Genie Z-80/60 Parts Manual 88618 Rev G2 – PDF Download

Genie Z-80/60 Parts Manual

Published under part number 88618, Revision G2, dated April 2016

The Genie Z-80/60 Parts Manual, published under part number 88618, Revision G2 and dated April 2016, is the illustrated parts catalog for the Z-80/60 articulating boom lift. It was compiled for machines built from serial number Z8003-101 through Z8016-5829, and from Z8016H-5830 onward. That serial-range focus is the reason this catalog is worth having: the illustrations, item numbers and breakdowns line up with the exact configuration of the machine you are standing in front of, not a generic version of it.

File Details

• Manual type: Illustrated Parts Manual (Parts Catalog)
• Brand: Genie, A Terex Brand
• Model: Z-80/60
• Part number: 88618
• Revision: G2
• Publication date: April 2016
• Language: English
• Page count: 346 pages
• File format: PDF
• Serial number coverage: from SN Z8003-101 to Z8016-5829 and from SN Z8016H-5830
• Manufacturer address shown: Terex South Dakota, Inc., 18340 NE 76th Street, Redmond, WA 98052, USA

Chapters Covered

The catalog is divided into numbered sections, each built around exploded-view figures with numbered callouts that key into a matching parts table:

IMAGES PREVIEW

• 001 Parts Stocking List — 001.1 Recommended spare parts by engine configuration
• 100 Decals — 101.1 Hydraulic Tank Side / Non-Steer End (Word); 102.1 Engine Side / Steer End (Word); 103.1 Booms (Word); 104.1 Platform (Word); 105.1 Hydraulic Tank Side / Non-Steer End (Symbols); 106.1 Engine Side / Steer End (Symbols); 107.1 Booms (Symbols); 108.1 Platform (Symbols)
• 200 Drive Chassis Components — 201.1 2WD Steer Axle Linkage; 202.1 / 202.2 4WD Steer Axle Linkage; 203.1 / 203.2 Front Steer Axle; 204.1 Axle Installation; 205.1 Drive Chassis and Axle Counterweights; 206.1 Drive Hub Assembly with Brake Type 1; 207.1 Drive Hub Assembly with Brake Type 2
• 300 Turntable Components — 301.1 / 301.2 / 301.3 Hydraulic and Fuel Tanks; 302.1 Turntable Rotator and Hydraulic Rotary Coupler Installation; 303.1 / 303.2 Ground Control Box; 304.1 / 304.2 Ground Controls Box (Perkins 404F-22T and Deutz TD 2.9L4); 305.1 Turntable Covers; 306.1 Turntable Components, Engine Side; 307.1 / 307.2 Relay Panel
• 400 Engine Components — Perkins 704-30; Perkins 804D-33; Perkins 404F-22T; Deutz F4L-913; Deutz BF4L-2011 / TD2011-L04i; Deutz TD 2.9L4; GM 3.0L EFI; Ford LRG-425 EFI; Continental TME-27; Engine Tray and Battery
• 500 Boom Components — 501.1 Primary and Secondary Lift Cylinders and Linkage; 502.1 / 503.1 Primary Boom and Cable Track; 504.1 Secondary Boom; 505.1 Jib Boom and Platform Rotator; 506.1 Riser Hose Bulkhead Mount
• 600 Platform Components — 601.1 Platform Installation; 602.1 / 603.1 Platform Controls; 604.1 Toggle Switch Lid Option; 605.1 Platform Controls; 605.2 Platform Controls (Perkins 404F-22T and Deutz TD2.9L4); 606.1 / 606.2 Joysticks
• 700 Hydraulic Components — 701.1 2WD Traction Manifold; 702.1 / 702.2 2WD Steer/Oscillate Manifold; 703.1 4WD Traction Manifold; 704.1 / 704.2 4WD Steer/Oscillate Manifold; 705.1 / 706.1 Function Manifold; 707.1 / 707.2 Platform Manifold; 708.1 Platform Rotate Manifold; 709.1 Remote Pilot Manifold; 710.1 Pumps; 711.1 Steer System Hoses and Fittings; 712.1 Drive System Hoses, 2WD; 713.1 / 713.2 / 713.3 Drive System Hoses, 4WD; 714.1 Turntable Hoses and Fittings; 715.1 Boom Hoses and Fittings
• 800 Accessories — 801.1 Alarm and Beacon Package, Driving Lights; 802.1 Platform Options; 803.1 Ground and Platform Control Box Covers; 804.1 Boom Wipers; 805.1 Turntable; 806.1 Cylinder Bellows; 807.1 / 807.2 Engine Air Cleaners; 808.1 Panel Cradle Option; 809.1 Platform Overload (European Models); 810.1 / 811.1 Belt Driven Generator Option; 812.1 Air Line to Platform; 813.1 / 814.1 / 815.1 Welder Option; 816.1 to 819.1 Hydraulic Generator Option; 820.1 / 820.2 Cold Start Package; 821.1 Half-Mesh and Pipe Cradle Options; 822.1 Spare LPG Tank Carrier Option; 823.1 Operators Protection Alarm; 824.1 / 825.1 / 825.2 Aircraft Protection Package; 826.1 Operator Protection Structure; 827.1 Traveling Fall Arrest Anchor System
• Indices — Part Number Index; Part Description Index
• Cross References — Fittings Cross Reference

