Genie Z-80, Z-60 Personal Lift User Manual
Contents
1. Part No Description Quantity Part No Description Quantity 27204 Arrow Blue 1 43595 Danger Tip over Hazard Tires 4 27205 Arrow Yellow 1 44986 Notice Max Manual Force 27206 Triangle Blue 2 POSTADO 1 27207 Triangle Yellow 2 52906 Gostnele Aka 1 27564 Danger Electrocution Hazard 2 AN Saa ata 1 28158 Label Unleaded 1 65269 Notice Operating Instructions 2 28159 Label Diesel 1 65278 Caution No Step 4 28160 Label LPG 1 72168 Notice Starter Battery 1 28161 Warning Crushing Hazard 3 72169 Notice Controls Battery 1 28163 Notice Max Side Force 150 Ibs 667 N 82202 Notice Engine Specifications Perkins 1 ANSI amp CSA 1 82203 Notice Engine Specifications GM 1 28164 Notice Hazardous Materials 1 82204 Notice Engine Specifications Deutz 1 28165 Notice Footswitch 1 82268 Cosmetic Genie Z 80 60 1 28171 Label No Smoking 1 82269 Ground Control Panel 1 28174 Label Power to Platform 230V 2 82281 Platform Control Panel 1 28175 Caution Compartment Access 1 82296 Notice Tire Specifications 4 28176 Notice Missing Manuals 1 82312 Cosmetic Z 80 1 28177 Warning Collision Hazard 2 82366 Label Chevron Rykon 1 28181 Warning No Step or Ride 1 82403 Label Fuse and Relay Panel Layout 1 28235 Label Power to Platform 115V 2 28236 Warning Failure To Read 1 30080 Notice Max Capacity2. Z 80 60 Controls 12V DC proportional Height working maximum 86 ft 26 2 m Platform dimensions 6 foot 72 in x 30 in length x width 1 8 m x 76 cm Height platform maximum 80 ft 24 4 m 7 7 7 Platform dimensions 8 foot 96 in x 36 in Height stowed maximum 9ft10in 3m length x width 24mx91cm Horizontal reach maximum 60 ft 18 3 m Platform leveling self leveling Wigh PEN 2 5 m Platform rotation 160 11 Langi stowad gen an AC outlet in platform standard Length stowed for transport 30 ft 9 1m 7 7 Hydraulic pressure maximum 3200 psi Maximum load capacity 500 Ib 227 kg boom functions 220 bar Wheelbase 9 ft 4 in 2 8m Tire size 18 625 16 ply FF Ground clearance 12 in 30 5 cm Gradeability 4WD stowed 50 Turning radius outside Gradeability 2WD stowed 30 2 wheel steer 24 ft 7 in 7 5m 4 wheel steer 15 ft 2 in 46m Fuel tank capacity 40 gallons 151 liters Turning radius inside Weight See Serial Plate 2 wheel steer 14 ft 6 in 4 4m Machine weights vary with option configurations 4 wheel steer 7 ft 2 1m Turntable rotation degrees 360 continuous Turntable tailswing secondary boom lowered 10 ft 10 in 3 3m Turntable tailswing secondary boom raised 3 ft 90 cm Power source Perkins Diesel 704 30 choice Deutz Diesel F4L913 GM 3 0L Drive speed stowed 3 mph 4 8 km h 40 ft 9 1 sec 12 2 m 9 1 sec 1 1 km h 12 2 m 40 sec Drive speed raised or extended
3. Result The secondary boom should raise and the LCD screen should display ODEG gt 0DEG AT65DEG AT OFT gt 0 FT gt 22 FT The secondary boom should raise and then extend The secondary boom should not extend until it is fully raised 2 4 Push 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 retracted 16 Genie Z 80 60 Part No 82258 First Edition Third Printing Operator s Manual At the Platform Controls Test Emergency Stop 22 Turn the key switch to platform control 23 Push in the platform red Emergency Stop button to the off position Result The engine should turn off and no functions should operate 24 Pull out the red Emergency Stop button and restart the engine Test the Hydraulic Oil Return Filter 25 Press the engine idle speed select button until the indicator light next to high idle rabbit symbol is on Filter condition indicator 26 Locate and check the hydraulic filter condition indicator Result The filter should be operating with the plunger inthe green area 27 Press the engine idle speed select button until the indicator light next to foot switch activated high idle rabbit and foot switch symbol is on Test the Horn 28 Push the horn button Result The horn should sound FUNCTION TESTS Test the Tilt Sensor Alarm 29 Push
