Genie Z-80/60 User manual

Service Manual
Part No. 88619
Rev F3
February 2015
Z-80/60
TM
Serial Number Range
from Z80-101 to Z8013-4591

Z-80/60 Part No. 88619
February 2015
ii
Important
Read, understand and obey the safety rules and
operating instructions in the Genie Z-80/60
Operator's Manual before attempting any
maintenance or repair procedure.
This manual provides detailed scheduled
maintenance information for the machine owner
and user. It also provides troubleshooting fault
codes 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 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.
Contact Us:
http://www.genieindustries.com
e-mail: [email protected]
Copyright © 2003 by Genie Industries
88619 Rev F June 2011
First Edition, Seventh 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.
Introduction

Part No. 88619 Z-80/60
February 2015
iii
Serial Number Legend
Z80 06 - 12345
Model
Model year
Sequence
number
PN - 77055
Country of manufacture: USA
This machine complies with:
Genie Industries
18340 NE 76th Street
Redmond, WA 98052
USA
ANSI A92.5-
CAN B.354.4-
Model: Z-80/60
Serial number: Z8006-12345
Electrical schematic number: ES0188
Machine unladen weight:
Rated work load (including occupants): 500 lb / 227 kg
Maximum allowable inclination of the chassis:
0 deg
Gradeability: N/A
Maximum allowable side force : 150 lb / 670 N
Maximum number of platfrm occupants: 2
Model year: Manufacture date: 01/05/06
2006
Maximum wind speed : 28 mph/ 12.5 m/s
Maximum platform height : 86 ft/ 26.38 m
Maximum platform reach : 60 ft/ 18.28 m
Serial number
(stamped on chassis)
Serial label
(located under cover)
INTRODUCTION

Z-80/60 Part No. 88619
February 2015
This page intentionally left blank.
iv

Part No. 88619 Z-80/60
February 2015
v
Safety Rules
Danger
Failure to obey the instructions and safety rules in
this manual, and the Operator's Manual will result
in death or serious injury.
Many of the hazards identified in the operator's
manual are also safety hazards when maintenance
and repair procedures are performed.
Do Not Perform Maintenance
Unless:
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.
Section 1 • Safety Rules

Z-80/60 Part No. 88619
July 2013
SAFETY RULES
vi
Section 1 • Safety Rules
Personal Safety
Any person working on or around a machine must
be aware of all known safety hazards. Personal
safety and the continued safe operation of the
machine should be your top priority.
Read each procedure thoroughly. This
manual and the decals on the machine
use signal words to identify the following:
Safety alert symbol—used to alert
personnel to potential personal
injury hazards. Obey all safety
messages that follow this symbol
to avoid possible injury or death.
Used to indicate the presence of
an imminently hazardous situation
which, if not avoided, will result in
death or serious injury.
Used to indicate the presence of a
potentially hazardous situation
which, if not avoided, could result
in death or serious injury.
With safety alert symbol—used to
indicate the presence of a
potentially hazardous situation
which, if not avoided, may result in
minor or moderate injury.
Used to indicate the presence of 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
Be sure to keep sparks, flames and
lighted tobacco away from flammable and
combustible materials like battery gases
and engine fuels. Always have an approved fire
extinguisher within easy reach.
Be sure that all tools and working areas
are properly maintained and ready for
use. Keep work surfaces clean and free of
debris that could get into machine components and
cause damage.
Be sure any forklift, overhead crane or
other lifting or supporting device is fully
capable of supporting and stabilizing the
weight to be lifted. Use only chains or straps that
are in good condition and of ample capacity.
Be sure that fasteners intended for one
time use (i.e., cotter pins and self-locking
nuts) are not reused. These components
may fail if they are used a second time.
Be sure 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.

