Genie Z-80/60 Operator's Manual
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Genie Z-80/60 Operator's Manual

Articulated boom lift
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See also: Service & Repair Manual , Service Manual
Operator's Manual
Z-80/60
Serial Number Range
from 3158
AUS
Australia
with
Information
Sixth Edition
Sixth Printing
Part No. 226482

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Summary of Contents for Genie Z-80/60

  • Page 1 Operator's Manual Serial Number Range Z-80/60 from 3158 Australia with Maintenance Information Sixth Edition Sixth Printing Part No. 226482...

  • Page 2: Table Of Contents

    Maintenance ............57 Specifications ............61 Copyright © 2002 by Terex Corporation Sixth Edition: Sixth Printing, May 2017 Genie and "Z" are registered trademarks of Terex South Dakota, Inc. in the U.S.A. and many other countries. These machines comply with AS 1418.10...

  • Page 3: Introduction

     You read, understand and obey employer’s safety rules and worksite regulations.  You read, understand and obey all applicable governmental regulations.  You are properly trained to safely operate the machine. Part No. 226482 Z-80/60...
  • Page 4 Indicates a hazardous situation which, if not avoided, could result in death or serious injury. CAUTION Indicates a hazardous situation which, if not avoided, could result in minor or moderate injury. NOTICE Indicates a property damage message. Z-80/60 Part No. 226482...

  • Page 5: Symbol And Hazard Pictorials Definitions

    Tip-over hazard Tip-over hazard Tip-over hazard Tip-over hazard Replace tires with tires of same specification. Lanyard anchorage Read the operator’s Only trained Wheel load Have fire points manual maintenance extinguisher near. personnel should access compartments Part No. 226482 Z-80/60...
  • Page 6 Weight of welder Tie-down instructions Tie-down instructions reduces capacity Recovery procedure if tilt alarm sounds while elevated. Platform uphill: Platform downhill: 1 Lower primary. 1 Retract primary. 2 Lower secondary. 2 Lower secondary. Retract primary. Lower primary. Z-80/60 Part No. 226482...

  • Page 7: Personal Safety

    Sixth Edition • Sixth Printing Operator's Manual Personal Safety Personal Safety Part No. 226482 Z-80/60...
  • Page 8 Operator's Manual Sixth Edition • Sixth Printing Personal Safety Z-80/60 Part No. 226482...
  • Page 9 82237 B other high energy starting with glow plugs. aids. 97602 B 82237 31060 31788 31060 28161 97602 28177 31060 28175 97875 114390 Part No. 226482 Z-80/60...
  • Page 10 Operator's Manual Sixth Edition • Sixth Printing Personal Safety Z-80/60 Part No. 226482...
  • Page 11 Operators must comply with employer, job site and governmental rules regarding the use of personal protective equipment. All PFPE must comply with applicable governmental regulations, and must be inspected and used in accordance with the PFPE manufacturer’s instructions. Part No. 226482 Z-80/60...

