Terex Genie Z-80/60 Articulated Boom Lift Service Manual
324 pages · Publication 88619
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- Models
- Genie Z-80/60
- Serial coverage
- from Z80-101to Z8013-4591
- Manual type
- Service Manual
- Pages
- 324
- Publication
- 88619
- Condition
- Brand new
What's inside
From the manual's own table of contents: 159 topics. See sample pages (PDF, 992 KB)
- Important Information
- Serial Number Legend
- General Safety Rules
- Machine Specifications
- Performance Specifications
- Function Speeds Specifications
- Hydraulic Oil Specifications
- Hydraulic Component Specifications
- Manifold Component Specifications
- Valve Coil Resistance Specifications
- GM 3.0L EFI Engine
- Ford LRG-425 Engine
- Continental TME27 Engine
- Deutz F4L-913 Engine (before serial number 339)
- Deutz TD2011L04i Engine (from serial number 2178)
- Perkins 704-30 Engine
- Machine Torque Specifications
- Hydraulic Hose and Fitting Torque Specifications
- SAE and Metric Fasteners Torque Charts
- Introduction
- Pre-Delivery Preparation
- Maintenance Inspection Report
- Inspect the Manuals and Decals
- Perform Pre-operation Inspection
Show all 159 topics
- Perform Function Tests
- Perform Engine Maintenance
- Check the Hydraulic Filter Condition Indicators
- Perform 30 Day Service
- Perform Engine Maintenance - Continental Models
- Perform Engine Maintenance - Perkins and Continental Models
- A-10 Grease the Turntable Rotation Bearing and Rotate Gear
- A-11 Inspect the Fuel Filter/Water Separator - Diesel Models
- A-12 Replace the Drive Hub Oil
- A-13 Perform Engine Maintenance - GM and Ford Models
- Inspect the Batteries
- Inspect the Electrical Wiring
- Test the Key Switch
- Check the Exhaust System
- Inspect the Engine Air Filter
- Engine Maintenance - Deutz F4L913 and Continental Models
- Check the Tires, Wheels and Lug Nut Torque
- Confirm the Proper Brake Configuration
- Check the Drive Hub Oil Level and Fastener Torque
- B-10 Test the Ground Control Override
- B-11 Test the Platform Self-leveling
- B-12 Test the Engine Idle Select Operation
- B-13 Test the Fuel Select Operation - Gasoline/LPG Models
- B-14 Test the Drive Brakes
- B-15 Test the Drive Speed - Stowed Position
- B-16 Test the Drive Speed - Raised or Extended Position
- B-17 Test the Alarm and Optional Flashing Beacon
- B-18 Perform Hydraulic Oil Analysis
- B-19 Check and Adjust the Engine RPM
- B-20 Test the Safety Envelope and Safety Circuits
- B-21 Test the Primary Boom Self-leveling
- B-22 Test the Primary Boom Angle Sensor
- B-23 Inspect the Fuel Tank Cap Venting Systems
- B-24 Perform Engine Maintenance - GM and Ford Models
- Perform Engine Maintenance - Diesel Models
- Grease the Platform Overload Mechanism (if equipped)
- Test the Platform Overload System (if equipped)
- Replace the Engine Air Filter
- Replace the Fuel Filter/Water Separator - Diesel Models
- Perform Engine Maintenance - GM and Ford Models
- Check the Boom Wear Pads
- Check the Free-wheel Configuration
- Check the Turntable Rotation Bearing Bolts
- Inspect for Turntable Bearing Wear
- Replace the Drive Hub Oil
- Replace the Hydraulic Filter Elements
- Test or Replace the Hydraulic Oil
- Grease the Steer Axle Wheel Bearings, 2WD Models
- Perform Engine Maintenance - Ford Models
- Perform Engine Maintenance - Deutz and Perkins Models
- Perform Engine Maintenance - Deutz BF4L2011 / TD2011L04i Models
- Perform Engine Maintenance - Deutz BF4L2011 Models
- Display Module
- ALC-1000 Circuit Board
- Membrane Decal
- Joysticks
- Platform
- Platform Leveling Cylinder
- Platform Rotator
- Calibrate the Platform Overload System (if equipped)
- Jib Boom
