Genie Z-80/60, Operator'S Manual

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

Page 2: ...times If you have any questions contact us Contact Us Internet www genielift com E mail awp techpub terex com Contents Introduction 1 Symbol and Hazard Pictorials Definitions 3 Personal Safety 5 Pers...

Page 3: ...pervision running the machine Danger Failure to obey the instructions and safety rules in this manual will result in death or serious injury Do Not Operate Unless You learn and practice the principles...

Page 4: ...ious injury Indicates a hazardous situation which if not avoided could result in death or serious injury Indicates a hazardous situation which if not avoided could result in minor or moderate injury I...

Page 5: ...g No flame Stop engine Electrocution hazard Maintain required clearance Crush hazard Keep away from path of moving platform Fall hazard Keep off this surface Tip over hazard Tip over hazard Tip over h...

Page 6: ...service manual Electrocution hazard Avoid contact Voltage rating for power to platform Pressure rating for air line to platform Access by trained and authorized personnel only Maximum capacity Manual...

Page 7: ...Sixth Edition Sixth Printing Operator s Manual Personal Safety Part No 226482 Z 80 60 5 Personal Safety...

Page 8: ...Operator s Manual Sixth Edition Sixth Printing Personal Safety 6 Z 80 60 Part No 226482...

Page 9: ...chines equipped with glow plugs 97875 DANGER Explosion Burn Hazard Ignition of explosive gases or contact with corrosive acid will cause death burns or blindness 31788 C Keep all open flames and spark...

Page 10: ...Operator s Manual Sixth Edition Sixth Printing Personal Safety 8 Z 80 60 Part No 226482...

Page 11: ...upants 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 governm...

Page 12: ...eware of strong or gusty winds Keep away from the machine if it contacts energized power lines Personnel on the ground or in the platform must not touch or operate the machine until energized power li...

Page 13: ...fy the condition of the boom on the slope as shown below Follow the steps to lower the boom before moving to a firm level surface Do not rotate the boom while lowering The recovery mode should be used...

Page 14: ...the platform perimeter Do not push off or pull toward any object outside of the platform Maximum allowable manual force 400 N Do not alter or disable machine components that in any way affect safety a...

Page 15: ...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 Opera...

Page 16: ...oor clear of debris Lower the platform entry mid rail or close the entry gate before operating Do not enter or exit the platform unless the machine is in the stowed position and the platform is at gro...

Page 17: ...n monoxide poisoning Do not operate the machine with a hydraulic oil or air leak An air leak or hydraulic leak can penetrate and or burn skin Improper contact with components under any cover will caus...

Page 18: ...d responsibilities manuals are complete legible and in the storage container located on the machine Component Damage Hazards Do not use any battery or charger greater than 12V to jump start the engine...

Page 19: ...movement of the platform with an overhanging load Do not cause a horizontal force or side load to machine by raising or lowering a fixed or overhanging load Electrocution Hazard Keep pipes away from...

Page 20: ...ity and must be factored into the total platform load The welder power supply weighs 34 kg Do not operate the welder unless a fire extinguisher is immediately available for instant use per OSHA regula...

Page 21: ...h Use 1 Select a safe parking location firm level surface clear of obstruction and traffic 2 Retract and lower the boom to the stowed position 3 Rotate the turntable so that the boom is between the no...

Page 22: ...80 60 Part No 226482 Legend 1 Circle end tire 2 Square end tire 3 Secondary boom 4 Ground controls 5 Primary boom 6 Lanyard anchorage points 7 Sliding mid rail 8 Manual storage container 9 Foot switc...

Page 23: ...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 STO...

Page 24: ...end Push the secondary boom down retract button and the secondary boom will retract and then lower 5 Primary boom up down buttons Press the primary boom up button and the boom will raise Press the pri...

Page 25: ...e jib boom will raise Press the jib boom down button and the jib boom will lower 16 Primary boom extend retract buttons Press the primary boom extend button and the primary boom will extend Press the...

Page 26: ...s 24 Z 80 60 Part No 226482 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 Instr...

Page 27: ...Sixth Edition Sixth Printing Operator s Manual Controls Part No 226482 Z 80 60 25 STOP 19 10 11 15 13 14 16 17 18 21 20 22 12 STOP 10 20 11 13 16 17 15 18 21 19 14 12 22...

Page 28: ...or release the button to turn the generator off 8 Emergency Auxiliary power control with indicator light Use emergency auxiliary power if the primary power source engine fails Move and hold the switch...

Page 29: ...axis proportional control handle for drive and steer functions OR Proportional control handle for drive function and thumb rocker for steer function Move the control handle in the direction indicated...

Page 30: ...ly move the drive control handle off center 25 Dual axis proportional control handle for primary boom up down and turntable rotate left right functions Move the control handle up and the primary boom...

Page 31: ...s designed to discover if anything is apparently wrong with a machine before the operator performs the function tests The pre operation inspection also serves to determine if routine maintenance proce...

Page 32: ...ck air filled tires for proper tire pressure Add air if needed See Maintenance section Check the following components or areas for damage improperly installed or missing parts and unauthorized modific...

Page 33: ...he machine as it was intended 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 i...