Part No. 88619 Z-80/60
July 2013
Table of Contents
vii
Introduction
Important Information ................................................................................................... ii
Serial Number Legend ................................................................................................. iii
Section 1 Safety Rules
General Safety Rules .................................................................................................. v
Section 2 Rev Specifications
G Machine Specifications .......................................................................................... 2 - 1
Performance Specifications ................................................................................... 2 - 2
Function Speeds Specifications ............................................................................. 2 - 2
Hydraulic Oil Specifications ................................................................................... 2 - 3
Hydraulic Component Specifications ...................................................................... 2 - 4
Manifold Component Specifications ....................................................................... 2 - 5
Valve Coil Resistance Specifications ..................................................................... 2 - 5
GM 3.0L EFI Engine .............................................................................................. 2 - 6
Ford LRG-425 Engine ............................................................................................. 2 - 7
Continental TME27 Engine .................................................................................... 2 - 9
Deutz F4L-913 Engine (before serial number 339) ................................................ 2 - 10
Deutz BF4L-2011 (from serial number 339 to 2177).............................................. 2 - 11
Deutz TD2011L04i Engine (from serial number 2178) ........................................... 2 - 13
Perkins 704-30 Engine ......................................................................................... 2 - 15
Perkins 804C-33 / 804D-33 Engine ...................................................................... 2 - 16
Machine Torque Specifications ............................................................................ 2 - 17
Hydraulic Hose and Fitting Torque Specifications ................................................ 2 - 18
SAE and Metric Fasteners Torque Charts ............................................................ 2 - 19
Section 3 Rev Scheduled Maintenance Procedures
Introduction ............................................................................................................ 3 - 1
Pre-Delivery Preparation ........................................................................................ 3 - 3
Maintenance Inspection Report .............................................................................. 3 - 5

Z-80/60 Part No. 88619
July 2013
TABLE OF CONTENTS
viii
Section 3 Rev Scheduled Maintenance Procedures, continued
EChecklist A Procedures
A-1 Inspect the Manuals and Decals .................................................................. 3 - 7
A-2 Perform Pre-operation Inspection ................................................................ 3 - 8
A-3 Perform Function Tests ............................................................................... 3 - 8
A-4 Perform Engine Maintenance ....................................................................... 3 - 8
A-5 Check the Hydraulic Filter Condition Indicators .......................................... 3 - 10
A-6 Perform 30 Day Service ............................................................................. 3 - 11
A-7 Perform Engine Maintenance - Continental Models .................................... 3 - 11
A-8 Perform Engine Maintenance - Perkins and Continental Models ................. 3 - 12
A-9 Perform Engine Maintenance ..................................................................... 3 - 13
A-10 Grease the Turntable Rotation Bearing and Rotate Gear ............................ 3 - 14
A-11 Inspect the Fuel Filter/Water Separator - Diesel Models ............................. 3 - 14
A-12 Replace the Drive Hub Oil .......................................................................... 3 - 16
A-13 Perform Engine Maintenance - GM and Ford Models ................................. 3 - 18
GChecklist B Procedures
B-1 Inspect the Batteries .................................................................................. 3 - 19
B-2 Inspect the Electrical Wiring ....................................................................... 3 - 20
B-3 Test the Key Switch ................................................................................... 3 - 22
B-4 Check the Exhaust System ....................................................................... 3 - 22
B-5 Inspect the Engine Air Filter ....................................................................... 3 - 23
B-6 Engine Maintenance - Deutz F4L913 and Continental Models .................... 3 - 24
B-7 Check the Tires, Wheels and Lug Nut Torque ............................................ 3 - 25
B-8 Confirm the Proper Brake Configuration...................................................... 3 - 25
B-9 Check the Drive Hub Oil Level and Fastener Torque .................................. 3 - 26
B-10 Test the Ground Control Override ............................................................... 3 - 27
B-11 Test the Platform Self-leveling ................................................................... 3 - 28
B-12 Test the Engine Idle Select Operation ........................................................ 3 - 29
B-13 Test the Fuel Select Operation - Gasoline/LPG Models ............................. 3 - 30

