Terex Genie Z-80/60, Operator'S Manual

Page 1: ...Operator s Manual Serial Number Range Z 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: ...ork Area Safety 15 Legend 25 Controls 26 Inspections 34 Operating Instructions 54 Transport and Lifting Instructions 69 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: ...Serial label located under cover Intended Use and Familiarization Guide The intended use of this machine is to lift personnel including tools and materials to an aerial work site Before operating the machine it s the operator s responsibility to read and understand this familiarization guide Each person must be trained to operate a Mobile Elevating Work Platform MEWP Familiarization with the MEWP ...

Page 4: ...ary boom up down and secondary boom retract lower Turntable rotate and platform rotate Sequential functions and movement Drive and steer Interlocked functions Elevated drive speed Elevated drive in an off level condition Rotate the turntable until the boom is positioned between the circle end wheels All platform and ground controls Limitations of use The intended use of this machine is to lift per...

Page 5: ...ction indicated in a respective bulletin To view any open bulletins for your machine visit us on the web at www genielift com Contacting the Manufacturer At times it may be necessary to contact Genie When you do be ready to supply the model number and serial number of your machine along with your name and contact information At minimum Genie should be contacted for Accident reporting Questions reg...

Page 6: ...ksite regulations You read understand and obey all applicable governmental regulations You are properly trained to safely operate the machine 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 Hazard Classificati...

Page 7: ...mbol and Hazard Pictorials Definitions Fire hazard Explosion hazard Explosion hazard Read the service manual No smoking No flame Stop engine Fire extinguisher No smoking Explosion hazard Electrocution hazard Maintain required clearance Tip over hazard Tip over hazard Tip over hazard Tip over hazard Tire specifications ...

Page 8: ...1294418GT Wheel load Wind speed Maximum capacity Manual force Weight of welder reduces capacity Tie down point Lifting point Platform tie down instructions Lifting tie down instructions Lanyard anchorage points Corrosive acid Color coded direction arrows Runaway hazard Collision hazard Overhead obstruction ...

Page 9: ... Support the platform or boom during maintenance Do not use ether or other high energy starting aids on machines equipped with glow plugs Explosion hazard Relieve all pressure Recovery procedure if tilt alarm sounds while elevated Platform uphill 1 Lower primary 2 Lower secondary 3 Retract primary Platform downhill 1 Retract primary 2 Lower secondary 3 Lower primary Read the operator s manual Emer...

Page 10: ...Operator s Manual Fifth Edition First Printing General Safety 8 Z 80 60 Part No 1294418GT General Safety Shading indicates decal is hidden from view i e under covers ...

Page 11: ...Fifth Edition First Printing Operator s Manual General Safety Part No 1294418GT Z 80 60 9 Shading indicates decal is hidden from view i e under covers ...

Page 12: ...Operator s Manual Fifth Edition First Printing General Safety 10 Z 80 60 Part No 1294418GT ...

Page 13: ...Fifth Edition First Printing Operator s Manual General Safety Part No 1294418GT Z 80 60 11 ...

Page 14: ...Operator s Manual Fifth Edition First Printing General Safety 12 Z 80 60 Part No 1294418GT ...

Page 15: ...Fifth Edition First Printing Operator s Manual General Safety Part No 1294418GT Z 80 60 13 Shading indicates decal is hidden from view i e under covers ...

Page 16: ...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 All PFPE must comply with applicable governmental regulations and must be inspected and used in accordance with the PFPE manufacturer ...

Page 17: ...sway or sag and beware 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 lines are shut off Do not operate the machine during lightning or storms Do not use the machine as a ground for welding Tip over Hazards Occupants equipment and materials shall not exce...

Page 18: ... 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 only by trained and authorized personnel If the tilt alarm sounds with the platform uphill 1 Lower the primary boom 2 Retract lower the secondary boom 3 Retract the primary boom If the tilt alarm sounds with the platform downhill 1 Retract the primary boom 2 Ret...

