Terex Genie z-80 Installation and operating manual

Service and Repair Manual

Serial Number Range

Z®-80/60

from Z8013-4592

to Z8016H-6399

from Z80H-6400

This manual includes:

Repair procedures

Fault Codes

Electrical and

Hydraulic Schematics

For detailed maintenance

procedures, refer to the

appropriate Maintenance

Manual for your machine.

Part No. 1268556GT

Rev C

June 2020

Service and Repair Manual June 2020

Introduction

ii Z®-80/60 Part No. 1268556GT

Introduction Introduction

Important

Read, understand and obey the safety rules and

operating instructions in the appropriate Operator's

Manual on your machine before attempting any

procedure.

This manual provides troubleshooting and repair

procedures for qualified service professionals.

Basic mechanical, hydraulic and electrical skills

are required to perform most procedures.

However, several procedures require specialized

skills, tools, lifting equipment and a suitable

workshop. In these instances, we strongly

recommend that maintenance and repair be

performed at an authorized Genie dealer service

center.

Compliance

Machine Classification

Group B/Type 3 as defined by ISO 16368

Machine Design Life

Unrestricted with proper operation, inspection and

scheduled maintenance.

Technical Publications

Genie has endeavored to deliver the highest

degree of accuracy possible. However, continuous

improvement of our products is a Genie policy.

Therefore, product specifications are subject to

change without notice.

Readers are encouraged to notify Genie of errors

and send in suggestions for improvement. All

communications will be carefully considered for

future printings of this and all other manuals.

Internet: www.genielift.com

E-mail: awp.techpub@terex.com

Find a Manual for this Model

Go to http://www.genielift.com

Use the links to locate Service Manuals,

Maintenance Manuals, Service and Repair

Manuals, Parts Manuals and Operator's Manuals.

1268556GT Rev C, June 2020

Third Edition, Third Printing

Genie and "Z" are registered trademarks of Terex South

Dakota, Inc. in the U.S.A. and many other countries.

June 2020 Service and Repair Manual

Introduction

Part No. 1268556GT Z®-80/60 iii

Revision History

Revision

Date

Section

Procedure / Page / Description

9/2015

Initial Release

11/2015

Schematics

Electrical Schematic

(from Z8013-4592 to Z8015-5653)

9/2016

Introduction

Serial Number Legend

Specifications

GM 3.0L engine

Fault Codes

GM 3.0L engine

Schematics

GM 3.0L engine; Electrical Schematics

1/2017

Repair

10-1 Calibrate Steer Sensors

12/2017

Specifications

Perkins 404D engine

Schematics

Electrical Schematic (from Z8016H-6188)

5/2020

All Sections

Add Deutz TCD 2.2 L3 engine

Reference Examples:

Electronic Version

Click on any content or procedure in the Table of Contents to view

the update.

Section –Repair Procedure, 4-2

Section –Fault Codes, All charts

Section –Schematics, Legends and schematics

Service and Repair Manual June 2020

Introduction

iv Z®-80/60 Part No. 1268556GT

Serial Number Legend

To August 31, 2016

1 Model

2 Model year

3 Facility code

4 Sequence number

5 Serial number (stamped on chassis)

6 Serial label (located under cover)

From September 1, 2016

1 Model

2 Facility code

3 Sequence number

4 Serial number (stamped on chassis)

5 Serial label (located under cover)

June 2020 Service and Repair Manual

Safety Rules

Part No. 1268556GT Z®-80/60 v

Section 1 SafetyRul es

Danger

Failure to obey the instructions and safety

rules in this manual and the appropriate

Operator's Manual on your machine will result

in death or serious injury.

Many of the hazards identified in the

operator's manual are also safety hazards

when maintenance and repair procedures are

performed.

Do Not Perform Maintenance

Unless:

You are trained and qualified to perform

maintenance on this machine.

