Terex Genie Z-80/60 Operator's Manual
  1. Manuals
  2. Brands
  3. Terex Manuals
  4. Boom Lifts
  5. Genie Z-80/60
  6. Operator's manual

Terex Genie Z-80/60 Operator's Manual

Hide thumbs Also See for Genie Z-80/60:
Table of Contents

Advertisement

Quick Links

Operator's Manual
Z
-80/60
®
Serial Number Range
from Z80H-7896
ANSI/CSA
North America
South America
Asia
with
Maintenance
Information
Original Instructions
Fifth Edition
First Printing
Part No. 1294418GT

Advertisement

Table of Contents
loading
Need help?

Need help?

Do you have a question about the Genie Z-80/60 and is the answer not in the manual?

Questions and answers

Subscribe to Our Youtube Channel

Related Manuals for Terex Genie Z-80/60

Summary of Contents for Terex Genie Z-80/60

  • Page 1 Operator's Manual Serial Number Range -80/60 ® from Z80H-7896 ANSI/CSA North America South America Asia with Maintenance Information Original Instructions Fifth Edition First Printing Part No. 1294418GT...

  • Page 2: Table Of Contents

    Maintenance ............72 Specifications ............76 Copyright © 2002 by Terex Corporation Fifth Edition: First Printing, October 2020 Genie and "Z" are registered trademarks of Terex South Dakota, Inc. in the U.S.A. and many other countries. These machines comply with ANSI/SAIA A92.20 CAN/CSA B354.6...

  • Page 3: Introduction

    Fifth Edition • First Printing Operator's Manual Introduction Introduction About this manual Intended Use and Familiarization Guide Genie appreciates your choice of our machine for your application. Our number one priority is user The intended use of this machine is to lift safety, which is best achieved by our joint efforts.
  • Page 4 Fifth Edition • First Printing Operator's Manual Introduction Platform controls symbology and related Ground controls symbology and related machine movement: machine movement: Platform level swtich Platform level, jib boom up/down, primary boom extend/retract, primary boom up/down, and secondary boom Platform rotate switch retract/lower.
  • Page 5 Fifth Edition • First Printing Operator's Manual Introduction Bulletin Distribution and Contacting the Manufacturer Compliance At times it may be necessary to contact Genie. When you do, be ready to supply the model Safety of product users is of paramount number and serial number of your machine, along importance to Genie.
  • Page 6 Fifth Edition • First Printing Operator's Manual Introduction Safety Sign Maintenance Replace any missing or damaged safety signs. Keep operator safety in mind at all times. Use mild soap and water to clean safety signs. Do not use solvent-based cleaners because they may damage the safety sign material.

  • Page 7: Symbol And Hazard Pictorials Definitions

    Fifth Edition • First Printing Operator's Manual Symbol and Hazard Pictorials Definitions Symbol and Hazard Pictorials Definitions Fire hazard Explosion hazard Explosion hazard Read the service No smoking. manual No flame. Stop engine. Electrocution hazard Maintain required Fire extinguisher No smoking Explosion hazard clearance Tip-over hazard...
  • Page 8 Fifth Edition • First Printing Operator's Manual Symbol and Hazard Pictorials Definitions Wheel load Wind speed Maximum capacity Manual force Weight of welder reduces capacity Platform tie-down Lifting & tie down Lanyard anchorage Tie-down point Lifting point instructions instructions points Corrosive acid.
  • Page 9 Fifth Edition • First Printing Operator's Manual Symbol and Hazard Pictorials Definitions Electrocution hazard Avoid contact Disconnect battery Voltage rating for Pressure rating for air power to platform line to platform Crush hazard Support the platform Do not use ether or Explosion hazard Relieve all pressure or boom during...

