harness
Electrical Schematic - Engine Options, Perkins 804D Engine
Electrical Schematic - Engine Options, Continental TME27 Engine
Electrical Schematic - Engine Options, GM 3.0 Engine
Electrical Schematic - Engine Options, Perkins 404D-22T Engine
Electrical Schematic - Safety Circuits
Electrical Schematic - Generator Options
Electrical Schematic - Welder Generator Option
Electrical Schematic - Hydraulic Generator Options
Hydraulic Schematics
Hydraulic Schematic - 2 Wheel Drive (2 and 4 Wheel Steer)
Hydraulic Schematic - 4 Wheel Drive (2 and 4 Wheel Steer)
Electrical Schematic – (from Z8016H-6188)

Inside this manual

Real pages from this service manual (215 pages). Open the sample pages (PDF, 576 KB)

Sample pages from the Terex Genie Z-80/60 Articulated Boom Lift Service Manual: Specifications, Troubleshooting, Diagram, Foldout diagram (color)
  • Specifications, page 26: Specifications
  • Troubleshooting, page 140: Fault Code Display - Deutz and Perkins Models
  • Diagram, page 191: Electrical Schematic - Engine Options,
  • Foldout diagram (color), page 199: December 2017

Other manuals for this machine

Save 10% on 2 manuals, 15% on 3 or more. Other manuals for the Genie Z-80/60 are listed below. Editions cover different serial number ranges: check the serial coverage and tick only the ones that match your machine.

This manual: Service Manual 1268556$69.81
Other manuals for the Genie Z-80/60

Parts manuals

Details
Details

This is a service manual

Here's how it compares to the other manual types.

This manual

Service manual

Factory repair procedures and technical information such as specifications, troubleshooting, and wiring and hydraulic diagrams, for the models and systems the manual covers. See What's inside for its topics.

Operator's manual

Safe operation, controls, maintenance schedules, lubrication points, inspections, and basic checks. Repair procedures are in the service manual.

Parts manual

Illustrated diagrams with factory part numbers for identifying components and ordering parts. Repair procedures are in the service manual.

Engine service manuals are sometimes sold separately, since certain machine models were offered with more than one engine option.

What it's used for

Factory manual for in-house farm and construction shop use. Straightforward, complete, and easy to follow. It contains the OEM information dealership service departments and parts counters use to diagnose problems, identify components, and perform maintenance or repairs correctly.

Service shops and owner/operators who repair their own equipment

Identifying correct parts and seeing how assemblies come apart and go back together

Keeping equipment running with less downtime

Factory manual, 215 pages

Quantity one is the manual described above.

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Ships in 1 business day.

60-day returns

Free if the mistake is ours. A manual ordered in error must come back unopened in its shrink-wrap; you pay return shipping and a 20% restocking fee applies. Return policy

Other editions and similar models

Questions about model, serial number, engine coverage or contents? Contact us before purchasing and we'll help confirm it's the right manual. Please verify the manual type, machine model, serial number range and engine coverage before purchasing: manuals ordered in error carry a 20% restocking fee (return policy).