Page 34: ...and platform functions should operate 8 Press and hold a function enable speed select button and activate each boom and platform function button Result All boom and platform functions should operate t...

Page 35: ...d until it is fully raised 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...

Page 36: ...le switch or button Result All functions should operate through a full cycle Test the Steering models with 4 wheel steer 37 Select square end blue arrow steer Push the square end blue arrow steer butt...

Page 37: ...ngles point on the drive chassis 48 Slowly move the control handle in the direction indicated by the yellow triangle on the control panel OR press the thumb rocker switch in the direction indicated by...

Page 38: ...on the control panel until the machine begins to move then return the handle to the center position Result The machine should move in the direction that the blue arrow points on the drive chassis then...

Page 39: ...e foot switch 68 Raise the primary boom to 10 above horizontal 69 Slowly move the drive control handle to the full drive position Result The maximum achievable drive speed with the primary boom raised...

Page 40: ...ld the switch or push and hold the button Activate each function control handle toggle switch or thumb rocker switch Note To conserve battery power test each function through a partial cycle Result Al...

Page 41: ...r determine if the workplace is suitable for safe machine operation It should be performed by the operator prior to moving the machine to the workplace It is the operator s responsibility to read and...

Page 42: ...4 82268 Cosmetic Genie Z 80 60 1 82269 Ground Control Panel 1 82281 Platform Control Panel 1 Part No Decal Description Qty 82296 Danger Label Tire Specifications Foam 4 82312 Cosmetic Z 80 60 1 82366...

Page 43: ...Sixth Edition Sixth Printing Operator s Manual Inspections Part No 226482 Z 80 60 41...

Page 44: ...operator s responsibility to follow all the safety rules and instructions in the operator s safety and responsibilities manuals Using the machine for anything other than lifting personnel along with t...

Page 45: ...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 All models If the engine fails to start after 15...

Page 46: ...d or platform control 2 Pull out the red Emergency Stop button to the on position 3 Press down the foot switch when using the controls from the platform 4 Activate the emergency controls Move and hold...

Page 47: ...indicator light next to the current steer mode will be on All models 3 Slowly move the drive control handle in the direction indicated by blue or yellow triangles OR press the thumb rocker switch loc...

Page 48: ...e drive setting Move the switch or push the button until the light next to the machine on incline symbol is on To determine the slope grade Measure the slope with a digital inclinometer OR use the fol...

Page 49: ...ll travel Generator if equipped To operate the generator press the generator button or move the switch The indicator light will come on the engine will continue to run Plug a power tool into the power...

Page 50: ...s or by using the platform level recovery toggle switch in the procedure above Once the platform level reaches 15 degrees the only way to recover is to use the Service Recovery key switch on the side...

Page 51: ...l envelope A trained operator on the ground will need to lower the platform from the ground controls Please see the Service Bypass Recovery Key Switch section in the service manual LCD Screen if equip...

Page 52: ...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 on the...

Page 53: ...cradles may limit the maximum number of occupants in the platform Maximum Pipe Cradle Capacity All models 90 7 kg Pipe Cradle Assembly Weight 9 5 kg Panel Cradle Assembly 1 Apply the warning decal to...

Page 54: ...e side of the clamp 3 Install the strap assembly end plate onto the bolt 4 Insert the bolt through the other side of the clamp 5 Secure with a washer and a nut Do not over tighten The strap assembly e...

Page 55: ...Use 1 Select a safe parking location firm level surface clear of obstruction and traffic 2 Retract and lower the boom to the stowed position 3 Rotate the turntable so that the boom is between the non...

Page 56: ...e the vehicle capacity loading surfaces and chains or straps are sufficient to withstand the machine weight Genie lifts are very heavy relative to their size See the serial label for the machine weigh...

Page 57: ...ransporting Inspect the entire machine for loose or unsecured items Securing the Chassis Use chains of ample load capacity Use a minimum of 5 chains Adjust the rigging to prevent damage to the chains...

Page 58: ...ng Instructions Fully lower and retract both the primary and secondary booms Remove all loose items on the machine Rotate the turntable 90 degrees Determine the center of gravity of your machine using...

Page 59: ...tools will be required to perform this procedure Indicates that new parts will be required to perform this procedure Indicates that a cold engine is required before performing this procedure Check the...

Page 60: ...ulic oil type Chevron Rando HD equivalent Check the Batteries Proper battery condition is essential to good machine performance and operational safety Improper fluid levels or damaged cables and conne...

Page 61: ...Result The fluid level should be in the NORMAL range Bodily Injury Hazard Fluids in the radiator are under pressure and extremely hot Use caution when removing cap and adding fluids Check the Tire Pr...

Page 62: ...Diesel LSD 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 Fue...

Page 63: ...2 5 m s2 Highest root mean square value of weighted acceleration to which the whole body is subjected does not exceed 0 5 m s2 Weight 17 010 kg Machine weights vary with option configurations See ser...

Page 64: ...Operator s Manual Sixth Edition Sixth Printing Specifications 62 Z 80 60 Part No 226482 Z 80 60 Range of Motion Z 80 60 Part No 226482 Operator s Manual Sixth Edition Sixth Printing...

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