Page 19: ...ide of the platform Maximum allowable side force ANSI CSA 90 lbs 400 N Do not alter or disable machine components that in any way affect safety and stability Do not replace items critical to machine stability with items of different weight or specification Do not replace factory installed tires with tires of different specification or ply rating Do not replace factory installed foam filled tires w...

Page 20: ...s 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 Operation on Slopes Hazards Do not drive the machine on a slope that exceeds the maximum uphill downhill or side slope rating of the machine Slope rating applies only to machines in the stowed position M...

Page 21: ...ot enter or exit the platform unless the machine is in the stowed position and the platform is at ground level Hazards related with the specific product application of exiting at height have been considered in the design of the machine for further information contact Genie see section Contacting the Manufacturer Collision Hazards Be aware of limited sight distance and blind spots when driving or o...

Page 22: ...bon 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 cause serious injury Only trained maintenance personnel should access compartments Access by the operator is only advised when performing a pre operation inspection All compartments must remain closed a...

Page 23: ...and 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 Do not use the machine as a ground for welding Do not operate the machine in locations where extremely high magnetic fields may be present Battery Safety Burn Hazards Batteries contain acid Always ...

Page 24: ... off at the platform controls Do not operate unless the weld cables are properly connected and the welder is properly grounded The weight of the welder will reduce the rated platform capacity and must be factored into the total platform load The welder power supply weighs 75 lbs 34 kg Do not operate the welder unless a fire extinguisher is immediately available for instant use per OSHA regulation ...

Page 25: ...t 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 all energized electrical conductors Panel Cradle Safety Read understand and obey all warnings and instructions provided with the panel cradles Do not exceed the rated platform capacity The combined weight of ...

Page 26: ... damage Do not exceed maximum towing speed or maximum towing time Maximum tow speed 8 mph 13 km h Maximum towing time at 8 mph 13 km h 30 minutes Maximum towing time at 6 mph 10 km h 60 minutes Lockout After Each 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 until the boom is posit...

Page 27: ...Legend Part No 1294418GT Z 80 60 25 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 switch 10 Platform controls 11 Platform ...

Page 28: ...on 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 When the ground control station is selected the platform controls are inoperable including the E stop switch ...

Page 29: ...en extend 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 primary boom down button and the boom will lower 6 LCD screen control buttons 7 Gasoline LPG models fuel select button Push the fuel select button to select the engine fuel source When the arrow ab...

Page 30: ... will lower 15 Jib boom up down buttons Press the jib boom up button and the 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 primary boom retract button and the primary boom will retract 17 20A circuit breaker for system circuit 18 Alarm 19 Bypass re...

Page 31: ...Fifth Edition First Printing Operator s Manual Controls Part No 1294418GT Z 80 60 29 ...

Page 32: ...itch will only work in the direction that will level the platform 3 Machine on incline indicator light Light on indicates all functions have stopped See the instructions in the Operating Instructions section 4 Lower primary boom indicator light Lower the primary boom until the light is off 5 Not used 6 Used for optional equipment 7 Generator control with indicator light if equipped Move the switch...

Page 33: ...gine idle control with indicator light 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 12 Gasoline LPG models Fuel select control with indicator light Move the switch or push the button to select the fuel source The indicator light next to the current fuel selection will be on 13 Platform overload indicator...

Page 34: ...er and the machine will steer to the left Press the right side of the thumb rocker and the machine will steer to the right 20 Steer mode control with indicator lights Move the switch or push the button to choose steer mode The indicator light next to the current steer mode will be on 21 Single axis proportional control handle for secondary boom up extend and down retract function Move the control ...

Page 35: ...otate switch Move the platform rotate switch to the right and the platform will rotate to the right Move the platform rotate switch to the left and the platform will rotate to the left 27 Platform level switch Move the platform level switch up and the level of the platform will raise Move the platform level switch down and the level of the platform will lower 28 Jib boom up down switch Move the ji...