You read, understand and obey:

•manufacturer's instructions and safety

rules

•employer's safety rules and worksite

regulations

•applicable governmental regulations

You have the appropriate tools, lifting

equipment and a suitable workshop.

Service and Repair Manual June 2020

Safety Rules

vi Z®-80/60 Part No. 1268556GT

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.

Indicates a imminently

hazardous situation which, if

not avoided, will result in death

or serious injury.

Indicates a potentially

hazardous situation which, if

not avoided, could result in

death or serious injury.

Indicates a potentially

hazardous situation which, if

not avoided, may cause minor

or moderate injury.

Indicates a potentially

hazardous situation which, if

not avoided, may result in

property damage.

Be sure to wear protective eye wear

and other protective clothing if the

situation warrants it.

Be aware of potential crushing

hazards such as moving parts, free

swinging or unsecured components

when lifting or placing loads. Always

wear approved steel-toed shoes.

Workplace Safety

Any person working on or around a machine

must be aware of all known safety hazards.

Personal safety and the continued safe

operation of the machine should be your top

priority.

Be sure to keep sparks, flames and

lighted tobacco away from flammable

and combustible materials like battery

gases and engine fuels. Always have

an approved fire extinguisher within

easy reach.

Be sure that all tools and working

areas are properly maintained and

ready for use. Keep work surfaces

clean and free of debris that could get

into machine components and cause

damage.

Be sure any forklift, overhead crane or

other lifting or supporting device is

fully capable of supporting and

stabilizing the weight to be lifted. Use

only chains or straps that are in good

condition and of ample capacity.

Be sure that fasteners intended for

one time use (i.e., cotter pins and self-

locking nuts) are not reused. These

components 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.

June 2020 
 Table of Contents 
 
 
 
 
Part No. 1268556GT Z®-80/60 vii 
 
 
 
Introduction Introduction......................................................................................................ii 
Important Information .........................................................................................ii 
Find a Manual for this Model...............................................................................ii 
Serial Number Legend.......................................................................................iv 
Section 1 Safety Rules......................................................................................................v 
General Safety Rules .........................................................................................v 
Section 2 Specifications...................................................................................................1 
Machine Specifications.......................................................................................1 
Performance Specifications................................................................................2 
Hydraulic Oil Specifications ................................................................................2 
Hydraulic Component Specifications...................................................................5 
Continental TME27 Engine Specifications...........................................................7 
GM 3.0L Engine Specifications...........................................................................8 
Deutz TD2011L04i Engine Specifications ...........................................................9 
Deutz TCD 2.2 L3 Engine Specifications...........................................................10 
Deutz TD 2.9 Engine Specifications..................................................................11 
Perkins 404D-22T Engine Specifications ..........................................................12 
Perkins 404F-22T Engine Specifications...........................................................13 
Perkins 804D-33 Engine Specifications ............................................................14 
Machine Torque Specifications.........................................................................15 
Hydraulic Hose and Fitting Torque Specifications .............................................16 
Torque Procedure ............................................................................................17 

 June 2020 
Table of Contents 
 
 
 
 
viii Z®-80/60 Part No. 1268556GT 
 
 
Section 3 Repair Procedures.........................................................................................19 
Introduction...................................................................................................... 19 
Platform Controls...........................................................................................21 
Platform Controls.............................................................................................21 
1-1 Platform Circuit Board................................................................................ 22 
How to Remove the LED Circuit Board........................................................23 
1-2 Joysticks - How to Calibrate a Joystick....................................................... 24 
How to Reset a Proportional Valve Coil Default........................................... 27 
How to Set the Function Thresholds and Default Functions Speeds ............28 
How to Adjust the Function Speeds.............................................................30 
How to Adjust the Function Ramp Rate Setting........................................... 31 
Platform Components.................................................................................... 33 
2-1 Platform.....................................................................................................33 
2-2 Platform Leveling Cylinder..........................................................................33 
How to Remove the Platform Leveling Cylinder...........................................33 
How to Bleed the Platform Leveling Cylinder............................................... 34 
2-3 Platform Rotator.........................................................................................35 
How to Bleed the Platform Rotator ..............................................................36 
2-4 Platform Overload System (if equipped) .....................................................37 
2-5 Platform Overload Recovery Message .......................................................40 
Jib Boom Components..................................................................................41 
3-1 Jib Boom....................................................................................................41 
3-2 Jib Boom Lift Cylinder................................................................................43 

