Terex Genie Z-80 Operator's Manual
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Terex Genie Z-80 Operator's Manual

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  • Page 2: Table Of Contents

    Copyright © 2002 by Terex Corporation Fourth Edition: Second Printing, March 2013 Internet: www.genielift.com "Genie" and "Z" are registered trademarks of E-mail: awp.techpub@terex.com Terex South Dakota in the U.S.A. and many other countries. These machines comply with Printed on recycled paper Printed in U.S.A.

  • Page 3: Introduction

    Fourth Edition · Second Printing Operator's Manual Introduction Owners, Users and Operators: Genie appreciates your choice of our machine for your application. Our number one priority is user safety, which is best achieved by our joint efforts. We feel that you make a major contribution to safety if you, as the equipment users and operators: Danger...
  • Page 4 Operator's Manual Fourth Edition · Second Printing Introduction Hazard Classification Intended Use Genie uses symbols, color coding and signal This machine is intended to be used only to lift words to identify the following: personnel, along with their tools and materials to an aerial work site.

  • Page 5: Symbol And Hazard Pictorial Definitions

    Fourth Edition · Second Printing Operator's Manual Symbol and Hazard Pictorials Definitions No smoking. Keep away from Burn Hazard Crush Hazard No flame. Tip-over Hazard moving parts. Stop engine. Read the operator’s Keep off this Fall Hazard Tip-over Hazard Tip-over Hazard manual.
  • Page 6 Operator's Manual Fourth Edition · Second Printing Symbol and Hazard Pictorials Definitions Lanyard Wheel load Voltage rating for Pressure rating for power to platform air line to platform attachment point Tie-down Tie-down Electrocution Keep clear. instructions instructions Hazard Fire Hazard Have fire Read service Weight of welder...

  • Page 7: General Safety

    Fourth Edition · Second Printing Operator's Manual General Safety Safety signs and locations 114251 133067 82472 114252 82487 114247 82671 82472 114249 82548 114249 82472 114247 82487 114252 82487 B 114252 A 114251 133067 82472 B 114251 A 82671 114249 82548 114249 A Part No.
  • Page 8 Operator's Manual Fourth Edition · Second Printing General Safety Safety signs and locations 82487 82604 82548 114252 400N 82487 B 12.5 m/sec 114252 A 82602 B 82481 114249 114248 82481 B 114249 A 114248 B 133067 82601 227 kg < = 227 kg 82601 B 114248...

  • Page 9: Personal Safety

    Fourth Edition · Second Printing Operator's Manual Personal Safety 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 10: Work Area Safety

    Operator's Manual Fourth Edition · Second Printing Work Area Safety Allow for platform movement, electrical line sway or Electrocution Hazards sag and beware of strong or gusty winds. This machine is not Keep away from the machine if it contacts electrically insulated energized power lines.
  • Page 11 Fourth Edition · Second Printing Operator's Manual Work Area Safety Do not raise or extend Do not raise the boom the boom unless the when wind speeds may machine is on a firm, exceed 28 mph / 12.5 level surface. m/s.
  • Page 12 Operator's Manual Fourth Edition · Second Printing Work Area Safety Do not push off or pull Do not place or attach toward any object outside overhanging loads to of the platform. any part of this machine. Do not place ladders or scaffolds in the platform or against any part of this machine.
  • Page 13 Fourth Edition · Second Printing Operator's Manual Work Area Safety Operation on Slopes Hazards Fall Hazards Do not drive the machine on a slope that exceeds Occupants must wear a the maximum uphill, downhill or side slope rating of safety belt or harness the machine.
  • Page 14 Operator's Manual Fourth Edition · Second Printing Work Area Safety No stunt driving or Collision Hazards horseplay while operating a machine. Be aware of limited sight distance and blind Do not lower the boom spots when driving or unless the area below operating.
  • Page 15 Fourth Edition · Second Printing Operator's Manual Work Area Safety Explosion and Fire Hazards Battery Safety Do not start the engine if you smell or detect liquid Burn Hazards petroleum gas (LPG), gasoline, diesel fuel or other explosive substances. Batteries contain acid. Always wear protective Do not refuel the machine with the engine running.
  • Page 16 Operator's Manual Fourth 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 17 Fourth Edition · Second Printing Operator's Manual Work Area Safety Welder Safety Weld Line to Platform Safety Read, understand and obey all warnings and Read, understand and obey all warnings and instructions provided with the welding power unit. instructions provided with the welding power unit. Do not connect weld leads or cables unless the Do not connect weld leads or cables unless the welding power unit is turned off at the platform...

  • Page 18: Legend

    Operator's Manual Fourth Edition · Second Printing Legend 1 Circle-end tire (yellow arrow) 2 Square-end tire (blue arrow) 3 Secondary boom 4 Ground controls 5 Primary boom 6 Platform controls 7 Platform 8 Lanyard anchorage point 9 Sliding mid-rail 10 Manual storage container 11 Foot switch Z-80/60 Part No.

