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.
Contact Us:
Internet: www.genielift.com
E-mail: [e-mail]
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.
Copyright © 2015 by Terex Corporation
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
A
9/2015
Initial Release
A1
11/2015
Schematics
Electrical Schematic
(from Z8013-4592 to Z8015-5653)
A2
9/2016
Introduction
Serial Number Legend
Specifications
GM 3.0L engine
Fault Codes
GM 3.0L engine
Schematics
GM 3.0L engine; Electrical Schematics
A3
1/2017
Repair
10-1 Calibrate Steer Sensors
B
12/2017
Specifications
Perkins 404D engine
Schematics
Electrical Schematic (from Z8016H-6188)
C
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

June 2020
Table of Contents
Part No. 1268556GT Z®-80/60 xi
8-9 Oil Diverter Manifold Components (welder option) ....................................109
8-10 Traction Manifold Components, 2WD......................................................110
8-11 Valve Adjustments, 2WD Traction Manifold.............................................112
8-12 Traction Manifold Components, 4WD......................................................114
8-13 Valve Adjustments, 4WD Traction Manifold.............................................116
8-14 Valve Coils.............................................................................................117
Turntable Rotation Components .................................................................119
9-1 Turntable Rotation Assembly....................................................................119
How to Adjust the Turntable Rotation Gear Backlash.................................120
Axle Components.........................................................................................121
10-1 Steer Sensors.........................................................................................121
How to Measure the Tire Alignment...........................................................121
How to Adjust a Steer Sensor....................................................................122
How to Calibrate the Steer Sensors...........................................................123
How to Adjust the Oscillate Limit Switches.................................................124
10-2 Oscillating Axle Cylinders .......................................................................125
Section 4 Fault Codes...................................................................................................126
Introduction ....................................................................................................126
Control System Fault Codes........................................................................127
How to Read Control System Fault Codes......................................................127
How to Clear Secondary Boom Safety Switch Faults ......................................127
Fault Code Source..........................................................................................135
Fault Code Display - Deutz and Perkins Models.........................................138
How to Retrieve Active Engine Fault Codes
Deutz D 2.9 L4 and Perkins 404F-22 Models....................................138
Deutz TD 2.9 L4 Engine Fault Codes...........................................................139
Deutz TCD 2.2 L3 Engine Fault Codes.........................................................150
Perkins 404F-E22TA Engine Fault Codes....................................................160
Continental TME27 Engine Fault Codes......................................................163
How to Retrieve Continental Engine Fault Codes.......................................163
How to Clear Engine Fault Codes from the ECM........................................163
Continental TME27 Engine Fault Codes....................................................164
GM 3.0L Engine Fault Codes........................................................................169

June 2020
Table of Contents
xii Z®-80/60 Part No. 1268556GT
Section 5 Schematics................................................................................................... 174
Introduction.................................................................................................... 174
Wire Circuit Legend........................................................................................ 175
Wire Color Legend......................................................................................... 179
Limit Switches and Angle Sensors.................................................................. 184
Drive Chassis and Platform Controller Pin Legend ......................................... 186
Turntable Controller Pin Legend..................................................................... 187
Relay and Fuse Panel Legends...................................................................... 189
Electrical Symbol Legend............................................................................... 191
Hydraulic Symbols Legend............................................................................. 192
Electrical Schematics .................................................................................. 193
Electrical Schematic - Engine Options, Deutz TD 2.9 L4 Engine..................... 194
Electrical Schematic - Engine Options, Deutz TD 2.9 L4 Engine Harness....... 195
Electrical Schematic - Engine Options, Deutz TCD 2.2 L3 Engine .................. 198
Electrical Schematic - Engine Options,
Deutz TCD 2.2 L3 Engine Harness, Tier IV Models................................. 199
Electrical Schematic - Engine Options,
Deutz TCD 2.2 L3 Engine Harness, Stage V Models............................... 202
Electrical Schematic - Engine Options, Perkins 404D-22T Engine.................. 203
Electrical Schematic - Engine Options,Perkins 404F-E22TA Engine............... 206
Electrical Schematic - Engine Options,
Perkins 404F-E22TA Engine Harness..................................................... 207
Electrical Schematic - Engine Options, Perkins 804D Engine ......................... 210
Electrical Schematic - Engine Options, Continental TME27 Engine................. 211
Electrical Schematic - Engine Options, GM 3.0 Engine................................... 214
Electrical Schematic - Safety Circuits............................................................. 215
Electrical Schematic - Generator Options....................................................... 218
Electrical Schematic - Welder Generator Option............................................. 219
Hydraulic Schematics.................................................................................. 221
Hydraulic Schematic - 2 Wheel Drive (2 and 4 Wheel Steer)........................... 222
Hydraulic Schematic - 4 Wheel Drive (2 and 4 Wheel Steer)........................... 223
Hydraulic Schematic - Hydraulic Generator Options ....................................... 226
Electrical Schematic –(from Z8013-4592 to Z8016H-6187)............................ 227
Electrical Schematic –(from Z8016H-6188) ................................................... 228