4. 0 7 mph 40 ft 40 sec Continuous improvement of our products is a Genie policy Product specifications are subject to change without notice or obligation Airborne noise emissions 80 dB Maximum sound level at normal operating workstations A weighted Floor Loading Information GVW Rated Load 38 000 Ibs 17 237 kg Axle load maximum 27 813 lbs 12 616 kg Wheel load maximum 13 530 Ibs 7044 kg Localized pressure per tire 217 psi 15 3 kg cm 1496 kPa Occupied pressure 358 psf 2468 kPa Note Floor loading information is approximate and does not incorporate different option configurations It should be used only with adequate safety factors Part No 82258 Genie Z 80 60 31 Operator s Manual First Edition Third Printing SPECIFICATIONS Z 80 60 Range of Motion 80 ft 24 4 m 70 ft 21 3 m 60 ft 1 83 m 50 ft 15 2 m 40 ft 12 2 m 30 ft 9 1 m 20 ft 6 1 m 10ft 3m 0ft Om 10 ft 3m we yor wo 0 we yor W 19 02 W f 6 H0E w g h Hor wu zZ St 409 West H O09 32 Genie Z 80 60 Part No 82258 California Proposition 65 WARNING The exhaust from this product contains chemicals known to the State of California to cause cancer birth defects or other reproductive harm Genie North America Phone 425 881 18
5. Genie Operator s Manual with Maintenance Information First Edition Third Printing Part No 82258 Z 80 60 Operator s Manual First Edition Third Printing Important Read understand and obey these safety rules and operating instructions before operating this machine Only trained and authorized personnel shall be permitted to operate this machine This manual should be considered a permanent part of your machine and should remain with the machine at all times If you have any questions call Genie Industries Contents Page Safety Rules cccceeeeceeeeneeeeeeeeeeteneeeeseeeeeeeaeeeesaes 1 Controls d icceecithicieiewinitienliwein eis 7 Pre operation Inspection 0 0 0 ee eeeeeeeeeeeeeeeeeneeeteeeaeees 10 MaiNtenanCe seien 12 Function TeSts s sicisieiiitiveat deiiaie denen tioes 15 Workplace Inspection eee ceeceeeeeeeteeeeeeeetneeeeeeeenee 21 Operating Instructions ccececeee tees eeetteeeteneeeee 22 DG CAIS sss va E E E E dead deeuecalcs 26 Transport and Lifting Instructions 0 eee 28 Specifications decuit ideta taeae 31 Contact us Internet http www genielift com e mail techpub genieind com Copyright 2002 by Genie Industries First Edition Third Printing October 2002 Genie and Z are registered trademarks of Genie Industries in the U S A and many other countries These machines comply with ANSI SIA 92 5 199
6. 22 Genie Z 80 60 Part No 82258 First Edition Third Printing Operator s Manual Auxiliary Controls Use auxiliary power if the primary power source engine fails 1 Turn the key switch to ground or platform control 2 Pull out the red Emergency Stop button to the on position 3 Press down the foot switch when operating the auxiliary controls from the platform 4 Simultaneously hold the auxiliary power button and activate the desired function Machines equipped with the auxiliary power drive option The drive function will operate 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 by pressing the fuel select button 4 Start the engine To Position Platform 1 Push and hold a function enable speed select button 4g 2 Push the appropriate function button according to the markings on the control panel Drive and steer functions are not available from the ground controls OPERATING INSTRUCTIONS Operation from Platform 1 Turn the key switch to platform control 2 Pullout both ground and platform red Emergency Stop buttons to the on position 3 Gasoline LPG models Choose fuel by pressing the fuel select button 4 Start the engine Do not press down the foot switch when starting the engine To Position Platform 1 Press down the foot switch 2 Slow
7. button for circle end yellow arrow steer 41 Press down the foot switch 42 Slowly move the drive steer 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 the yellow triangle Result The circle end wheels should turn in the direction that the yellow triangles point on the drive chassis 43 Push the steer mode select button for crab steer 44 Press down the foot switch 45 Slowly move the drive steer control handle in the direction indicated by the blue triangle on the control panel OR press the thumb rocker switch in the direction indicated by the blue triangle Result All wheels should turn in the direction that the blue triangles point on the drive chassis 46 Push the steer mode select button for coordinated steer 47 Press down the foot switch 48 Slowly move the drive steer control handle in the direction indicated by the blue triangle on the control panel OR press the thumb rocker switch in the direction indicated by the blue 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 49 Press down the foot switch 50 Press the thumb rocker switch on top of the drive contr