Part No. 88619 Z-80/60
July 2013
TABLE OF CONTENTS
ix
Section 3 Rev Scheduled Maintenance Procedures, continued
B-14 Test the Drive Brakes ................................................................................ 3 - 31
B-15 Test the Drive Speed - Stowed Position ..................................................... 3 - 31
B-16 Test the Drive Speed - Raised or Extended Position ................................. 3 - 32
B-17 Test the Alarm and Optional Flashing Beacon ........................................... 3 - 33
B-18 Perform Hydraulic Oil Analysis .................................................................. 3 - 33
B-19 Check and Adjust the Engine RPM ............................................................ 3 - 34
B-20 Test the Safety Envelope and Safety Circuits ............................................ 3 - 37
B-21 Test the Primary Boom Self-leveling .......................................................... 3 - 40
B-22 Test the Primary Boom Angle Sensor ........................................................ 3 - 41
B-23 Inspect the Fuel Tank Cap Venting Systems ............................................. 3 - 42
B-24 Perform Engine Maintenance - GM and Ford Models ................................. 3 - 43
DChecklist C Procedures
C-1 Perform Engine Maintenance - Diesel Models ............................................ 3 - 44
C-2 Grease the Platform Overload Mechanism (if equipped) ............................. 3 - 45
C-3 Test the Platform Overload System (if equipped) ....................................... 3 - 45
C-4 Replace the Engine Air Filter ...................................................................... 3 - 47
C-5 Replace the Fuel Filter/Water Separator - Diesel Models ............................ 3 - 48
C-6 Perform Engine Maintenance - GM and Ford Models ................................. 3 - 50
EChecklist D Procedures
D-1 Check the Boom Wear Pads ...................................................................... 3 - 51
D-2 Check the Free-wheel Configuration ........................................................... 3 - 52
D-3 Check the Turntable Rotation Bearing Bolts ............................................... 3 - 53
D-4 Inspect for Turntable Bearing Wear ............................................................ 3 - 54
D-5 Replace the Drive Hub Oil .......................................................................... 3 - 55
D-6 Perform Engine Maintenance ..................................................................... 3 - 56
D-7 Replace the Hydraulic Filter Elements ........................................................ 3 - 57

Z-80/60 Part No. 88619
July 2013
Section 3 Rev Scheduled Maintenance Procedures, continued
DChecklist E Procedures
E-1 Test or Replace the Hydraulic Oil ............................................................... 3 - 61
E-2 Grease the Steer Axle Wheel Bearings, 2WD Models ................................ 3 - 63
E-3 Perform Engine Maintenance ..................................................................... 3 - 64
E-4 Perform Engine Maintenance - Ford Models ............................................... 3 - 65
E-5 Perform Engine Maintenance - Deutz and Perkins Models ......................... 3 - 66
E-6 Perform Engine Maintenance - Deutz BF4L2011 / TD2011L04i Models ...... 3 - 67
E-7 Perform Engine Maintenance - Deutz BF4L2011 / TD2011L04i Models ...... 3 - 68
E-8 Perform Engine Maintenance - Deutz BF4L2011 Models ............................ 3 - 68
Section 4 Rev Repair Procedures
Introduction ............................................................................................................ 4 - 1
E Display Module ...................................................................................................... 4 - 2
FPlatform Controls
1-1 ALC-1000 Circuit Board .............................................................................. 4 - 10
1-2 Membrane Decal ........................................................................................ 4 - 11
1-3 Joysticks ................................................................................................... 4 - 13
CPlatform Components
2-1 Platform ..................................................................................................... 4 - 19
2-2 Platform Leveling Cylinder .......................................................................... 4 - 19
2-3 Platform Rotator ......................................................................................... 4 - 21
2-4 Calibrate the Platform Overload System (if equipped) ................................ 4 - 23
BJib Boom Components
3-1 Jib Boom .................................................................................................... 4 - 26
3-2 Jib Boom Lift Cylinder ................................................................................ 4 - 28
DBoom Components
4-1 Primary Boom Cable Track ........................................................................ 4 - 30
4-2 Primary Boom ............................................................................................ 4 - 33
4-3 Primary Boom Lift Cylinder ......................................................................... 4 - 36
4-4 Primary Boom Extension Cylinder .............................................................. 4 - 38
x
TABLE OF CONTENTS