- Jib Boom Lift Cylinder
- Primary Boom Cable Track
- Primary Boom
- Primary Boom Lift Cylinder
- Primary Boom Extension Cylinder
- Primary Boom Angle Sensor
- Secondary Boom Cable Track
- Secondary Boom
- Secondary Boom Lift Cylinder
- Secondary Boom Extension Cylinder
- RPM Adjustment
- Flex Plate
- Engine Fault Codes - Gasoline/LPG Models
- Service Bypass/Recovery Keyswitch
- Circuit Boards
- Function Pump
- Drive Pump
- Function Manifold - View 1
- Function Manifold - View 2
- Valve Adjustments - Function Manifold
- Platform Manifold
- Turntable Rotation Manifold
- Platform Rotate Manifold
- Wheel Steer and Oscillate Manifold (before serial number 990)
- Wheel Steer and Oscillate Manifold (from serial number 990)
- Wheel Steer and Oscillate Manifold (before serial number 990)
- Wheel Steer and Oscillate Manifold (from serial number 990)
- Oil Diverter Manifold (welder option)
- 8-12 Traction Manifold, 2WD
- Valve Adjustments, 2WD Traction Manifold
- Traction Manifold, 4WD
- Valve Adjustments, 4WD Traction Manifold
- Valve Coils
- Turntable Rotation Assembly
- Steer Sensors
- Hub and Bearings, 2WD Models
- Oscillating Axle Cylinders
- Fault Diagnostics Control System
- How to Clear Secopndary Boom Safety Switch Faults
- Ford Engine ECM Fault Code Chart
- Continental Engine ECM Fault Code Chart
- Wire Circuit Legend
- Limit Switches and Angle Sensors
- Drive Chassis and Platform Controller Pin Legend
- Engine Relay and Fuse Panel Legend
- Turntable Controller Pin Legend
- Electrical Symbols Legend
- Hydraulic Symbols Legend
- Electrical Schematic Legend
- Electrical Schematic - View 1, Drive Chassis Controller (DCON)
- Electrical Schematic - View 2, Platform Controls (PCON)
- Electrical Schematic - View 3, Ground Controls (TCON)
- Electrical Schematic - View 4 (before serial number 2511)
- Electrical Schematic - View 5
- Electrical Schematic - View 6, Ground Controls (TCON)
- Electrical Schematic - View 7 (before serial number 2511)
- Electrical Schematic - View 8 (before serial number 2511)
- Electrical Schematic - View 9
- Electrical Schematic - View 10, Limit Switches
- Electrical Schematic - View 11, Deutz F4L-913 Engine
- Electrical Schematic - View 11, Deutz BF4L-2011 / TD2011L04i Engine
- Electrical Schematic - View 12
- Electrical Schematic - Perkins 704-30 Engine
- Electrical Schematic - Perkins 804C-33 / 804D-33 Engine
- Electrical Schematic - Perkins 804D-33 Engine
- Electrical Schematic - Continental TME27 Engine
- Electrical Schematic - Ford LRG 425 Engine
- Electrical Schematic - GM 3.0L Engine
- Electrical Schematic - Safety Circuits
- Electrical Schematic - Generator Options
- Electrical Schematic - Welder Generator Option
- Hydraulic Schematic, 2 Wheel Drive (2 and 4 Wheel Steer)
- Hydraulic Schematic, 4 Wheel Drive (2 and 4 Wheel Steer)
- Hydraulic Schematic, Hydraulic Generator Options
Inside this manual
Real pages from this service manual (324 pages). Open the sample pages (PDF, 992 KB)
- Specifications, page 15: Section 2 • Specifications
- Troubleshooting, page 235: Section 5 • Fault Codes
- Diagram, page 310: Hydraulic Schematic
- Foldout diagram, page 323: C56FTS-RD
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.
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This is a service manual
Here's how it compares to the other manual types.
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, 324 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
Binder not included
Manuals over about 300 pages may need a standard 3-ring binder, which you can buy locally to keep the pages organized for shop use.
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).