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Genie Z-80/60 Service Manual

Genie Z-80/60
182 pages
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Maintenance Manual
- Booms
This manual includes detailed
procedures for each
maintenance inspection.
For Repair procedures, Fault
Codes, Electrical and Hydraulic
Schematics, refer to the
appropriate Service and Repair
Manual for your machine.
Part No. 1268489GT
Rev G
October 2018

Table of Contents

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Genie Z-80/60 Specifications

General IconGeneral
Power SourceDiesel
Platform Rotation160°
Vertical Jib Rotation135°
Gradeability - 4WD45%
ControlsProportional
Drive4WD
Platform Capacity227 kg
Stowed Height3.00 m
Machine Width2.49 m
Lift Capacity227 kg
Drive Speed - 4WD4.8 km/h
Engine TypeDeutz TD 2.9 L4
Engine Power74 hp
Drive Speed4.8 km/h
Steering4-wheel

Summary

Introduction

Important Information

Manual provides detailed scheduled maintenance information for machine owner and user.

Models included in this manual

Chart to identify specific serial numbers for models included in the manual.

Safety Rules

Personal and Workplace Safety

Awareness of hazards for personnel and safety precautions for workshop areas.

Performance Specifications

Function Speeds - All Other Models

Table detailing function speeds for various boom models in seconds.

Drive Speeds

Table detailing drive speeds in seconds for various models and conditions.

Engine Specifications

Perkins Engine Models

Specifications for Perkins engine models including idle speeds and capacities.

GM Engine Models

Specifications for GM engine models including idle speeds and capacities.

Hydraulic Specifications

Hydraulic Relief Valve Pressure

Table of manifold relief valve pressures in psi and bar for various models.

Hydraulic and Drive Hub Fluid Capacities

Fluid capacities for drive hubs, hydraulic tank, and hydraulic system by model.

Maintenance Procedures

Observe and Obey

General rules and warnings to follow before performing maintenance.

Symbols Legend

Explains symbols used to indicate requirements for maintenance procedures.

Quarterly Maintenance Procedures

Q-1 Check for Open Bulletins and Owner Registration

Procedure to check for mandatory bulletins and update owner registration.

Q-2 Battery Inspection

Steps for inspecting battery condition, specific gravity, and connections.

Q-11 Check and Adjust the Engine RPM

Procedure to check and adjust engine RPM for low and high idle settings.

Annual Maintenance Procedures

A-1 Grease the Turntable Rotation Bearing and Rotate Gear

Procedure for lubricating the turntable bearing and rotate gear annually.

A-3 Inspect for Turntable Bearing Wear

Steps to inspect turntable bearing for wear using a dial indicator.

A-11 Inspect the Boom Extend/Retract Cables - S-60/65 and S-80/85 Models

Procedure to inspect boom extend/retract cables for damage and wear.

Programmed Maintenance Procedures

P0-1 Check the Track Tension and Fastener Torque, TRAX Models

Procedure to check track tension and fastener torque on TRAX models.

P1-2 Replace the Drive Hub Oil

Procedure for replacing drive hub oil after initial 50 hours and every 1000 hours.

P2-5 Check the Boom Wear Pads

Procedure to check boom wear pad thickness and inspect for wear.

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