June 2020 Service and Repair Manual
Specifications
Part No. 1268556GT Z®-80/60 1
Section 2 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) (Rough terrain)
622 lbs
282 kg
Tire ply rating
(Hi-flotation)
14
Overall tire diameter
(foam filled and non-marking)
40.7 in
103.3 cm
Overall tire diameter
(Hi-flotation)
45.47 in
115.5 cm
Wheel diameter
(foam filled and non-marking)
24.5 in
62.2 cm
Wheel diameter
(Hi-flotation)
28 in
71.1 cm
Wheel width
(foam filled, non-marking and Hi-
flotation)
15 in
38.1 cm
Tire Pressure (Hi-flotation)
80 lbs
5.5 bar
Wheel lugs
11 @ 3/4 -16
Lug nut torque, dry
420 ft-lbs
570 Nm
Lug nut torque, lubricated
320 ft-lbs
434 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 (including tank)
80 gallons
303 liters
Drive hubs, 2WD
Drive hubs, 4WD
30.5 fl oz
902 cc
23 fl oz
680 cc
Turntable rotation drive hub
40 fl oz
1183 cc
Drive hub oil type: SAE 90 multipurpose hypoid gear oil API
service classification GL5

Service and Repair Manual June 2020
Specifications
2 Z®-80/60 Part No. 1268556GT
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
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
40 ft / 62 - 70 sec
12.2 m / 62 - 70 sec
Braking distance, maximum
High range on paved surface
6 ft
1.8 m
Gradeability
See Operator's
Manual
Boom function speeds, maximum from platform
controls
Jib boom up
23 to 33 seconds
Jib boom down
21 to 31 seconds
Primary boom up, retracted
-35° to 65°
60 to 70 seconds
Primary boom down, retracted
-35° to 65°
75 to 85 seconds
Secondary boom up
38 to 48 seconds
Secondary boom down
38 to 48 seconds
Primary boom extend
48 to 52 seconds
Primary boom retract
38 to 42 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
For operational specifications, refer to the
Operator's Manual.
Hydraulic Oil Specifications
Hydraulic Fluid Specifications
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 prevention, corrosion inhibition, seal
conditioning, and foam and aeration suppression
properties.
Cleanliness level,
minimum
ISO 15/13
Water content,
maximum
250 ppm
Recommended Hydraulic Fluid
Hydraulic oil type
Chevron Rando HD Premium
Viscosity grade
32
Viscosity index
200
Optional Hydraulic Fluids
Mineral based
Shell Tellus S2 V 32
Shell Tellus S2 V 46
Shell Tellus S4 VX 32 Shell
Shell Donax TG (Dexron III)
Chevron 5606A
Biodegradable
Petro Canada Environ MV 46
Fire resistant
UCON Hydrolube HP-5046
Note: Genie specifications require additional
equipment and special installation instructions for
the approved optional fluids. Consult Genie
Product Support before use.
Optional fluids may not have
the same hydraulic lifespan and
may result in component
damage.
Note: Extended machine operation can cause the
hydraulic fluid temperature to increase beyond it's
maximum allowable range. If the hydraulic fluid
temperature consistently exceeds 200°F / 90°C an
optional oil cooler may be required.