June 2020 
 Table of Contents 
 
 
 
 
Part No. 1268556GT Z®-80/60 ix 
 
 
Boom Components ........................................................................................44 
4-1 Primary Boom Cable Track.........................................................................45 
How to Repair the Primary Boom Cable Track.............................................47 
4-2 Primary Boom ............................................................................................48 
How to Shim the Primary Boom...................................................................48 
How to Disassemble the Primary Boom.......................................................50 
4-3 Primary Boom Lift Cylinder.........................................................................51 
4-4 Primary Boom Extension Cylinder...............................................................52 
4-5 Primary Boom Angle Sensor.......................................................................54 
How to Replace the Primary Boom Angle Sensor ........................................54 
How to Calibrate the Primary Boom Angle Sensor.......................................55 
4-6 Secondary Boom Cable Track....................................................................57 
How to Remove the Secondary Boom Cable Track......................................57 
How to Repair the Secondary Boom Cable Track........................................57 
4-7 Secondary Boom........................................................................................58 
4-8 Secondary Boom Lift Cylinder.....................................................................59 
4-9 Secondary Boom Extension Cylinder..........................................................61 
Engines...........................................................................................................63 
5-1 RPM Adjustment ........................................................................................63 
5-2 Flex Plate...................................................................................................63 
How to Remove the Flex Plate.....................................................................63 
How to Install the Flex Plate ........................................................................66 
How to install the Pump and Bell Housing Assembly....................................67 
5-3 How to Access Perkins 404F Engine Regeneration Service........................68 
_5-4 Diesel Particle Filter Regeneration - Deutz TCD 2.2 L3.............................69 

 June 2020 
Table of Contents 
 
 
 
 
x Z®-80/60 Part No. 1268556GT 
 
 
Ground Controls ............................................................................................70 
6-1 Bypass/Recovery Key Switch.....................................................................70 
How to Use the Recovery Mode..................................................................72 
6-2 Circuit Boards............................................................................................73 
6-3 Membrane Decal........................................................................................74 
Display Module............................................................................................... 75 
Hydraulic Pumps............................................................................................83 
7-1 Function Pump...........................................................................................83 
7-2 Drive Pump................................................................................................84 
How to Prime the Drive Pump .....................................................................85 
Manifolds........................................................................................................ 86 
8-1 Function Manifold Components - View 1.....................................................86 
8-2 Function Manifold Components - View 2.....................................................88 
8-3 Valve Adjustments - Function Manifold....................................................... 90 
How to Adjust the System Relief Valve........................................................90 
How to Adjust the Primary Boom Down Relief Valve....................................91 
How to Adjust the Primary Boom Extend Relief Valve..................................92 
How to Adjust the Secondary Boom Up Relief Valve ...................................93 
How to Adjust the Secondary Boom Down Relief Valve...............................94 
How to Adjust the Secondary Boom Extend Relief Valve.............................95 
How to Adjust the Platform Manifold Relief Valve ........................................95 
8-4 Platform Manifold....................................................................................... 96 
8-5 Turntable Rotation Manifold .......................................................................98 
8-6 Platform Rotate Manifold............................................................................ 99 
8-7 Two Wheel Steer and Oscillate Manifold .................................................. 100 
How to Adjust the Oscillate Relief Valve.................................................... 102 
8-8 Four Wheel Steer and Oscillate Manifold.................................................. 104 
How to Adjust the Oscillate Relief Valve.................................................... 108 