8. 32 C 10W 40 above 4 F 34 C 15W 40 Engine oil should have properties of API classification CC SE or CC SF grades OR ACEA classification E1 96 Perkins 704 30 Engine Oil viscosity requirements below 60 F 15 5 C 15W 40 10 F to 90 F 23 C to 32 C 10W 30 above 4 F 20 C 15W 40 Engine oil should have properties of API classification CF4 grade Units ship with 10 40 CC SG MAINTENANCE Check the Hydraulic Oil Level Maintaining the hydraulic oil at the proper level is essential to machine operation Improper hydraulic oil levels can damage hydraulic components Daily checks allow the inspector to identify changes in the oil level that might indicate the presence of hydraulic system problems 1 Be sure that the engine is off and the boom is in the stowed position 2 Visually inspect the sight gauge located on the side of the hydraulic oil tank Result The hydraulic oil level should be within the top 2 inches 5 cm of the sight gauge Hydraulic oil specifications Hydraulic oil type Chevron Rykon Premium MV equivalent Part No 82258 Genie Z 80 60 13 Operator s Manual First Edition Third Printing MAINTENANCE Check the Batteries Proper battery condition is essential to good engine performance and operational safety Improper fluid levels or damaged cables and connections can result in engine component damage and hazardous conditions Electrocuti
9. a button such as the engine RPM button or the fuel select button Result The alarm should sound at the platform controls Test the Foot Switch 30 Push in the platform red Emergency Stop button to the off position 31 Pull out the red Emergency Stop button to the on position but do not start the engine 32 Press down the foot switch and attempt to start the engine by pushing the engine start button Result The engine should not start 33 Do not press down the foot switch and restart the engine 34 Do not press down the foot switch and test each machine function Result No machine functions should operate Test Machine Functions 35 Press down the foot switch 36 Activate each machine function control handle toggle switch or button Result All functions should operate through a full cycle Part No 82258 Genie Z 80 60 17 Operator s Manual First Edition Third Printing FUNCTION TESTS Test the Steering models with 4 wheel steer 37 Push the steer mode select button for square end blue arrow steer 38 Press down the foot switch 39 Slowly move the drive steer control handle in the direction indicated by the blue triangle on the control panel OR press the thumb rocker switch in the direction indicated by the blue triangle Result The square end wheels should turn in the direction that the blue triangles point on the drive chassis 40 Push the steer mode select
10. all expected to follow all safety rules and instructions in the operator s safety and responsibilities manuals That means every new operator should perform a pre operation inspection function tests and a workplace inspection before using the machine Starting the Engine 1 At the ground controls turn the key switch to the desired position 2 Besure both the ground and platform control red Emergency Stop buttons are pulled out to the on position 3 Gasoline LPG models Choose fuel by pressing the fuel select button Ta 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 4 Press the engine start button If the engine fails to start or dies the restart delay will disable the start button for 3 seconds All models In extreme cold conditions 20 F 6 C and below warm the engine for 5 minutes to prevent hydraulic system damage Gasoline LPG models In extreme cold conditions 20 F 6 C and below the machine should be started on gasoline then switched to LPG Emergency Stop Push in either the ground or platform red Emergency Stop button to the off position to stop all functions and turn the engine off Repair any function that operates when the red Emergency Stop button is pushed in to the off position Selecting and operating the ground controls will override the platform red Emergency Stop button