June 2020 Service and Repair Manual
Specifications
Part No. 1268556GT Z®-80/60 3
Do not top off with incompatible
hydraulic fluids. Hydraulic fluids
may be incompatible due to the
differences in base additive
chemistry. When incompatible
fluids are mixed, insoluble
materials may form and deposit
in the hydraulic system,
plugging hydraulic lines, filters,
control valves and may result in
component damage.
Note: Do not operate the machine when the
ambient air temperature is consistently above
120°F / 49°C.
Hydraulic Fluid Temperature
Range
Ambient air temperature
1 Chevron hydraulic oil 5606A
2 Petro-Canada Environ MV 46
3 UCON Hydrolube HP-5046D
4 Chevron Rando HD premium oil MV
Chevron Rando HD Premium Oil
MV Fluid Properties
ISO Grade
32
Viscosity index
200
Kinematic Viscosity
cSt @ 200°F/ 100°C
cSt @ 104°F/ 40°C
7.5
33.5
Brookfield Viscosity
cP @ -4°F / -20°C
cP @ -22°F / -30°C
1040
3310
Flash point
375°F / 190°C
Pour point
-58°F / -50°C
Maximum continuous operating
temperature
171°F / 77°C
Note: A hydraulic oil heating system is
recommended when the ambient temperature is
consistently below 0°F / -18°C.
Note: Do not operate the machine when the
ambient temperature is below -20°F / -29°C with
Rando HD Premium MV.

Service and Repair Manual June 2020
Specifications
4 Z®-80/60 Part No. 1268556GT
Chevron 5606A Hydraulic Oil
Fluid Properties
ISO Grade
15
Viscosity index
300
Kinematic Viscosity
cSt @ 200°F/ 100°C
cSt @ 104°F/ 40°C
cSt @ -40°F / -40°C
5.5
15.0
510
Flash point
180°F / 82°C
Pour point
-81°F / -63°C
Maximum continuous operating
temperature
124°F / 51°C
Note: Use of Chevron 5606A hydraulic fluid, or
equivalent, is required when ambient temperatures
are consistently below 0°F / -17°C unless an oil
heating system is used.
Continued use of Chevron
5606A hydraulic fluid, or
equivalent, when ambient
temperatures are consistently
above 32°F / 0°C may result in
component damage
Petro-Canada Environ MV 46
Fluid Properties
ISO Grade
46
Viscosity index
154
Kinematic Viscosity
cSt @ 200°F/ 100°C
cSt @ 104°F/ 40°C
8.0
44.4
Flash point
482°F / 250°C
Pour point
-49°F / -45°C
Maximum continuous operating
temperature
180°F / 82°C
Shell Tellus S4 VX Fluid
Properties
ISO Grade
32
Viscosity index
300
Kinematic Viscosity
cSt @ 200°F/ 100°C
cSt @ 104°F/ 40°C
9
33.8
Brookfield Viscosity
cSt @ -4°F / -20°C
cSt @ -13°F / -25°C
cSt @ -40°F / -40°C
481
702.4
2624
Flash point
>100
Pour point
-76°F / -60°C
Maximum continuous operating
temperature
103°F / 75°C