Part No. 88619 Z-80/60
July 2013
TABLE OF CONTENTS
xi
Section 4 Rev Repair Procedures, continued
4-5 Primary Boom Angle Sensor ...................................................................... 4 - 40
4-6 Secondary Boom Cable Track .................................................................... 4 - 42
4-7 Secondary Boom ........................................................................................ 4 - 43
4-8 Secondary Boom Lift Cylinder .................................................................... 4 - 45
4-9 Secondary Boom Extension Cylinder ......................................................... 4 - 47
CEngines
5-1 RPM Adjustment ........................................................................................ 4 - 49
5-2 Flex Plate................................................................................................... 4 - 49
5-3 Engine Fault Codes - Gasoline/LPG Models ............................................... 4 - 56
BGround Controls
6-1 Service Bypass/Recovery Keyswitch ......................................................... 4 - 57
6-2 Circuit Boards ............................................................................................ 4 - 59
6-3 Membrane Decal ........................................................................................ 4 - 60
BHydraulic Pumps
7-1 Function Pump ........................................................................................... 4 - 61
7-2 Drive Pump ................................................................................................ 4 - 62
EManifolds
8-1 Function Manifold - View 1 ......................................................................... 4 - 64
8-2 Function Manifold - View 2 ......................................................................... 4 - 66
8-3 Valve Adjustments - Function Manifold ...................................................... 4 - 68
8-4 Platform Manifold ....................................................................................... 4 - 74
8-5 Turntable Rotation Manifold ........................................................................ 4 - 76
8-6 Platform Rotate Manifold ............................................................................ 4 - 77
8-7 2 Wheel Steer and Oscillate Manifold (before serial number 990) ............... 4 - 78
8-8 2 Wheel Steer and Oscillate Manifold (from serial number 990) .................. 4 - 82
8-9 4 Wheel Steer and Oscillate Manifold (before serial number 990) ............... 4 - 88
8-10 4 Wheel Steer and Oscillate Manifold (from serial number 990) .................. 4 - 94
8-11 Oil Diverter Manifold (welder option) ........................................................... 4 - 99

Z-80/60 Part No. 88619
July 2013
xii
TABLE OF CONTENTS
Section 4 Rev Repair Procedures, continued
8-12 Traction Manifold, 2WD ........................................................................... 4 - 100
8-13 Valve Adjustments, 2WD Traction Manifold .............................................. 4 - 102
8-14 Traction Manifold, 4WD ............................................................................. 4 - 104
8-15 Valve Adjustments, 4WD Traction Manifold .............................................. 4 - 106
8-16 Valve Coils ................................................................................................ 4 - 107
BTurntable Rotation Components
9-1 Turntable Rotation Assembly ....................................................................4 - 109
BAxle Components
10-1 Steer Sensors ........................................................................................... 4 - 111
10-2 Hub and Bearings, 2WD Models ................................................................ 4 - 114
10-3 Oscillating Axle Cylinders ......................................................................... 4 - 116
Section 5 Rev Fault Codes
Introduction ............................................................................................................ 5 - 1
C Fault Diagnostics Control System .......................................................................... 5 - 2
How to Clear Secopndary Boom Safety Switch Faults ......................................... 5 - 10
B Ford Engine ECM Fault Code Chart ..................................................................... 5 - 11
B Continental Engine ECM Fault Code Chart ........................................................... 5 - 16
Section 6 Rev Schematics
Introduction ............................................................................................................ 6 - 1
B Wire Circuit Legend ................................................................................................ 6 - 2
C Limit Switches and Angle Sensors ......................................................................... 6 - 8
C Drive Chassis and Platform Controller Pin Legend ............................................... 6 - 10
D Engine Relay and Fuse Panel Legend .................................................................. 6 - 11
C Turntable Controller Pin Legend ........................................................................... 6 - 14
B Electrical Symbols Legend .................................................................................. 6 - 15
B Hydraulic Symbols Legend .................................................................................. 6 - 16