Page 36: ...n is 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 procedures are required Only routine maintenance items specified in this manual may be performed by the operator Refer to the list on the next page and check each of the items If damage or any unauthori...

Page 37: ...Check 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 modifications Electrical components wiring and electrical cables Hydraulic hoses fittings cylinders and manifolds Fuel and hydraulic tanks Drive and turntable motors and drive hubs Wear pads Tires and whe...

Page 38: ...e the 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 instructions to test all machine functions A malfunctioning machine must never be used If malfunctions are discovered the machine must be tagged and removed from service Repairs to the machine may o...

Page 39: ...tions 7 Do not press and hold a function enable speed select button Attempt to activate each boom and platform function button Result No boom 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 through a full cycle The descent alarm should sound while t...

Page 40: ...splayed 17 Raise the primary boom and observe the LCD screen Result The primary boom should raise and the LCD screen should display the primary boom angle in degrees from 35 to 65 The primary boom should stop when the screen reads 65 degrees 18 Lower the primary boom 19 Simultaneously press the 2 LCD screen control buttons shown to activate status mode 20 Press the LCD screen control buttons shown...

Page 41: ... indicator light next to the foot switch activated high idle rabbit and foot switch symbol is on Test the Horn 29 Press the horn button Result The horn should sound Test the Tilt Sensor Alarm 30 Push a button or move a switch such as the engine idle select Result The alarm should sound at the platform controls Test the Foot Switch 31 Push in the platform red Emergency Stop button to the off positi...

Page 42: ...dle in the direction indicated by the yellow triangle on the control panel OR press the thumb rocker switch in the direction indicated by the yellow triangle Result The circle end wheels should turn in the direction that the blue triangles point on the drive chassis 45 Slowly move the drive control handle in the direction indicated by the blue triangle on the control panel OR press the thumb rocke...

Page 43: ...in the direction indicated by the yellow triangle Result The square end wheels should turn in the direction that the blue triangles point on the drive chassis The circle end wheels should turn in the direction that the yellow triangles point on the drive chassis Test the Steering models with 2 wheel steer 54 Press down the foot switch 55 Press the thumb rocker switch on top of the drive control ha...

Page 44: ...irm contact with the ground 62 Drive the left square end tire up onto a 6 in 15 cm block or curb Result The three remaining tires should stay in firm contact with the ground 63 Drive both square end tires up onto a 6 in 15 cm block or curb Result The circle end tires should stay in firm contact with the ground Test the Drive Enable System 64 Press down the foot switch and lower the boom to the sto...

Page 45: ...bove horizontal 76 Slowly move the drive control handle to the full drive position Result The maximum achievable drive speed with the secondary boom raised should not exceed 1 ft 30 cm per second Note Models with foam filled tires will travel 40 ft 12 m in 40 seconds Models with high flotation tires will travel 40 ft 12 m in 62 seconds 77 Lower the secondary boom to the stowed position If the driv...

Page 46: ...g the Y Axis front to back Result The machine should stop once the machine reaches 4 5 of chassis tilt and the alarm should sound at the platform controls 90 Lower the secondary boom to the stowed position or drive in the opposite direction Result The alarm should turn off and the machine should drive 91 With the boom fully stowed drive the machine onto a slope where the chassis angle is greater t...

Page 47: ...site direction Result The alarm should turn off and the machine should drive Test the Platform Level Recovery 103Press down the foot switch 104Push and hold the platform level recovery switch up 105Move the platform level switch up and the level of the platform will raise Result The platform should return to a level position 106Move the platform level switch down and the level of the platform will...

Page 48: ...witch by pressing the foot switch down Result The contact alarm lights will flash and the machine horn will sound 117Insert the actuator into the switch socket Result The lights and horn will turn off 118Activate the foot switch by pressing the foot switch down and press on the contact alarm cable to release the actuator from the switch socket Result The contact alarm lights will flash and the mac...

