Terex Z80H-7733 Operator's Manual
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Terex Z80H-7733 Operator's Manual

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Operator's Manual
Z
-80/60
®
Front Matter
Serial Number Range
from Z80H-7733
CE
with
Maintenance
Information
Original Instructions
Seventh Edition
Second Printing
Part No. 1305317GT

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Summary of Contents for Terex Z80H-7733

  • Page 1 Operator's Manual Serial Number Range -80/60 ® from Z80H-7733 with Maintenance Information Original Instructions Seventh Edition Second Printing Part No. 1305317GT Front Matter...

  • Page 2: Table Of Contents

    Copyright © 2002 by Terex Corporation Seventh Edition: Second Printing, April 2022 Genie and "Z" are registered trademarks of Terex South Dakota, Inc. in the U.S.A. and many other countries. Complies with EC Directive 2006/42/EC See EC Declaration of Conformity Supply of Machinery (Safety) Regulations 2008 ®...

  • Page 3: Introduction

    Seventh Edition • Second 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 Operator's Manual Seventh Edition • Second Printing Introduction Platform controls symbology and related Ground controls symbology and related machine movement: machine movement: Platform level switch Platform level, jib boom up/down, primary boom extend/retract, primary boom up/down, and secondary boom Platform rotate switch retract/lower.
  • Page 5 Seventh Edition • Second 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 Operator's Manual Seventh Edition • Second Printing 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

    Seventh Edition • Second 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. Fire extinguisher No smoking Explosion hazard Electrocution hazard Maintain required clearance Tip-over hazard Tip-over hazard...
  • Page 8 Operator's Manual Seventh Edition • Second Printing Symbol and Hazard Pictorials Definitions Wheel load Wind speed Maximum capacity Manual force Weight of welder reduces capacity Tie-down point Lifting point Platform tie-down Lifting and tie down Lanyard anchorage instructions instructions points Corrosive acid.
  • Page 9 Seventh Edition • Second 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

    Operator's Manual Seventh Edition • Second Printing General Safety General Safety ® -80/60 Part No. 1305317GT...
  • Page 11 Seventh Edition • Second Printing Operator's Manual General Safety Part No. 1305317GT ® -80/60...
  • Page 12 Operator's Manual Seventh Edition • Second Printing General Safety Shading indicates decal is hidden from view, i.e. under covers ® -80/60 Part No. 1305317GT...

  • Page 13: Personal Safety

    Seventh Edition • Second 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 14: Work Area Safety

    Operator's Manual Seventh Edition • Second Printing 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 15 Seventh Edition • Second 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 16 Operator's Manual Seventh Edition • Second Printing 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 17 Seventh Edition • Second 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 18 Operator's Manual Seventh Edition • Second Printing 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 19 Seventh Edition • Second 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 20 Operator's Manual Seventh Edition • Second Printing 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 21 Seventh Edition • Second 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 22 Operator's Manual Seventh Edition • Second Printing 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 23 Seventh Edition • Second 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 24: Legend

    Operator's Manual Seventh Edition • Second Printing 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 ® -80/60 Part No. 1305317GT...

  • Page 25: Controls

    Seventh Edition • Second 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 26 Operator's Manual Seventh Edition • Second Printing Controls Ground Control Panel LCD screen control buttons Gasoline/LPG models: fuel select button Low speed function enable button Press the low speed function enable button to Push the fuel select button to select the engine enable the functions on the ground control fuel source.
  • Page 27 Seventh Edition • Second 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 28 Operator's Manual Seventh Edition • Second Printing Controls ® -80/60 Part No. 1305317GT...
  • Page 29 Seventh Edition • Second Printing Operator's Manual Controls Platform Control Panel Lower primary boom indicator light 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 30 Operator's Manual Seventh Edition • Second Printing 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 31 Seventh Edition • Second 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 32 Operator's Manual Seventh Edition • Second Printing 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 33: Inspections