Part No. 88619 Z-80/60
July 2013
Section 6 Rev Schematics, continued
D Electrical Schematic Legend ................................................................................ 6 - 17
C Electrical Schematic - View 1, Drive Chassis Controller (DCON) ......................... 6 - 20
D Electrical Schematic - View 2, Platform Controls (PCON) .................................... 6 - 21
(before serial number 1167)
A Electrical Schematic - View 2, Platform Controls (PCON) .................................... 6 - 23
(from serial number 1167 to 2510)
D Electrical Schematic - View 3, Ground Controls (TCON) ...................................... 6 - 26
(before serial number 2511)
C Electrical Schematic - View 4 (before serial number 2511) ................................... 6 - 27
C Electrical Schematic - View 5 .............................................................................. 6 - 30
(before serial number 2511)
C Electrical Schematic - View 6, Ground Controls (TCON) ...................................... 6 - 31
(before serial number 2511)
C Electrical Schematic - View 7 (before serial number 2511) ................................... 6 - 34
C Electrical Schematic - View 8 (before serial number 2511) ................................... 6 - 35
D Electrical Schematic - View 9 .............................................................................. 6 - 38
(before serial number 2511)
C Electrical Schematic - View 10, Limit Switches ................................................... 6 - 39
(before serial number 2511)
B Electrical Schematic - View 11, Deutz F4L-913 Engine ........................................ 6 - 42
(before serial number 339)
C Electrical Schematic - View 11, Deutz BF4L-2011 / TD2011L04i Engine .............. 6 - 43
(from serial number 339 to 2316)
A Electrical Schematic - View 11, Deutz BF4L-2011 / TD2011L04i Engine .............. 6 - 46
(from serial number 2313 to 2510)
C Electrical Schematic - View 12 ............................................................................ 6 - 48
(before serial number 2511)
A Electrical Schematic - Perkins 704-30 Engine...................................................... 6 - 50
(before serial number 329)
C Electrical Schematic - Perkins 804C-33 / 804D-33 Engine ................................... 6 - 51
(from serial number 329 to 2316)
A Electrical Schematic - Perkins 804C-33 / 804D-33 Engine ................................... 6 - 54
(from serial number 2317 to 2510)
A Electrical Schematic - Perkins 804D-33 Engine ................................................... 6 - 55
(from serial number 2511)
TABLE OF CONTENTS
xiii

Z-80/60 Part No. 88619
July 2013
xiv
Section 6 Rev Schematics, continued
B Electrical Schematic - Continental TME27 Engine ............................................... 6 - 58
(before serial number 2511)
A Electrical Schematic - Continental TME27 Engine ............................................... 6 - 59
(from serial number 2510)
A Electrical Schematic - Ford LRG 425 Engine ....................................................... 6 - 62
C Electrical Schematic - GM 3.0L Engine ............................................................... 6 - 63
A Electrical Schematic - Safety Circuits .................................................................. 6 - 65
A Electrical Schematic - Generator Options ............................................................ 6 - 68
A Electrical Schematic - Welder Generator Option .................................................. 6 - 69
A Electrical Schematic (ES0508B) (from serial number 2511) ................ at end of manual
D Hydraulic Schematic, 2 Wheel Drive (2 and 4 Wheel Steer) ................................. 6 - 72
(before serial number 990)
D Hydraulic Schematic, 2 Wheel Drive (2 and 4 Wheel Steer) ................................. 6 - 74
(from serial number 990 to 2674)
A Hydraulic Schematic, 2 Wheel Drive (2 and 4 Wheel Steer) ................................. 6 - 75
(serial number 1543 and from serial number 2675)
D Hydraulic Schematic, 4 Wheel Drive (2 and 4 Wheel Steer) ................................. 6 - 78
(before serial number 990)
D Hydraulic Schematic, 4 Wheel Drive (2 and 4 Wheel Steer) ................................. 6 - 80
(from serial number 990 to 2674)
A Hydraulic Schematic, 4 Wheel Drive (2 and 4 Wheel Steer) ................................. 6 - 81
(serial number 1543 and from serial number 2675)
A Hydraulic Schematic, Hydraulic Generator Options .............................................. 6 - 83
TABLE OF CONTENTS