  • Page 12: Work Area Safety

    See the decals with the options and accessories. If using accessories, read, understand and obey the decals, instructions and manuals with the accessory. Z-80/60 Part No. 226482...
  • Page 13 Do not rotate the platform or the load. Increasing the area exposed boom while lowering. to the wind will decrease machine stability. The recovery mode should be used only by trained and authorized personnel. Part No. 226482 Z-80/60...
  • Page 14 Do not tie the boom or platform to adjacent structures. Do not place loads outside the platform perimeter. Do not push off or pull toward any object outside of the platform. Maximum allowable manual force – 400 N Z-80/60 Part No. 226482...
  • Page 15 Do not use the platform controls to free a platform that is caught, snagged or otherwise prevented from normal motion by an adjacent structure. All personnel must be removed from the platform before attempting to free the platform using the ground controls. Part No. 226482 Z-80/60...
  • Page 16 Lower the platform entry mid-rail or close the entry governmental rules regarding use of personal gate before operating. protective equipment. Do not enter or exit the platform unless the machine is in the stowed position and the platform is at ground level. Z-80/60 Part No. 226482...
  • Page 17 Do not operate the machine or charge the battery No stunt driving or horseplay while operating a in hazardous locations or locations where machine. potentially flammable or explosive gases or particles may be present. Do not spray ether into engines equipped with glow plugs. Part No. 226482 Z-80/60...
  • Page 18 Be sure all maintenance has been performed as Avoid spilling or contacting specified in this manual and the appropriate Genie battery acid. Neutralize service manual. battery acid spills with Be sure all decals are in place and legible.
  • Page 19 Maximum wind speed: 6.7 m/sec Do not cause a horizontal force or side load to Maximum panel area: 3 m machine by raising or lowering a fixed or overhanging load. Electrocution Hazard: Keep pipes away from all energized electrical conductors. Part No. 226482 Z-80/60...
  • Page 20 The welder power supply Clamp the negative lead to the ground post at the weighs 34 kg. turntable and platform. Do not operate the welder unless a fire extinguisher is immediately available for instant use, per OSHA regulation 1926.352(d). Z-80/60 Part No. 226482...
  • Page 21 Retract and lower the boom to the stowed position. Rotate the turntable so that the boom is between the non-steer wheels. Turn the key switch to the off position and remove the key to secure from unauthorized use. Part No. 226482 Z-80/60...

  • Page 22: Legend

    Operator's Manual Sixth Edition • Sixth Printing Legend Legend Lanyard anchorage points Circle-end tire Sliding mid-rail Square-end tire Manual storage container Secondary boom Foot switch Ground controls 10 Platform controls Primary boom 11 Platform Z-80/60 Part No. 226482...

  • Page 23: Controls

    The Z-80 machines will have one of these two styles of ground control panel. The descriptions in this section and the instructions in the Function Test and Operating Instructions apply to both panels, unless specifically noted. STOP STOP Part No. 226482 Z-80/60...
  • Page 24 Primary boom up/down buttons 10 Glow plug button (if equipped with manual Press the primary boom up button and the glow plugs) boom will raise. Press the primary boom down button and the boom will lower. Z-80/60 Part No. 226482...
  • Page 25 16 Primary boom extend/retract buttons Press the primary boom up button and the Press the primary boom extend button and the boom will raise. primary boom will extend. Press the primary boom retract button and the primary boom will retract. Part No. 226482 Z-80/60...
  • Page 26 The Z-80 machines will have one of these two styles of platform control panel. The descriptions in this section and the instructions in the Function Test and Operating Instructions apply to both panels, unless specifically noted. Z-80/60 Part No. 226482...
  • Page 27 Sixth Edition • Sixth Printing Operator's Manual Controls 16 17 STOP STOP Part No. 226482 Z-80/60...
  • Page 28 11 Engine idle control with indicator light release the button to turn the generator off. Move the switch or push the button to select the engine idle setting. The indicator light next to the current engine idle setting will be on. Z-80/60 Part No. 226482...
  • Page 29 Move the switch or push the button to choose engine off. Pull out the red Emergency Stop steer mode. The indicator light next to the button to the on position to operate the current steer mode will be on. machine. Part No. 226482 Z-80/60...
  • Page 30 29 Platform level recovery switch (located on the side of the platform controls) Push and hold the platform level recovery switch up. Use the platform level switch to level the platform. Z-80/60 Part No. 226482...