Page 49: ...ator 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 remember the workplace hazards then watch for and avoid them while moving setting up and operating the machine Workplace Inspection Checklist Be aware of and avoid the following hazardous situation...

Page 50: ...ion Override 1 52475 Label Transport Tie Down 6 52865 Warning Annual Inspection Record 1 65278 Caution No Step 4 Part No Decal Description Qty 72053 Label Circuit Breaker 30 amp 1 72086 Label Lifting Point 4 72168 Label Starter Battery 1 72169 Label Controls Battery 1 72875 Warning Pipe Cradle option 2 82237 Danger Electrocution Hazard option 4 82281 Platform Control Panel 1 82314 Danger Tip over ...

Page 51: ...Fifth Edition First Printing Operator s Manual Inspections Part No 1294418GT Z 80 60 49 ...

Page 52: ...tructions Perkins Engine Specs 404D 22T 1 1263541 Warning Tip over Hazard 1 Part No Decal Description Qty 1263543 Warning Compartment Access 2 1263544 Bypass Key Switch 1 1263545 Instructions Bypass Key Switch 1 1267121 Warning Crush Hazard Service 3 1271397 Instructions GM 3 0L Engine 1 1272242 Label Machine Registration Owner Transfer 1 1278542 Label Contact Alarm Weight 1 1278982 Label Actuator...

Page 53: ...Fifth Edition First Printing Operator s Manual Inspections Part No 1294418GT Z 80 60 51 ...

Page 54: ...36 Label CB Symbol 1 114248 Label Tip over Hazard Tilt Alarm 1 Part No Decal Description Qty 114249 Label Tip over Hazard Tires 4 114251 Label Explosion Hazard 1 114252 Label Tip over Hazard Limit Switches 5 133067 Label Electrocution Hazard 3 133163 Label Function Override Aircraft Protection Package 1 133400 Label Wheel Load 4 219954 Label Tip over Hazard CE 1 219956 Label Platform Overload 1 21...

Page 55: ...Fifth Edition First Printing Operator s Manual Inspections Part No 1294418GT Z 80 60 53 ...

Page 56: ...e 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 their tools and materials to an aerial work site is unsafe and dangerous Only trained and authorized personnel should be permitted to operate a machine If more than one operator is expected to use a ...

Page 57: ...w plugs Amber light will be on when glow plugs are on 2 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 seconds of cranking determine the cause and repair any malfunction Wait 60 seconds before trying to start again In cold conditions 20 F 6 C and ...

Page 58: ...rols 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 auxiliary power Operation from Ground 1 Turn the key switch to ground control 2 Pull out the red Emergency Stop button to the on position 3 Gasoline LPG models Choose fuel source 4 Start the engine To Position Platform 1 Push and hold a function ...

Page 59: ...The 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 located on top of the drive control handle Use the color coded direction arrows on the platform controls and the drive chassis to identify the direction the wheels will turn To Drive 1 Press down the ...

Page 60: ... uphill configuration only Be sure the boom is below horizontal and the platform is between the circle end yellow arrow wheels Select machine on incline 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 following procedure You will need carpenter s level ...

Page 61: ...the color coded direction arrows on the platform controls and the drive chassis to identify the direction the machine will 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 to platform GFCI outlet To turn off the generator press the generator button or...

Page 62: ...hen this light is flashing The Platform Level toggle switch will only work in the direction that will level the platform Level the platform until the indicator light is off Platform Level Recovery 1 Press down the foot switch 2 Push and hold the platform level recovery switch up 3 Move the platform level switch in the desired direction Note The platform level switch will only work in the direction...

Page 63: ...run position 6 Remove the key from the bypass recovery key switch and insert the key into the main key switch 7 Push in and then pull out the red Emergency Stop button 8 If the P22 code is still visible tag and remove the machine from service until the fault has been corrected by a qualified service technician Tilt Sensor Activation Settings Model Chassis Angle side to side Chassis Angle front to ...