Part No.88619 Z-80/60 2 - 1
Section 2 • SpecificationsFebruary 2015
REV G Specifications
Machine Specifications
Tires and wheels
Tire size
(foam filled and non-marking) 18-625 FF
Tire size
(Hi-flotation) 445D50/70
Tire ply rating
(foam filled and non-marking) 16
Tire weight, new foam-filled (minimum) 622 lbs
(Rough terrain) 282 kg
Tire ply rating
(Hi-flotation) 14
Overall tire diameter 40.7 in
(foam filled and non-marking) 103.3 cm
Overall tire diameter 45.47 in
(Hi-flotation) 115.5 cm
Wheel diameter 24.5 in
(foam filled and non-marking) 62.2 cm
Wheel diameter 28 in
(Hi-flotation) 71.1 cm
Wheel width 15 in
(foam filled, non-marking and Hi-flotation) 38.1 cm
Tire Pressure (Hi-flotation) 80 lbs / 5.5 bar
Wheel lugs 10 @ 3/4 -16
Lug nut torque, lubricated 320 ft-lbs
434 Nm
Lug nut torque, dry 420 ft-lbs
570 Nm
Fluid capacities
Fuel tank 35 gallons
132.5 liters
LPG tank 33.5 lbs
15.2 kg
Hydraulic tank 45 gallons
170 liters
Hydraulic system 80 gallons
(including tank) 303 liters
Drive hubs 50 fl oz
(before serial number 958) 1.5 liters
Drive hubs 44 fl oz
(after serial number 957) 1.3 liters
Turntable rotation drive hub 40 fl oz
1.2 liters
Drive hub oil type: EP 80-90W gear oil
API Service Classification GL5
Continuous improvement of our products is a
Genie policy. Product specifications are
subject to change without notice.
For operational specification, refer to the
Operator's Manual.

2 - 2 Z-80/60 Part No. 88619
Section 2 • Specifications February 2015
REV GSPECIFICATIONS
Performance Specifications
Drive speed, maximum
(models with rough terrain tires)
Stowed position 40 ft / 8.7-9.3 sec
12.2 m / 8.7-9.3 sec
Raised or extended position 40 ft / 40-45 sec
12.2 m / 40-45 sec
Drive speed, maximum
(models with Hi-flotation tires)
Stowed position 40 ft / 13.6-14.5 sec
12.2 m / 13.6-14.5 sec
Raised or extended position 40 ft / 62-70 sec
12.2 m / 62-70 sec
Gradeability - Refer to Operator's Manual
Braking distance, maximum
High range on paved surface 6 ft
1.83 m
Function speeds
Primary boom up, retracted
(retracted -35° to 65°) 60 to 70 seconds
Primary boom down, retracted
(retracted -35° to 65°) 75 to 85 seconds
Secondary boom up, retracted 38 to 48 seconds
Secondary boom down, retracted 38 to 48 seconds
Primary boom up, extended
(-35° to 65°) 80 to 96 seconds
Primary boom down, extended
(-35° to 65°) 80 to 96 seconds
Primary Boom extend 48 to 52 seconds
Primary Boom retract 38 to 42 seconds
Jib Boom up 23 to 33 seconds
Jib Boom down 21 to 31 seconds
Platform Rotate 160° 10 to 14 seconds
Turntable rotate, 360°
boom fully retracted 114 to 126 seconds
Turntable rotate, 360°
boom extended 200 to 240 seconds
Continuous improvement of our products is a
Genie policy. Product specifications are
subject to change without notice.