  • Page 31: Inspections

    Scheduled maintenance inspections shall be performed by qualified service technicians, according to the manufacturer’s specifications and the requirements listed in the responsibilities manual. Part No. 226482 Z-80/60...
  • Page 32  Electrical components, wiring and electrical cables  Hydraulic hoses, fittings, cylinders and manifolds  Fuel and hydraulic tanks  Drive and turntable motors and drive hubs Z-80/60 Part No. 226482...
  • Page 33 3 Always perform function tests prior to use. Know and understand the function tests before going on to the next section. 4 Inspect the workplace. 5 Only use the machine as it was intended. Part No. 226482 Z-80/60...
  • Page 34 Result: The LCD screen should display the button and activate each boom and platform angle in degrees. function button. Result: All boom and platform functions should operate through a full cycle. The descent alarm should sound while the boom is lowering. Z-80/60 Part No. 226482...
  • Page 35 21 Press and hold the secondary boom down/retract button. Result: The secondary boom should fully retract and then lower. The secondary boom should not lower unless it is fully retracted. Part No. 226482 Z-80/60...
  • Page 36 35 Press down the foot switch. steer button or move the steer select 36 Activate each machine function control handle, switch. toggle switch or button. 42 Press down the foot switch. Result: All functions should operate through a full cycle. Z-80/60 Part No. 226482...
  • Page 37 The circle-end wheels should turn in the direction that the yellow triangles point on the drive chassis. Part No. 226482 Z-80/60...
  • Page 38 Result: The machine should move in the direction that the yellow arrow points on the drive chassis, then come to an abrupt stop. Note: The brakes must be able to hold the machine on any slope it is able to climb. Z-80/60 Part No. 226482...
  • Page 39 76 Lower the secondary boom to the stowed position. If the drive speed with the primary or secondary boom raised or the primary boom extended exceeds 30 cm per second, immediately tag and remove the machine from service. Part No. 226482 Z-80/60...
  • Page 40 Activate each function control handle, toggle switch or thumb rocker switch. Note: To conserve battery power, test each function through a partial cycle. Result: All boom and steer functions should operate. Z-80/60 Part No. 226482...
  • Page 41 It should be performed by the operator prior to moving the machine to the workplace. It is the operator’s responsibility to read and remember the workplace hazards, then watch for and avoid them while moving, setting up and operating the machine. Part No. 226482 Z-80/60...
  • Page 42 Label – No Step 72875 Warning – Pipe Cradle (option) 82237 Danger – Electrocution Hazard (option) Shading indicates decal is hidden from view, i.e. under covers 82268 Cosmetic – Genie Z-80/60 82269 Ground Control Panel 82281 Platform Control Panel Z-80/60 Part No. 226482...
  • Page 43 Sixth Edition • Sixth Printing Operator's Manual Inspections Part No. 226482 Z-80/60...

  • Page 44: Operating Instructions

    That means 4 Inspect the workplace. every new operator should perform a pre-operation inspection, function tests, and a workplace 5 Only use the machine as it was inspection before using the machine. intended. Z-80/60 Part No. 226482...
  • Page 45 Activate the glow plugs. Push the button or move the switch. Start the engine. Push the button or move the switch. If the engine fails to start or dies, the restart delay with disable the start switch for 3 seconds. Part No. 226482 Z-80/60...
  • Page 46 Activate the emergency controls. Move and hold the switch or push and hold the button. Activate each function control handle, switch or button. The drive function will not operate with emergency power. Z-80/60 Part No. 226482...
  • Page 47 Use the color-coded direction arrows on the platform controls and the drive chassis to identify the direction the machine will travel. Machine travel speed is restricted when the platform is raised or extended. Part No. 226482 Z-80/60...
  • Page 48 0.3 m ÷ 3.6 m = 0.083 x 100 = 8.3% grade If the slope exceeds the maximum uphill, downhill or side slope rating, then the machine must be winched or transported up or down the slope. See Transport and Lifting section. Z-80/60 Part No. 226482...
  • Page 49 To turn off the generator, press the generator Remove weight from the platform button or move the switch. The indicator light will until the light goes off and then turn off. restart the engine. Part No. 226482 Z-80/60...
  • Page 50 +/-15 degrees the only way to recover is to use the Service/Recovery key switch on the side of the or a qualified service technician. ground controls to activate Recovery Mode. Z-80/60 Part No. 226482...
  • Page 51 Press down the foot switch. Light on: Tag and remove the machine Move and hold the aircraft from service. protection override switch. Move the appropriate function control handle or toggle switch to move the machine away from aircraft components. Part No. 226482 Z-80/60...
  • Page 52 Install two U-bolts from the outside of the platform rails through each pipe cradle mount. Secure each U-bolt with 2 washers and 2 nuts. strap U-bolts pipe cradle mount upper platform railing pipe cradle weldment middle platform railing flat washers nylock nuts Z-80/60 Part No. 226482...
  • Page 53 Place the tube between the panel cradle and Pipe Cradle Assembly Weight 9.5 kg the platform floor. Insert the U-bolt through the floor, around the tube and into the panel cradle base. Repeat above for the second set of parts. Part No. 226482 Z-80/60...
  • Page 54 Secure both panel cradles to the platform. Place the load so that it rests in both panel cradles. padding Center the load on the platform. Secure the load to the platform using the strap. Tighten the strap. clamp hook Z-80/60 Part No. 226482...
  • Page 55 Retract and lower the boom to the stowed position. Rotate the turntable so that the boom is between the non-steer wheels. Turn the key switch to the off position and remove the key to secure from unauthorized use. Part No. 226482 Z-80/60...