What makes this Genie Z-80/60 parts catalog genuinely useful on the shop floor is that it does not stop at the big assemblies. The 700 series breaks the hydraulic system down to individual hose assemblies and the ORFS fittings that join them, with a dedicated fittings cross-reference at the back so a hose number can be traced to the correct end fitting. The 400 series is split by engine family, so you are not hunting through a single generic engine drawing hoping to spot the variant that matches your machine. Electrical items — limit switches, harnesses, the ground control box, the platform control box, the relay panel — all carry their own part numbers, which is what you need when a boom-angle limit switch or a section of SAE 11C cable track harness fails.

Serial Numbers and Configuration Changes

Genie changes part numbers as production runs. This catalog reflects that by printing break points directly into the figures and tables. You will see entries such as “to SN 3225” and “from SN 3226” on the steer axle and yoke assemblies, “from SN 3156” on the high-flotation wheel drive, and multiple engine harness and air cleaner variants tied to specific serial cut-offs. The platform controls alone run through several revisions, with a toggle-switch lid option documented alongside the push-button layout. Reading the serial number off the machine before ordering is not optional with a parts book like this — it is the whole point, and the manual tells you exactly where the stamped chassis number and the serial label sit.

Engines and Machine Configurations Covered

The engine section in this Genie Z-80/60 parts manual covers Perkins 704-30, Perkins 804D-33 and Perkins 404F-22T diesels, Deutz F4L-913, Deutz BF4L-2011 / TD2011-L04i and Deutz TD 2.9L4 diesels, the GM 3.0L EFI and Ford LRG-425 EFI gasoline/LPG engines, and the Continental TME-27. Because engine choice changes the harness, the air cleaner, the exhaust, the cold-start package and even the fuel tank plumbing, each family is given its own view rather than being compressed into one. That is what allows a single parts catalog to serve a machine population built across a long production window with several engine suppliers.

Why the Genie Z-80/60 Parts Manual Earns Its Place in the Workshop

A boom lift out of service is an expensive object. The fastest way back is to identify the failed item correctly, first time, and order the right part. This catalog gives you the exploded view, the item number, the part number, the description and the quantity — the full chain from “that bracket broke” to “order this number.” Beyond ordering, the diagrams double as assembly aids. When a steer cylinder, an oscillate cylinder, a drive hub with brake, a rotary coupler or a cable track assembly comes apart on the bench, the figure shows how the pieces stack back together. Hydraulic techs get the hose and fitting routing for steer, drive, turntable and boom systems. Electrical techs get harness part numbers, limit switch part numbers, contactor and relay references.

Add the accessories and options sections and the coverage widens further: hostile environment packages with boom wipers and cylinder bellows, aircraft protection packages, the welder option, hydraulic and belt-driven generator options, the cold start package, pipe cradles, half-mesh, panel cradles, spare LPG tank carrier, the operator protection structure and the traveling fall arrest anchor system. If the machine left the factory with it, this Genie Z80-60 parts book very likely shows it.

Instant PDF Delivery

This Genie Z-80/60 parts manual is delivered as an instant PDF download once payment clears. There is no shipping, no waiting on a courier and no physical book to keep clean in a dirty workshop. Open it on a laptop in the office, a tablet on the machine or a phone in the pit — whatever is closest when you need a part number. Pages can be printed for the job at hand, so the exploded view you are working from can go on the bench where the parts actually are, and the fittings cross-reference can be pinned up next to the hose bench. Whether you are running a fleet, servicing a single Z-80/60 or rebuilding one of these booms lift by lift, having the illustrated parts catalog to hand turns guesswork into a part number.