Part No.88619 Z-80/60 2 - 3
Section 2 • SpecificationsFebruary 2015
REV G
Continuous improvement of our products is a
Genie policy. Product specifications are
subject to change without notice.
SPECIFICATIONS
Hydraulic Oil Specifications
Hydraulic Oil Specifications
Hydraulic oil type Chevron Rando HD Premium
MV equivalent
Viscosity grade Multi-viscosity
Viscosity index 200
Cleanliness level, minimum 15/13
Water content, maximum 200 ppm
Chevron Rando HD Premium MV oil is fully
compatible and mixable with Shell Donax TG (Dexron
III) oils.
Genie specifications require hydraulic oils which are
designed to give maximum protection to hydraulic
systems, have the ability to perform over a wide
temperature range, and the viscosity index should
exceed 140. They should provide excellent antiwear,
oxidation, corrosion inhibition, seal conditioning, and
foam and aeration suppression properties.
Optional fluids
Biodegradable Petro Canada Environ MV46
Statoil Hydra Way Bio SE 32
BP Biohyd SE-S
Fire resistant UCON Hydrolube HP-5046
Quintolubric 822
Mineral based Shell Tellus T32
Shell Tellus T46
Chevron Aviation A
Continued use of Chevron Aviation
A hydraulic oil when ambient
temperatures are consistently
above 32°F / 0°C may result in
component damage.
Note: Use Chevron Aviation A hydraulic oil when
ambient temperatures are consistently
below 0°F / -18°C.
Note: Use Shell Tellus T46 hydraulic oil when oil
temperatures consistently exceed 205°F / 96°C.
Note: Genie specifications require additional
equipment and special installation instructions for
the approved optional fluids. Consult the Genie
Industries Service Department before use.

2 - 4 Z-80/60 Part No. 88619
Section 2 • Specifications February 2015
REV GSPECIFICATIONS
Hydraulic Component
Specifications
Drive pump
Type: bi-directional variable displacement piston pump
Displacement 2.81 cu in
46 cc
Flow rate @ 2300 rpm 28 gpm
106 L/min
Drive pressure, maximum 3625 psi
250 bar
Charge pump
Type: gerotor
Displacement 0.85 cu in
13.9 cc
Flow rate @ 2300 rpm 9 gpm
34 L/min
Charge pressure @ 2300 rpm 320 psi
Neutral position 22 bar
Function pumps
Type: two-section tandem gear pump
Displacement - Pump 1 (inner) 1.94 cu in
31.8 cc
Flow rate @ 2300 rpm 17 gpm
64.4 L/min
Displacement - Pump 2 (outer) 0.58 cu in
9.5 cc
Flow rate @ 2300 rpm 5 gpm
19 L/min
Auxiliary pump
Type: two-section fixed displacement gear pump
Displacement - Section 1 (inner) 0.159 cu in
2.61 cc
Flow rate @ 2687 rpm 1.7 gpm
6.4 L/min
Displacement - Section 2 (outer) 0.051 cu in
0.84 cc
Flow rate @ 2687 rpm 0.3 gpm
1.1 L/min
Function manifold
System relief pressure 3200 psi
(measured at PTEST port) 220.6 bar
Primary boom down relief pressure 1300 psi
(measured at PTEST port) 89.6 bar
Secondary boom down relief pressure 2500 psi
(measured at PTEST port) 172 bar
Secondary boom up relief pressure 2500 psi
(measured at PTEST port) 172 bar
Primary boom extend relief pressure 1300 psi
(measured at PTEST port) 89.6 bar
Secondary boom extend relief pressure 2600 psi
(measured at PTEST port) 179 bar
Platform manifold relief pressure 3000 psi
207 bar
Platform manifold flow regulator 3 gpm
11.4 L/min
Oscillate manifold
Oscillate relief pressure (item BE or CH) 800 psi
55.1 bar
Continuous improvement of our products is a
Genie policy. Product specifications are
subject to change without notice.