    Seventh Edition • Second 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 34 Operator's Manual Seventh Edition • Second Printing Inspections Pre-operation Inspection Check the following components or areas for damage, improperly installed, or missing parts and unauthorized modifications:  Be sure that the operator’s manual is complete, legible and in the storage container ...
  • Page 35 Seventh Edition • Second 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 Do Not Operate Unless: malfunctions are discovered, the machine must be tagged and removed from service.
  • Page 36 Operator's Manual Seventh Edition • Second Printing Inspections At the Ground Controls Test Machine Functions Select a test area that is firm, level and free of Do not press and hold hazards. a function enable/speed select Turn the key switch to ground control. button.
  • Page 37 Seventh Edition • Second 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 38 Operator's Manual Seventh Edition • Second Printing Inspections Test the Tilt Sensor Alarm At the Platform Controls 30 Push a button or move a switch, such as the engine idle select. Test Emergency Stop Result: The alarm should sound at the 23 Turn the key switch to platform control.
  • Page 39 Seventh Edition • Second Printing Operator's Manual Inspections 44 Slowly move the control handle in the direction Test the Steering indicated by the yellow triangle on the control (models with 4 wheel steer) panel OR press the thumb rocker switch in the direction indicated by the yellow triangle.
  • Page 40 Operator's Manual Seventh Edition • Second Printing Inspections 49 Slowly move the control handle in the direction Test the Steering indicated by the yellow triangle on the control (models with 2 wheel steer) panel OR press the thumb rocker switch in the 54 Press down the foot switch.
  • Page 41 Seventh Edition • Second 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 42 Operator's Manual Seventh Edition • Second Printing 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 43 Seventh Edition • Second 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 44 Operator's Manual Seventh Edition • Second Printing Inspections Test the Platform Level Recovery 97 Retract the primary boom to the stowed 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 45 Seventh Edition • Second 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 46 Operator's Manual Seventh Edition • Second Printing Inspections Workplace Inspection Checklist Be aware of and avoid the following hazardous situations:  drop-offs or holes  bumps, floor obstructions, or debris Do Not Operate Unless:  sloped surfaces  unstable or slippery surfaces You learn and practice the principles of safe ...
  • Page 47 Seventh Edition • Second Printing Operator's Manual Inspections Inspection for Decals with Part No. Decal Description Symbols 133067 Label – Electrocution Hazard 133163 Label – Function Override (Aircraft Use the inspection to verify that all decals are Protection Package) legible and in place. 133400 Label –...
  • Page 48 Operator's Manual Seventh Edition • Second Printing Inspections 27204 27207 1301115** 27206 28160* 133067 114251 27205 1263542 27206 27207 72086** 82487 28158* 72086** 28159* 52475** 230386 1301030* 52475** 65278** 72086 82247 114249** 114249** 1272242 133400** 52475** 133400** 65278** 1263545 72086 1263540 1305382 822820...