  • Page 10: General Safety

    Fifth Edition • First Printing Operator's Manual General Safety General Safety Shading indicates decal is hidden from view, i.e. under covers ® -80/60 Part No. 1294418GT...
  • Page 11 Fifth Edition • First Printing Operator's Manual General Safety Shading indicates decal is hidden from view, i.e. under covers ® Part No. 1294418GT -80/60...
  • Page 12 Fifth Edition • First Printing Operator's Manual General Safety ® -80/60 Part No. 1294418GT...
  • Page 13 Fifth Edition • First Printing Operator's Manual General Safety ® Part No. 1294418GT -80/60...
  • Page 14 Fifth Edition • First Printing Operator's Manual General Safety ® -80/60 Part No. 1294418GT...
  • Page 15 Fifth Edition • First Printing Operator's Manual General Safety Shading indicates decal is hidden from view, i.e. under covers ® Part No. 1294418GT -80/60...

  • Page 16: Personal Safety

    Fifth Edition • First Printing Operator's Manual Personal Safety Personal Safety Personal Fall Protection Personal fall protection equipment (PFPE) is required when operating this machine. Occupants must wear a safety belt or harness in accordance with governmental regulations. Attach the lanyard to the anchor provided in the platform. Operators must comply with employer, job site and governmental rules regarding the use of personal protective equipment.

  • Page 17: Work Area Safety

    Fifth Edition • First Printing Operator's Manual Work Area Safety Work Area Safety Electrocution Hazards Keep away from the machine if it contacts This machine is not electrically insulated and will energized power lines. not provide protection from contact with or Personnel on the ground proximity to electrical current.
  • Page 18 Fifth Edition • First Printing Operator's Manual Work Area Safety Do not raise or extend the If the tilt alarm sounds boom unless the machine with the platform uphill: is on a firm, level surface. Lower the primary boom. Retract/lower the secondary boom.
  • Page 19 Fifth Edition • First Printing Operator's Manual Work Area Safety Do not alter or disable machine components that Use extreme care and in any way affect safety and stability. slow speeds while driving the machine in the stowed Do not replace items critical to machine stability position across uneven with items of different weight or specification.
  • Page 20 Fifth Edition • First Printing Operator's Manual Work Area Safety Operation on Slopes Hazards Do not place or attach fixed or overhanging loads Do not drive the machine on a slope that exceeds to any part of this the maximum uphill, downhill or side slope rating machine.
  • Page 21 Fifth Edition • First Printing Operator's Manual Work Area Safety Fall Hazards Collision Hazards Occupants must wear a Be aware of limited sight safety belt or harness in distance and blind spots accordance with when driving or operating. governmental regulations. Attach the lanyard to the anchor provided in the Be aware of the boom position and tailswing when...
  • Page 22 Fifth Edition • First Printing Operator's Manual Work Area Safety Bodily Injury Hazard Observe and use the color-coded direction arrows on the platform controls and drive chassis for drive Always operate the machine in a well-ventilated and steer functions. area to avoid carbon monoxide poisoning. Do not lower the boom Do not operate the machine with a hydraulic oil or unless the area below is...
  • Page 23 Fifth Edition • First Printing Operator's Manual Work Area Safety Damaged Machine Hazards Battery Safety Do not use a damaged or malfunctioning machine. Burn Hazards Conduct a thorough pre-operation inspection of Batteries contain acid. the machine and test all functions before each Always wear protective work shift.
  • Page 24 Fifth Edition • First Printing Operator's Manual Work Area Safety Contact Alarm Safety Weld Line to Platform Safety Read, understand and obey all warnings and Read, understand and obey all warnings and instructions provided with the contact alarm. instructions provided with the welding power unit. Do not exceed the rated platform capacity.
  • Page 25 Fifth Edition • First Printing Operator's Manual Work Area Safety Pipe Cradle Safety Panel Cradle Safety Read, understand, and obey all warnings and Read, understand and obey all warnings and instructions provided with the pipe cradles. instructions provided with the panel cradles. Do not exceed the rated platform capacity.
  • Page 26 Fifth Edition • First Printing Operator's Manual Work Area Safety Tow Package Safety Lockout After Each Use Read, understand and obey all warnings and Select a safe parking location—firm level instructions provided with the tow package. surface, clear of obstruction and traffic. Retract and lower the boom to the stowed When vehicle is in free-wheel configuration, there position.