Part No.88619 Z-80/60 2 - 5
Section 2 • SpecificationsFebruary 2015
REV G
Drive manifold
Hot oil relief pressure 280 psi
19.3 bar
Brakes
Brake release pressure 215 psi
14.8 bar
Drive motors
Displacement per revolution, variable 0.9 to 2.7 cu in
(2 speed motor) 14.7 to 45 cc
Hydraulic tank return filter
High pressure filter Beta 3≥200
High pressure filter 102 psi
bypass pressure 7 bar
Medium pressure filter Beta 3≥200
Medium pressure filter 51 psi
bypass pressure 3.5 bar
Hydraulic tank return filter 10 micron with
25 psi / 1.7 bar bypass
Manifold Component
Specifications
Plug torque
SAE No. 2 50 in-lbs / 6 Nm
SAE No. 4 14 ft-lbs / 18.9 Nm
SAE No. 6 23 ft-lbs / 31.2 Nm
SAE No. 8 36 ft-lbs / 48.8 Nm
SAE No. 10 62 ft-lbs / 84.1 Nm
SAE No. 12 84 ft-lbs / 113.9 Nm
Valve Coil Resistance
Specifications
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 / 20°C
that your air temperature increases or decreases
from 68°F / 20°C.
Proportional solenoid valve, 12V DC 4.8 Ω
(schematic items G, W and AB)
Proportional solenoid valve, 12V DC 9 Ω
(schematic items R)
3 position 4 way solenoid valve, 12V DC 9 Ω
(schematic items BA, BB, CA, CB, CP, CQ,
GB, GP and GQ)
3 position 4 way solenoid valve, 10V DC 6.3 Ω
(schematic items O and S)
2 position 2 way solenoid valve, 10V DC 3.3 Ω
(schematic items J)
2 position 2 way solenoid valve, 10V DC 6.3 Ω
(schematic items C and P)
2 position 3 way solenoid valve, 10V DC 6.3 Ω
(schematic items H, V, X, Z, AA, EE and EF)
2 position 3 way solenoid valve, 12V DC 9 Ω
(schematic items BC, BD, CE, CF,
FB and FC)
Continuous improvement of our products is a
Genie policy. Product specifications are
subject to change without notice.
SPECIFICATIONS

2 - 6 Z-80/60 Part No. 88619
Section 2 • Specifications February 2015
REV GSPECIFICATIONS
Starter motor
Normal engine cranking speed 350 rpm
Current draw, normal load 400A
Current draw, maximum load 600A
Current draw, minimum 100A
Batteries
Type 12V DC
Group 31
Quantity 2
Cold cranking ampere 1000A
Reserve capacity @ 25A rate 200 minutes
Electronic fuel pump
Fuel pressure, static 9 to 11 psi
0.6 to 0.76 bar
Fuel flow rate 0.3 gpm
1.14 L/min
Fuel Requirement
For fuel requirements, refer to the engine Operator's
Manual on your machine.
Ignition system
Spark plug type AC ACMR-43-LTS
Spark plug gap 0.040 inch
1.01 mm
Engine coolant
Capacity 12 quarts
11.4 liters
Alternator
Output 66A, 12V DC
Fan belt deflection 0.5 inch
12 mm
GM 3.0L EFI Engine
Displacement 181 cu in
3 liters
Number of cylinders 4
Bore & stroke 4 x 3.6 inches
101.6 x 91.44 mm
Horsepower
Intermittent 67 @ 2300 rpm
50 kW @ 2300 rpm
Continuous 60 @ 2300 rpm
45 kW @ 2300 rpm
Firing order 1 - 3 - 4 - 2
Low idle 1650 rpm
Frequency 386.1 Hz
High idle 2300 rpm
Frequency 538.2 Hz
Compression ratio 9.25:1
Compression pressure - minimum 100 psi
Pressure (psi or bar) of lowest cylinder 6.9 bar
must be at least 75% of highest cylinder
Valve clearances Zero lash + 1 full turn
Lubrication system
Oil pressure - minimum 18 psi
(operating temp. @ 2000 rpm) 1.24 bar
Oil capacity 5 quarts
(including filter) 4.7 liters
Oil viscosity requirements
Extreme operating temperatures my require the use of
alternative engine oils. For oil requirements, refer to the
Engine Operator Handbook on your machine.
Continuous improvement of our products is a
Genie policy. Product specifications are
subject to change without notice.