June 2020 Service and Repair Manual
Specifications
Part No. 1268556GT Z®-80/60 5
UCON Hydrolube HP-5046 Fluid
Properties
ISO Grade
46
Viscosity index
192
Kinematic Viscosity
cSt @ 149°F/ 65°C
cSt @ 104°F/ 40°C
cSt @ 0°F / -18°C
22
46
1300
Flash point
None
Pour point
-81°F / -63°C
Maximum continuous operating
temperature
189°F / 87°C
Hydraulic Component
Specifications
Drive Pump
Type: bi-directional variable displacement piston pump
Displacement per revolution
2.8 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 per revolution
0.85 cu in
13.9 cc
Flow rate @ 2300 rpm
9 gpm
34 L/min
Charge pressure @ 2300 rpm
Neutral position
320 psi
22 bar
Function Pump
Type: two-section tandem gear pump
Displacement per revolution
Pump 1 (inner)
1.94 cu in
31.8 cc
Flow rate @ 2300 rpm
17 gpm
64 L/min
Displacement per revolution
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 per revolution
Section 1 (inner)
0.159 cu in
2.61 cc
Flow rate @ 2687 rpm
1.7 gpm
6.4 L/min
Displacement per revolution
Section 2 (outer)
0.051 cu in
0.84 cc
Flow rate @ 2687 rpm
0.3 gpm
1.1 L/min

Service and Repair Manual June 2020
Specifications
6 Z®-80/60 Part No. 1268556GT
Function manifold
System relief valve pressure, maximum
(measured at PTEST port)
3200 psi
220.6 bar
Primary boom down relief valve pressure
(measured at LS port)
1300 psi
89.6 bar
Secondary boom down relief pressure
(measured at LS port)
2500 psi
172 bar
Secondary boom up relief pressure
(measured at LS port)
2500 psi
172 bar
Primary boom extend relief pressure
(measured at LS port)
1300 psi
89.6 bar
Secondary boom extend relief pressure
(measured at LS port)
2600 psi
179 bar
Platform manifold relief pressure
3000 psi
207 bar
Platform manifold flow regulator
3 gpm
11.4 L/min
Outrigger manifold
Oscillate relief pressure (item BE or CH)
800 psi
55.1 bar
Drive manifold
Hot oil relief pressure
280 psi
19.3 bar
Brakes
Brake relief pressure
240 psi
16.5 bar
Hydraulic Filters
High pressure filter:
Beta 3 ≥200
High pressure filter bypass pressure
102 psi
7 bar
Medium pressure filter
Beta 3 ≥200
Medium pressure filter bypass pressure
51 psi
3.5 bar
Hydraulic tank return filter
10 micron
with 25 psi / 1.7 bar bypass
Manifold Component Specifications
Plug torque
SAE No. 2
36 in-lbs / 4 Nm
SAE No. 4
10 ft-lbs / 13 Nm
SAE No. 6
14 ft-lbs / 19 Nm
SAE No. 8
38 ft-lbs / 51 Nm
SAE No. 10
41 ft-lbs / 55 Nm
SAE No. 12
56 ft-lbs / 76 Nm
Valve coil resistance specifications
Proportional solenoid valve, 12V DC
(schematic items G, W and AB)
4.8Ω
Proportional solenoid valve, 12V DC
(schematic items R)
9Ω
Solenoid valve, 3 position 4 way, 12V DC
(schematic items BA, BB, CA, CB, CP, CQ,
GB, GP and GQ)
9Ω
Solenoid valve, 3 position 4 way, 10V DC
(schematic items O and S)
6.3Ω
Solenoid valve, 2 position 2 way, 10V DC
(schematic items J)
3.3Ω
Solenoid valve, 2 position 2 way, 10V DC
(schematic items C and P)
6.3Ω
Solenoid Valve, 2 position 3 way, 10V DC
(schematic items H, V, X, Z, AA, EE and EF)
6.3Ω
Solenoid Valve, 2 position 3 way, 12V DC
(schematic items BC, BD, CE, CF, FB and
FC)
9Ω
Continuous improvement of our products is a
Genie policy. Product specifications are
subject to change without notice or obligation.