  • Page 49: Operating Instructions

    Seventh Edition • Second 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 manual.
  • Page 50 Operator's Manual Seventh Edition • Second Printing Operating Instructions Starting the Engine All models 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 51 Seventh Edition • Second 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 52 Operator's Manual Seventh Edition • Second Printing Operating Instructions Operation from Platform All models: Slowly move the drive control Turn the key switch to platform 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 53 Seventh Edition • Second Printing Operator's Manual Operating Instructions Driving on a slope To determine the slope grade: Determine the uphill, downhill and side slope Measure the slope with a digital inclinometer OR ratings for the machine and determine the slope use the following procedure.
  • Page 54 Operator's Manual Seventh Edition • Second Printing 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 55 Seventh Edition • Second Printing Operator's Manual Operating Instructions Standstill Regeneration To start the regeneration, proceed as follows. When the LCD screen displays the message Close the engine side cover. "Regen Required" and the Regeneration lamp is Select a safe parking location—firm and level, flashing, the DPF (Diesel Particulate Filter) clear of obstructions and traffic, clear of requires a Standstill Regeneration.
  • Page 56 Operator's Manual Seventh Edition • Second Printing Operating Instructions 10 If the engine is not already running, the LCD Platform Out of Level (P22 code) screen displays the message START THE Bypass key position to be used to level the ENGINE THEN PRESS ENTER.
  • Page 57 Seventh Edition • Second Printing Operator's Manual Operating Instructions Platform Out of Level (Platform Level > 15 Tilt Sensor Activation Settings Degrees Fault) Model Chassis Angle Chassis Angle If ground control display shows PLATFORM (side to side) (front to back) LEVEL >...
  • Page 58 Operator's Manual Seventh Edition • Second Printing Operating Instructions Operating Envelope Indicator Lights Generator (if equipped) The operating envelope indicator lights will come To operate the generator, press the generator on to notify the operator that a function has been button or move the switch.
  • Page 59 Seventh Edition • Second Printing Operator's Manual Operating Instructions Machine Not Level Indicator Light Machine Malfunction Indicator Light If the tilt alarm sounds when the Light on indicates all functions have platform is raised, the Machine Not stopped. Level indicator light will come on and the drive function in one or Push in and then pull out the red Emergency both directions will not operate.
  • Page 60 Operator's Manual Seventh Edition • Second Printing Operating Instructions Out of Operational Envelope Recovery Aircraft Protection Package (if equipped) If all functions stop operating, you may have If the platform bumper comes exceeded the operational envelope. A trained into contact with an object, the operator on the ground will need to lower the machine will shut down and no platform from the ground controls.
  • Page 61 Seventh Edition • Second Printing Operator's Manual Operating Instructions Contact Alarm (if equipped) Pipe Cradle Instructions The contact alarm is designed to alert ground The pipe cradle assembly consists of 2 pipe personnel when an operator makes contact with cradles positioned at either side of the platform the platform control panel, interrupting boom and mounted to the guardrails with U-bolts.
  • Page 62 Operator's Manual Seventh Edition • Second Printing Operating Instructions Observe and Obey: Pipe cradles must be installed on the inside of  the platform.  Pipe cradles must not obstruct the platform controls or the platform entrance. The bottom of the pipe cradle tube must rest ...
  • Page 63 Seventh Edition • Second 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 64 Operator's Manual Seventh Edition • Second Printing 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 65 Seventh Edition • Second 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 66: Transport And Lifting Instructions

    Operator's Manual Seventh Edition • Second Printing Transport and Lifting Instructions Transport and Lifting Instructions  Be sure the turntable is secured with the turntable rotation lock before transporting. Be sure to unlock the turntable for operation.  Do not drive the machine on a slope that exceeds the uphill, downhill or side slope rating.
  • Page 67 Seventh Edition • Second Printing Operator's Manual Transport and Lifting Instructions Securing to Truck or Trailer for Securing the Chassis 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 68 Operator's Manual Seventh Edition • Second Printing Transport and Lifting Instructions Lifting Instructions Fully lower and retract the boom. Fully lower the jib. (if equipped) Determine the center of gravity of your machine using the table and the picture on this page. Observe and Obey: Attach the rigging only to the designated lifting points on the machine.

  • Page 69: Maintenance

    Seventh Edition • Second 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. Operating the machine with an improper oil level Observe and Obey: can damage engine components.
  • Page 70 Operator's Manual Seventh Edition • Second Printing Maintenance Check the Hydraulic Oil Level Check the Engine Coolant 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 71 Seventh Edition • Second 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 72: Specifications

    Operator's Manual Seventh Edition • Second Printing Specifications Specifications Model ® -80/60 Airborne noise emissions Height, working maximum 84 ft 25.6 m Guaranteed sound power level 107dBA Height, platform maximum 78 ft 23.8 m Sound pressure level at ground workstation 85dBA Height, stowed maximum 9 ft 10 in...
  • Page 73 Seventh Edition • Second Printing Operator's Manual Specifications Z-80 Range of motion chart Max Height Max Reach 80 ft 24.4 m -10 ft -3 m 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...
  • Page 74 Operator's Manual Seventh Edition • Second Printing Specifications ® -80/60 Part No. 1305317GT...
  • Page 75 Seventh Edition • Second Printing Operator's Manual Specifications Part No. 1305317GT ® -80/60...
  • Page 76 Operator's Manual Seventh Edition • Second Printing Specifications ® -80/60 Part No. 1305317GT...
  • Page 77 Seventh Edition • Second Printing Operator's Manual Specifications Z®-80/60 Part No. 1305317GT Operator's Manual Seventh Edition • Second Printing Part No. 1305317GT ® -80/60...

This manual is also suitable for:

Genie z-80/60

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