Page 64: ...ght will go off Plug a power tool into the power to platform GFCI outlet To turn off the generator press the generator button or move the switch The indicator light will turn off Drive Speed Select Machine on incline symbol Low range operation for inclines Machine on level surface symbol High range operation for maximum drive speed Machine Not Level Indicator Light If the tilt alarm sounds when th...

Page 65: ...hine from service Out of Operational Envelope Recovery If all functions stop operating you may have exceeded the operational 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 equipped The LCD screen displays hour meter voltage oil pressure and coolant tempe...

Page 66: ...f equipped The contact alarm is designed to alert ground personnel when an operator makes contact with the platform control panel interrupting boom movement sounding an alarm and flashing warning lights When the contact alarm cable is tripped the lift and drive functions are disabled at the platform The audio and visual warnings will activate alerting others that assistance may be needed These not...

Page 67: ...rve 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 platform floor Be sure the platform is level before installing a pipe cradle Pipe Cradle Installation 1 Install a pipe cradle on each side of the platform Refer to the illustration on the left Mak...

Page 68: ...es may limit the maximum number of occupants in the platform Maximum Pipe Cradle Capacity All models 200 lbs 90 7 kg Pipe Cradle Assembly Weight 21 lbs 9 5 kg Panel Cradle Assembly 1 Apply the warning decal to the front of each panel cradle if needed 2 Install rubber bumper 1 in the panel cradle base See the illustration 3 Secure the bumper with 2 high profile lock nuts and 2 washers Panel Cradle ...

Page 69: ...atform rail tube 2 Insert a bolt with a washer through one 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 end plate should be able to slide on the platform rail Panel Cradle Operation 1 Secure both panel cradles to the platform 2 Place the load so th...

Page 70: ...e 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 until the boom is positioned between the circle end wheels 4 Turn the key switch to the off position and remove the key to secure from unauthorized use ...

Page 71: ...ed Be sure 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 weight 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 uphi...

Page 72: ...e transporting 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 Securing the Platform Make sure the jib and platform are in the stowed position Place a block under the platform rotator Do not allow the block to contact the platform cylinder Secure the platform ...

Page 73: ...he machine weight Lifting 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 the picture on this page Attach the rigging only to the designated lifting points on the machine Attach the rigging to the 2 chassis lifting points farthest from the turnable l...

Page 74: ...ools 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 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 can damage engine components Note Che...

Page 75: ...ions Hydraulic oil type Chevron Rando HD equivalent Check the Engine Coolant Level Liquid Cooled Models Maintaining the engine coolant at the proper level is essential to engine service life Improper coolant level will affect the engine s cooling capability and damage engine components Daily checks will allow the inspector to identify changes in coolant level that might indicate cooling system pro...

Page 76: ...tery cable connections are tight and free of corrosion 3 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 Diesel Fuel Requirements Satisfactory engine performance is dependent on the use of a good quality fuel The use of a good quality fuel w...

Page 77: ...ally 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 Machines that have been out of service for more than three months must receive the quarterly inspection before they are put back into service ...

Page 78: ...allons 114 liters Total vibration value to which the hand arm system is subjected does not exceed 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 Airborne noise emissions Guaranteed sound power level 107dBA Sound pressure level at ground workstation 85dBA Sound pressure level at platform workstation 74dBA Maximum slope ...

Page 79: ... Reach 1 80 ft 24 4 m 11 10 ft 3 m 2 70 ft 21 3 m 12 0 ft 0 m 3 60 ft 18 3 m 13 10 ft 3 m 4 50 ft 15 2 m 14 20 ft 6 1 m 5 40 ft 12 2 m 15 30 ft 9 1 m 6 30 ft 9 1 m 16 40 ft 12 2 m 7 20 ft 6 1 m 17 50 ft 15 2 m 8 10 ft 3 m 18 60 ft 18 3 m 9 0 ft 0 m 10 10 ft 3 m Z 80 60 Part No 1294418GT Operator s Manual Fifth Edition First Printing ...

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