  • Page 27: Legend

    Fifth Edition • First Printing Operator's Manual Legend Legend Circle-end tire Lanyard anchorage points Square-end tire Sliding mid-rail Secondary boom Manual storage container Ground controls Foot switch Primary boom 10 Platform controls 11 Platform ® Part No. 1294418GT -80/60...

  • Page 28: Controls

    Fifth Edition • First Printing Operator's Manual Controls Controls The ground control station is to be used as a means to raise the platform for storage purposes and for function tests. The ground control station can be used in the event of an emergency to rescue an incapacitated person in the platform.
  • Page 29 Fifth Edition • First Printing Operator's Manual Controls Ground Control Panel LCD screen control buttons Gasoline/LPG models: fuel select button Low speed function enable button Push the fuel select button to select the engine Press the low speed function enable button to enable the functions on the ground control fuel source.
  • Page 30 Fifth Edition • First Printing Operator's Manual Controls 11 Key switch for off/ground/platform selection 19 Bypass/recovery key switch Turn the key switch to the off position and the Bypass key position to be used only to level machine will be off. Turn the key switch to the the platform if the ground control display ground position and the ground controls will shows platform out of level (P22) and platform...
  • Page 31 Fifth Edition • First Printing Operator's Manual Controls ® Part No. 1294418GT -80/60...
  • Page 32 Fifth Edition • First Printing Operator's Manual Controls Lower primary boom indicator light Platform Control Panel Lower the primary boom until the light is off. Horn button Not used Press this button and the horn will sound. Release the button and the horn will stop. Used for optional equipment Platform not level indicator light Generator control with indicator light (if...
  • Page 33 Fifth Edition • First Printing Operator's Manual Controls Auxiliary power switch with indicator light 12 Gasoline/LPG models: Fuel select control with indicator light Use auxiliary power if the primary power source (engine) fails. Move the switch or push the button to select Simultaneously hold the auxiliary power switch the fuel source.
  • Page 34 Fifth Edition • First Printing Operator's Manual Controls 19 Dual axis proportional control handle for drive 21 Single axis proportional control handle for and steer functions. secondary boom up/extend and down/retract function Proportional control handle for drive function Move the control handle up and the secondary and thumb rocker for steer function.
  • Page 35 Fifth Edition • First Printing Operator's Manual Controls 25 Dual axis proportional control handle for 27 Platform level switch primary boom up/down and turntable rotate Move the platform level switch up and the level left/right functions of the platform will raise. Move the platform Move the control handle up and the primary level switch down and the level of the platform boom will raise.