  • Page 56: Transport And Lifting Instructions

    Genie lifts are very heavy relative to their size. See the serial label for the Towing the Genie Z-80/60 is not recommended. If machine weight. the machine must be towed, do not exceed 3.2 km/h.
  • Page 57 Place a block under the platform rotator. Do not items. allow the block to contact the platform cylinder. Secure the platform with a nylon strap placed through the lower platform support. Do not use excessive downward force when securing the boom section. Part No. 226482 Z-80/60...
  • Page 58 Attach the rigging to the 2 chassis lifting points farthest from the turnable lifting point. Adjust the rigging to prevent damage to the machine and to keep the machine level. Turntable Lifting Chassis Point Lifting Points (2) 1.42 m 86.8 cm Z-80/60 Part No. 226482...

  • Page 59: Maintenance

    5W-40 and the requirements specified in the responsibilities manual. Perkins 804D-33 Engine  Oil type 15W-40 Use only Genie approved replacement parts. Oil type - cold conditions 5W-40 Perkins 404D-22T Engine Maintenance Symbols Legend Oil type 15W-40 The following symbols have been used in this...
  • Page 60 Chevron Rando HD equivalent Be sure that the battery hold-down brackets are in place and secure. Note: Adding terminal protectors and a corrosion preventative sealant will help eliminate the corrosion on the battery terminals and cables. Z-80/60 Part No. 226482...
  • Page 61 Bodily Injury Hazard. Fluids in the radiator are under pressure and extremely hot. Use caution Check each tire with an air pressure gauge. when removing cap and adding fluids. Add air as needed. 5.5 bar High flotation tire pressure Part No. 226482 Z-80/60...
  • Page 62 Perkins 804D-33 Engine Fuel Type Low Sulfur Diesel (LSD) Perkins 404D-22T Engine Fuel Type Low Sulfur Diesel (LSD) Continental TME27 Engine Fuel Type Low Sulfur Diesel (LSD) Deutz BF4L Engine Fuel Type Low Sulfur Diesel (LSD) Z-80/60 Part No. 226482...

  • Page 63: Specifications

    Platform rotation 160° be used only with adequate safety factors. AC outlet in platform standard Continuous improvement of our products is a Genie Hydraulic pressure, maximum 220 bar policy. Product specifications are subject to change (boom functions) without notice or obligation.
  • Page 64 Operator's Manual Sixth Edition • Sixth Printing Specifications Z-80/60 Range of Motion Z-80/60 Part No. 226482 Operator's Manual Sixth Edition • Sixth Printing Z-80/60 Part No. 226482...
  • Page 65 www.genielift.com...

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