  • Page 19: Controls

    Fourth Edition · Second Printing Operator's Manual Controls 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 sections apply to both panels, unless specifically noted.
  • Page 20 Operator's Manual Fourth Edition · Second Printing Controls Ground Control Panel 7 Gasoline/LPG models: Fuel select button Push the fuel select button to select the engine 1 Low speed function enable button fuel source. When the arrow above the LPG Push the low speed function enable switch to tank is lit, the engine will run on LPG.
  • Page 21 Fourth Edition · Second Printing Operator's Manual Controls 12 Engine start button 19 Platform rotate left/right buttons Push the engine start button and the engine will Push the platform rotate left button and the start. platform will rotate to the left. Push the platform rotate right button and the platform will rotate to 13 Engine speed select button the right.
  • Page 22 Operator's Manual Fourth Edition · Second Printing Controls 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 sections apply to both panels, unless specifically noted.
  • Page 23 Fourth Edition · Second Printing Operator's Manual Controls Part No. 133094 Z-80/60...
  • Page 24 Operator's Manual Fourth Edition · Second Printing Controls Platform Control Panel 9 Diesel models: Glow plug control with indicator light 1 Horn button Move the switch or push the button to activate Press the button and the horn will sound. the glow plugs.
  • Page 25 Fourth Edition · Second Printing Operator's Manual Controls 16 Low fuel indicator light 20 Steer mode control with indicator lights Light on indicates the machine is low on fuel. Move the switch or push the button to choose steer mode. 17 Fault indicator light The indicator light next to the current steer mode Light on indicates a system fault.
  • Page 26 Operator's Manual Fourth Edition · Second Printing Controls Light on indicates that the primary boom has moved past either circle-end wheel and the drive function is turned off. To drive, move the drive enable switch or push the drive enable button and slowly move the drive/steer control handle off center.

  • Page 27: Inspections

    Fourth Edition · Second Printing Operator's Manual 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 Do Not Operate Unless: performed by the operator prior to each work shift. The inspection is designed to discover if anything You learn and practice the principles of safe is apparently wrong with a machine before the...
  • Page 28 Operator's Manual Fourth Edition · Second Printing Inspections Pre-operation Inspection Engine and related components Be sure that the operator’s, safety and responsibilities manuals are complete, legible Limit switches and horn and in the storage container located in the Alarms and beacons (if equipped) platform.
  • Page 29 Fourth 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 30 Operator's Manual Fourth Edition · Second Printing Inspections 1 Select a test area that is firm, level and free of Test Emergency Controls obstruction. 9 Shut the engine off. At the Ground Controls 10 Pull out the red Emergency Stop button to the on position.
  • Page 31 Fourth Edition · Second Printing Operator's Manual Inspections Test the Operating Envelope At the Platform Controls 15 Push one of the LCD Test Emergency Stop screen buttons shown until 22 Turn the key switch to platform control. PRI BOOM ANGLE is displayed.
  • Page 32 Operator's Manual Fourth Edition · Second Printing Inspections Test the Tilt Sensor Alarm Test the Steering (models with 4 wheel steer) 29 Push a button or move a switch, such as the 37 Select square-end (blue arrow) steer. engine idle select. Push the square-end (blue arrow) steer button or move the steer mode switch.
  • Page 33 Fourth Edition · Second Printing Operator's Manual Inspections Result: All wheels should turn in the direction Test Drive and Braking that the blue triangles point on the drive 52 Press down the foot switch. chassis. 53 Slowly move the drive/steer control handle in 46 Select coordinated steer.
  • Page 34 Operator's Manual Fourth Edition · Second Printing Inspections Test the Oscillate Axle Test the Drive Enable System (oscillating axle-equipped models) 59 Press down the foot switch and lower the booms 55 Start the engine from the platform controls. to the stowed position. 56 Drive the right square-end tire up onto a 15 cm 60 Rotate the turntable until the primary boom block or curb.
  • Page 35 Fourth Edition · Second Printing Operator's Manual Inspections Test Limited Drive Speed 70 Raise the secondary boom to 10° above horizontal. 63 Press down the foot switch. 71 Slowly move the drive control handle to the full 64 Raise the primary boom to 10° above horizontal. drive position.
  • Page 36 Operator's Manual Fourth Edition · Second Printing Inspections Test Emergency Controls 73 Push in the red Emergency Stop button to the off position to shut off the engine. 74 Pull out the red Emergency Stop button to the on position. 75 Press down the foot switch.
  • Page 37 Fourth Edition · Second Printing Operator's Manual Inspections Workplace Inspection Be aware of and avoid the following hazardous situations: · drop-offs or holes · bumps, floor obstructions or debris Do Not Operate Unless: · sloped surfaces You learn and practice the principles of safe ·...
  • Page 38 Cosmetic - 4 x 4 114251 Label - Explosion Hazard 65278 Label - No Step 114252 Label - Tip-over, Limit Switches 82268 Cosmetic - Genie Z-80/60 133067 Label - Electrocution Hazard 82269 Ground Control Panel 133400 Label - Wheel Load 82281...
  • Page 39 Fourth Edition · Second Printing Operator's Manual Inspections Ground Controls Side Platform Drive Chassis Shading indicates decal is hidden from view, i.e. under covers Engine Side Part No. 133094 Z-80/60...