  • Page 36: Inspections

    Fifth Edition • First Printing Operator's Manual Inspections Inspections Pre-operation Inspection Fundamentals It is the responsibility of the operator to perform a pre-operation inspection and routine maintenance. The pre-operation inspection is a visual inspection performed by the operator prior to each work shift. Do Not Operate Unless: The inspection is designed to discover if anything is apparently wrong with a machine before the...
  • Page 37 Fifth Edition • First Printing Operator's Manual Inspections Pre-operation Inspection  Wear pads  Tires and wheels  Be sure that the operator’s, safety, and  Engine and related components responsibilities manuals are complete, legible and in the storage container located in the ...
  • Page 38 Fifth Edition • First Printing Operator's Manual Inspections Function Test Fundamentals The function tests are designed to discover any malfunctions before the machine is put into service. The operator must follow the step-by-step instructions to test all machine functions. A malfunctioning machine must never be used. If malfunctions are discovered, the machine must be Do Not Operate Unless: tagged and removed from service.
  • Page 39 Fifth Edition • First Printing Operator's Manual Inspections Test Machine Functions At the Ground Controls Select a test area that is firm, level and free of Do not press and hold a function hazards. enable/speed select Turn the key switch to ground control. button.
  • Page 40 Fifth Edition • First Printing Operator's Manual Inspections 18 Lower the primary boom. Test the Tilt Sensor 19 Simultaneously press the 2 13 Press one of the LCD LCD screen control buttons screen control buttons until shown to activate status TURNTABLE LEVEL mode.
  • Page 41 Fifth Edition • First Printing Operator's Manual Inspections Test the Tilt Sensor Alarm At the Platform Controls 30 Push a button or move a switch, such as the Test Emergency Stop engine idle select. 23 Turn the key switch to platform control. Result: The alarm should sound at the platform controls.
  • Page 42 Fifth Edition • First Printing Operator's Manual Inspections 44 Slowly move the control handle in the direction Test the Steering (models with 4 wheel indicated by the yellow triangle on the control steer) panel OR press the thumb rocker switch in the 38 Select square-end (blue arrow) steer.
  • Page 43 Fifth Edition • First Printing Operator's Manual Inspections Test the Steering (models with 2 wheel 50 Select coordinated steer. Push the steer) coordinated steer button or move the steer mode switch. 54 Press down the foot switch. 55 Press the thumb rocker switch on top of the 51 Press down the foot switch.
  • Page 44 Fifth Edition • First Printing Operator's Manual Inspections Test Drive and Braking Test the Drive Enable System 57 Press down the foot switch. 64 Press down the foot switch and lower the boom to the stowed position. 58 Slowly move the drive control handle in the direction indicated by the blue arrow on the 65 Rotate the turntable until the primary boom control panel until the machine begins to...
  • Page 45 Fifth Edition • First Printing Operator's Manual Inspections 75 Raise the secondary boom to 10° above Test Limited Drive Speed horizontal. 68 Press down the foot switch. 76 Slowly move the drive control handle to the full 69 Raise the primary boom to 10° above drive position.
  • Page 46 Fifth Edition • First Printing Operator's Manual Inspections 82 Lower the primary boom to the stowed position 90 Lower the secondary boom to the stowed or drive in the opposite direction. position or drive in the opposite direction. Result: The alarm should turn off and the Result: The alarm should turn off and the machine should drive.
  • Page 47 Fifth Edition • First Printing Operator's Manual Inspections 97 Retract the primary boom to the stowed Test the Platform Level Recovery position or drive in the opposite direction. 103 Press down the foot switch. Result: The alarm should turn off and the 104 Push and hold the platform level recovery machine should drive.
  • Page 48 Fifth Edition • First Printing Operator's Manual Inspections Test Aircraft Protection Package 119 Operate each machine function. (if equipped) Result: All machine functions should not Note: Two people may be required to perform this operate. test. 120 Insert the actuator into the switch socket. 111 Move the yellow bumper at the bottom of the Result: The lights and horn will turn off.
  • Page 49 Fifth Edition • First Printing Operator's Manual Inspections Workplace Inspection Checklist Be aware of and avoid the following hazardous situations:  drop-offs or holes  bumps, floor obstructions, or debris  sloped surfaces Do Not Operate Unless:  unstable or slippery surfaces ...
  • Page 50 Fifth Edition • First Printing Operator's Manual Inspections Inspection for Decals with Words Part No. Decal Description Label – Circuit Breaker 30 amp 72053 Determine whether the decals on your machine Label – Lifting Point 72086 have words or symbols. Use the appropriate inspection to verify that all decals are legible and Label –...
  • Page 51 Fifth Edition • First Printing Operator's Manual Inspections ® Part No. 1294418GT -80/60...
  • Page 52 Fifth Edition • First Printing Operator's Manual Inspections Inspection for Decals with Words Part No. Decal Description 1263543 Warning – Compartment Access Continued from previous page. 1263544 Bypass Key Switch Below is a numerical list with quantities and 1263545 Instructions – Bypass Key Switch descriptions.
  • Page 53 Fifth Edition • First Printing Operator's Manual Inspections ® Part No. 1294418GT -80/60...
  • Page 54 Fifth Edition • First Printing Operator's Manual Inspections Inspection for Decals with Part No. Decal Description Label – Tip-over Hazard, Tires Symbols 114249 Label – Explosion Hazard 114251 Use the inspection to verify that all decals are Label – Tip-over Hazard, Limit Switches 114252 legible and in place.
  • Page 55 Fifth Edition • First Printing Operator's Manual Inspections ® Part No. 1294418GT -80/60...