June 2020 Service and Repair Manual
Specifications
Part No. 1268556GT Z®-80/60 7
Continental TME27 Engine
Displacement
164 cu. in
2.68 liters
Number of cylinders
4
Bore and Stroke
3.58 x 4.06 inches
91 x 103.2 mm
Horsepower, continuous
@ 2500 rpm
59 hp / 43.9 kW
Firing order
1 - 3 - 4 - 2
Standby idle-computer
controlled Frequency
1000 rpm
Low function idle-computer
controlled Frequency
1500 rpm
53.33 Hz
High function idle-computer
controlled Frequency
2500 rpm
83.33 Hz
Compression ratio
8.2:1
Compression pressure pressure (psi or bar) of the
lowest cylinder must be at least 75% of the highest
cylinder
Governor
electronic
Valve clearance, warm
Intake
0.014 in
0.36 mm
Exhaust
0.018 in
0.45 mm
Lubrication system
Oil pressure, hot
40 to 60 psi
2.8 to 4.1 bar
Oil capacity (including filter)
7 quarts
6.6 liters
Oil viscosity requirements
-22°F to 86°F / -30°C to 30°C
5W-20
-4°F to 104°F / -20°C to 40°C
10W-40
Above 5°F / -15°C
15W-40
Unit ships with 15W-40. Extreme operating
temperatures may require the use of alternative engine
oils. For oil requirements, refer to the Engine Operator
Manual for your engine.
Oil Pressure switch
Installation torque
8 - 18 ft-lbs
11 - 24 Nm
Pressure switch point
7 psi
0.55 bar
Fuel Pump
Fuel pressure
39-40 psi
2.7 bar
Fuel flow rate
0.42 gpm
1.59 L/min
Fuel requirement
For fuel requirements, refer to the engine Operator
Manual for your engine.
Starter motor
Current draw, normal load
150-345A
Cranking speed
200 - 250 rpm
Battery –Engine starting and control system
Type
12V DC, Group 31
Quantity
2
Battery capacity, maximum
1000A
Reserve capacity @ 25A rate
200 Minutes
Engine coolant
Capacity
(engine only)
10.7 quarts
10.1 liters
Coolant temperature switch
Installation torque
8 - 18 ft-lbs
11 - 24 Nm
Temperature switch point
230°F
110°C
Alternator output
65A @ 13.8V DC
Fan belt deflection
1/2 inch
12 mm

Service and Repair Manual June 2020
Specifications
8 Z®-80/60 Part No. 1268556GT
GM 3.0L Engine
Displacement
183 cu. in
3.0 liters
Number of cylinders
4
Bore and Stroke
4.0 x 3.6 inches
101.6 x 91.44 mm
Horsepower @ 2500 rpm
Horsepower @ 1500 rpm
70 hp / 52 kW
40 hp / 30kW
Firing order
1 - 3 - 4 - 2
Standby idle-computer
controlled Frequency
1000 rpm
Low function idle-computer
controlled Frequency
1500 rpm
High function idle-computer
controlled Frequency
2500 rpm
Compression ratio
9.25:1
Compression pressure pressure (psi or bar) of the
lowest cylinder must be at least 75% of the highest
cylinder
Governor
electronic
Lubrication system
Oil pressure, hot
minimum @ 1000 rpm
6 psi
0.4 bar
Oil capacity (including filter)
5 quarts
4.7 liters
Oil viscosity requirements
-22°F to 86°F / -30°C to 30°C
5W-20
-4°F to 104°F / -20°C to 40°C
10W-40
Above 5°F / -15°C
15W-40
Unit ships with 5W-30.
Extreme operating temperatures may require the use of
alternative engine oils. For oil requirements, refer to the
Engine Operator Manual for your engine.
Fuel requirement
For fuel requirements, refer to the engine Operator
Manual for your engine.
Battery –Engine starting and control system
Type
12V DC, Group 31
Quantity
2
Battery capacity, maximum
1000A
Reserve capacity @ 25A rate
200 Minutes
Engine coolant
Capacity
12 quarts
11.4 liters
Alternator output
70A @ 12V DC
Fan belt deflection
1/2 inch
12 mm