  • Page 40: Operating Instructions

    Operator's Manual Fourth Edition · Second Printing 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. Do Not Operate Unless: Using the machine for anything other than lifting personnel, along with their tools and materials, to...
  • Page 41 Fourth Edition · Second Printing Operator's Manual Operating Instructions Starting the Engine In extreme cold conditions, 0°F / -18°C and below, machines should be equipped with optional cold start kits. Attempting to start the engine when 1 At the ground controls, turn the key switch to temperatures are below 0°F / -18°C may require the the desired position.
  • Page 42 Operator's Manual Fourth Edition · Second Printing Operating Instructions Operation from Ground To Steer 1 Press down the foot switch. 1 Turn the key switch to ground control. Models with 4 wheel steer: 2 Pull out the red Emergency Stop button to the on position.
  • Page 43 Fourth Edition · Second Printing Operator's Manual Operating Instructions Driving on a slope Lay the piece of wood on the slope. Determine the uphill, downhill and side slope ratings At the downhill end, lay the level on the top edge of for the machine and determine the slope grade.
  • Page 44 Operator's Manual Fourth Edition · Second Printing Operating Instructions Drive Enable Engine Idle Select (rpm) Light on indicates that the Select the engine idle (rpm). Push the button or boom has moved past either move the switch. The indicator light next to the circle-end wheel and the current setting will be on.
  • Page 45 Fourth Edition · Second Printing Operator's Manual Operating Instructions Operating Envelope Indicator Non-regulated Generator Lights (if equipped) The operating envelope indicator lights will come on To operate the generator, press the generator to notify the operator that a function has been button or move the switch.
  • Page 46 Operator's Manual Fourth Edition · Second Printing Operating Instructions Stopping the Engine Pipe Cradle Instructions The pipe cradle assembly consists of 2 pipe Push in the red Emergency Stop button and turn cradles positioned at either side of the platform and the key switch to the off position.
  • Page 47 Fourth Edition · Second Printing Operator's Manual Operating Instructions Observe and Obey: Pipe Cradle Operation Pipe cradles must be installed on the inside of 1 Be sure the pipe cradle assembly and the platform. installation instructions have been followed properly and that the pipe cradles are secured to Pipe cradles must not obstruct the platform the platform railings.
  • Page 48 Operator's Manual Fourth Edition · Second Printing Operating Instructions Panel Cradle Assembly Installation of Padding 1 Apply the warning decal to the front of each 1 Install the 2 pieces of padding on the platform panel cradle (if needed). rails. Position the padding to protect the panels from contact with the platform rails.
  • Page 49 Fourth Edition · Second Printing Operator's Manual Operating Instructions Panel Cradle Operation rubber 1 Secure both panel cradles to the platform. bumper 2 2 Place the load so that it rests in both panel cradles. U-bolt mounting 3 Center the load on the platform. rubber slots bumper 1...

  • Page 50: Transport And Lifting Instructions

    See the Inspections section brakes. for the serial label location. Note: Towing the Genie Z-80/60 is not Be sure the turntable is secured with the recommended. If the machine must be towed, do turntable rotation lock before transporting. Be not exceed 3.2 km/h.
  • Page 51 Fourth Edition · Second Printing Operator's Manual Transport and Lifting Instructions Securing the Platform Securing to Truck or Trailer for Transit Make sure the jib and platform are in the stowed position. Always use the turntable rotation lock pin each time the machine is transported.
  • Page 52 Operator's Manual Fourth Edition · Second Printing 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 measurements on the pictures on this Only qualified riggers should rig and lift the page.

  • Page 53: Maintenance

    Fourth Edition · Second Printing Operator's Manual 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. Only routine maintenance items specified in this Note: Check the oil level with the engine off.
  • Page 54 Operator's Manual Fourth Edition · Second Printing Maintenance Check the Hydraulic Oil Level Check the Batteries Proper battery condition is essential to good Maintaining the hydraulic oil at the proper level is engine performance and operational safety. essential to machine operation. Improper hydraulic Improper fluid levels or damaged cables and oil levels can damage hydraulic components.
  • Page 55 Fourth Edition · Second Printing Operator's Manual Maintenance Check the Engine Coolant Level Check the Tire Pressure - Liquid Cooled Models Note: This procedure does not need to be performed on machines equipped with the foam- Maintaining the engine coolant at the proper level is filled tire option.

  • Page 56: Specifications

    Operator's Manual Fourth Edition · Second Printing Specifications Z-80/60 Hydraulic pressure, maximum 220 bar Height, working maximum 25.6 m System voltage Tire size 18-625, 16 ply FF Height, platform maximum 23.8 m Tire size - high flotation tires 445D50/710 18PR Height, stowed maximum Airborne noise emissions 113 dB...
  • Page 57 Fourth Edition · Second Printing Operator's Manual Specifications Floor loading information Tire load, maximum 10,206 kg Tire contact pressure 9.1 kg/cm 896 kPa Occupied pressure 1841 kg/m 18.05 kPa Note: Floor loading information is approximate and does not incorporate different option configurations. It should be used only with adequate safety factors.

This manual is also suitable for:

Genie z-60

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