  • Page 56: Operating Instructions

    Fifth Edition • First Printing Operator's Manual Operating Instructions Operating Instructions Fundamentals The Operating Instructions section provides instructions for each aspect of machine operation. It is the operator’s responsibility to follow all the safety rules and instructions in the operator’s, safety, and responsibilities manuals.
  • Page 57 Fifth Edition • First Printing Operator's Manual Operating Instructions All models Starting the Engine If the engine fails to start after 15 seconds of At the ground controls, turn the key switch to cranking, determine the cause and repair any the desired position.
  • Page 58 Fifth Edition • First Printing Operator's Manual Operating Instructions Emergency Stop Operation from Ground Push in the red Emergency Stop button to the off Turn the key switch to ground control. position at the ground controls or the platform Pull out the red Emergency Stop button to the controls to stop all machine functions and turn the on position.
  • Page 59 Fifth Edition • First Printing Operator's Manual Operating Instructions All models: Operation from Platform Turn the key switch to platform control. Slowly move the drive control handle in the direction Pull out both ground and platform red indicated by blue or yellow Emergency Stop buttons to the on position.
  • Page 60 Fifth Edition • First Printing Operator's Manual Operating Instructions Platform Overload Indicator Light To determine the slope grade: Light flashing indicates the platform is overloaded. Measure the slope with a digital inclinometer OR The engine will stop and no functions will operate. use the following procedure.
  • Page 61 Fifth Edition • First Printing Operator's Manual Operating Instructions Drive Enable Engine Idle Select (rpm) Select engine idle (rpm). Push the button or move Light on indicates that the boom the switch. The indicator light next to the current has moved just past either setting will be on.
  • Page 62 Fifth Edition • First Printing Operator's Manual Operating Instructions Operating Envelope Indicator Lights Platform Level Recovery The operating envelope indicator lights will come Press down the foot switch. on to notify the operator that a function has been Push and hold the platform level recovery interrupted and/or an action is required by the switch up.
  • Page 63 Fifth Edition • First Printing Operator's Manual Operating Instructions Platform Out of Level (P22 code) Tilt Sensor Activation Settings Bypass key position to be used to level the Model Chassis Angle Chassis Angle platform if ground control display shows platform (front to back) (side to side) out of level (P22) and platform level controls do...
  • Page 64 Fifth Edition • First Printing Operator's Manual Operating Instructions Platform Out of Level (Platform Level > 15 Machine Not Level Indicator Light Degrees Fault) If the tilt alarm sounds when the If ground control display shows PLATFORM platform is raised, the Machine Not LEVEL >...
  • Page 65 Fifth Edition • First Printing Operator's Manual Operating Instructions Machine Malfunction Indicator Light Out of Operational Envelope Recovery If all functions stop operating, you may have Light on indicates all functions have exceeded the operational envelope. A trained stopped. operator on the ground will need to lower the platform from the ground controls.
  • Page 66 Fifth Edition • First Printing Operator's Manual Operating Instructions Aircraft Protection Package (if equipped) Contact Alarm (if equipped) The contact alarm is designed to alert ground If the platform bumper comes personnel when an operator makes contact with into contact with an object, the the platform control panel, interrupting boom machine will shut down and no movement, sounding an alarm and flashing...
  • Page 67 Fifth Edition • First Printing Operator's Manual Operating Instructions Pipe Cradle Instructions Observe and Obey:  The pipe cradle assembly consists of 2 pipe Pipe cradles must be installed on the inside of cradles positioned at either side of the platform the platform.
  • Page 68 Fifth Edition • First Printing Operator's Manual Operating Instructions Pipe Cradle Operation Panel Cradle Assembly Be sure the pipe cradle assembly and Apply the warning decal to the front of each installation instructions have been followed panel cradle (if needed). properly and that the pipe cradles are secured Install rubber bumper 1 in the panel cradle to the platform railings.
  • Page 69 Fifth Edition • First Printing Operator's Manual Operating Instructions Installation of Padding Install the 2 pieces of padding on the platform rails. Position the padding to protect the panels from contact with the platform rails. Installation of Strap Open the clamp and install it around a vertical platform rail tube.
  • Page 70 Fifth Edition • First Printing Operator's Manual Operating Instructions After Each Use Select a safe parking location—firm level surface, clear of obstruction and traffic. Retract and lower the boom to the stowed position. Rotate the turntable until the boom is positioned between the circle end wheels.

  • Page 71: Transport And Lifting Instructions

    Genie lifts are very heavy the brakes. relative to their size. See the serial label for Towing the Genie Z-80/60 is not recommended. If the machine weight. the machine must be towed, do not exceed 2 mph / 3.2 km/h.
  • Page 72 Fifth Edition • First Printing Operator's Manual Transport and Lifting Instructions Securing the Chassis Securing to Truck or Trailer for Transit Use chains of ample load capacity. Always use the turntable rotation lock pin each Use a minimum of 5 chains. time the machine is transported.
  • Page 73 Fifth Edition • First Printing Operator's Manual Transport and Lifting Instructions Lifting Instructions Fully lower and retract both the primary and secondary booms. Remove all loose items on the machine. Rotate the turntable 90 degrees. Observe and Obey: Determine the center of gravity of your machine using the picture on this page.

  • Page 74: Maintenance

    Fifth Edition • First Printing Operator's Manual Maintenance Maintenance Check the Engine Oil Level Maintaining the proper engine oil level is essential to good engine performance and service life. Observe and Obey: Operating the machine with an improper oil level can damage engine components.
  • Page 75 Fifth Edition • First Printing Operator's Manual Maintenance Check the Engine Coolant Level – Check the Hydraulic Oil Level Liquid Cooled Models Maintaining the hydraulic oil at the proper level is essential to machine operation. Improper hydraulic Maintaining the engine coolant at the proper level oil levels can damage hydraulic components.
  • Page 76 Fifth Edition • First Printing Operator's Manual Maintenance Check the Batteries Diesel Fuel Requirements Proper battery condition is essential to good Satisfactory engine performance is dependent on machine performance and operational safety. the use of a good quality fuel. The use of a good Improper fluid levels or damaged cables and quality fuel will give the following result: long connections can result in component damage and...
  • Page 77 Fifth Edition • First Printing Operator's Manual Maintenance Scheduled Maintenance Maintenance performed quarterly, annually and every two years must be completed by a person trained and qualified to perform maintenance on this machine according to the procedures found in the service and maintenance manuals for this machine.

  • Page 78: Specifications

    Fifth Edition • First Printing Operator's Manual Specifications Specifications Model Total vibration value to which the hand/arm system is Z-80/60 subjected does not exceed 2.5 m/s Height, working maximum 84 ft 25.6 m Highest root mean square value of weighted acceleration to Height, platform maximum 78 ft 23.8 m...
  • Page 79 Fifth Edition • First Printing Operator's Manual Specifications Z-80 Range of motion chart Max Height Max Reach 80 ft 24.4 m -10 ft 70 ft 21.3 m 0 ft 60 ft 18.3 m 10 ft 50 ft 15.2 m 20 ft 6.1 m 40 ft 12.2 m...

This manual is also suitable for:

Genie z80-60Z80h-7896

Table of Contents