11. indicator lights will come on to notify the operator that a function has been interrupted and or an action is required by the operator O light flashing The tilt alarm will be sounding when 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 Lower Primary Boom indicator light flashing Lower the primary boom until the indicator light is off Machine Not Level indicator light flashing The tilt alarm will be sounding when this light is flashing Move the machine to a firm level surface Platform Not Level indicator OPERATINGINSTRUCTIONS Stopping the Engine Push in the red Emergency Stop button and turn the key switch to the off position After Each Use 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 circle end wheels 4 Turn the key switch to the off position and remove the key to secure from unauthorized use 5 Chock the wheels Part No 82258 Genie Z 80 60 25 Operator s Manual First Edition Third Printing Decals Decal Inspection Use the pictures on the next page to verify that all decals are legible and in place Below is a numerical list with quantities and descriptions
12. up onto a 6 inch 15 2 cm block or curb Result The circle end tires should stay in firm contact with the ground Part No 82258 Genie Z 80 60 19 Operator s Manual First Edition Third Printing FUNCTION TESTS Test Limited Drive Speed 63 Press down the foot switch 64 Raise the primary boom to 10 above horizontal 65 Slowly move the drive control handle to the full drive position Result The maximum achievable drive speed with the primary boom raised should not exceed 1 foot 30 cm per second Note The machine will travel 40 feet 12 m in 40 seconds 66 Lower the primary boom to the stowed position 67 Extend the primary boom 4 feet 1 2 m 68 Slowly move the drive control handle to the full drive position Result The maximum achievable drive speed with the primary boom extended should not exceed 1 foot 30 cm per second Note The machine will travel 40 feet 12 m in 40 seconds 69 Retract the primary boom to the stowed position 70 Raise the secondary boom to 10 above horizontal 71 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 foot 30 cm per second Note The machine will travel 40 feet 12 m in 40 seconds 72 Lower the secondary boom to the stowed position If the drive speed with the primary or secondary boom raised or the primary boom extended exceeds 1
13. 00 Toll Free USA and Canada 800 536 1800 Fax 425 883 3475 Genie Holland Genie Australia Pty Ltd Phone 31 7051 78836 Phone 61 7 3375 1660 Fax 31 7051 13993 Fax 61 7 3375 1002 Genie Scandinavia Genie China Phone 46 31 3409612 Phone 86 21 53852570 Fax 46 31 3409613 Fax 86 21 53852569 Genie France Genie Malaysia Phone 33 0 2 37 26 09 99 Phone 60 4 228 1235 Fax 33 0 2 37 26 09 98 Fax 60 4 226 6872 Genie Ib rica Genie Japan Phone 34 93 579 5042 Phone 81 3 3453 6082 Fax 34 93 579 5059 Fax 81 3 3453 6083 Genie Germany Genie Korea Phone 49 0 4202 88520 Phone 82 2 558 7267 Fax 49 0 4202 8852 20 Fax 82 2 558 3910 Genie U K Genie Africa Phone 44 0 1476 584333 Phone 27 11 455 0373 Fax 44 0 1476 584334 Fax 27 11 455 0355 Genie Mexico City Genie Latin America Phone 52 55 5666 5242 Phone 55 11 4055 2499 Fax 52 55 5666 3241 Fax 55 11 4043 1661
14. 2 Printed on recycled paper Printed in U S A Genie Z 80 60 Part No 82258 First Edition Third Printing Operator s Manual Safety Rules Danger Failure to obey the instructions and safety rules in this manual will result in death or serious injury Do Not Operate Unless M You learn and practice the principles of safe machine operation contained in this operator s manual 1 Avoid hazardous situations Know and understand the safety rules before going on to the next section 2 Always perform a pre operation inspection 3 Always perform function tests prior to use 4 Inspect the workplace 5 Only use the machine as it was intended MI You read understand and obey Manufacturer s instructions and safety rules safety and operator s manuals and machine decals employer s safety rules and worksite regulations applicable governmental regulations M You are properly trained to safely operate the machine PartNo 82258 Genie Z 80 60 1 Operator s Manual First Edition Third Printing SAFETY RULES Electrocution Hazards This machine is not electrically insulated and will not provide protection from contact with or proximity to electrical current Se aw E QA K amp S T ig a Maintain safe distances from electrical power lines and apparatus in accordance with applicable governmental regulations and the following chart Minimum Safe Approach Distance Volta
15. 500 Ibs 227 kg 1 31060 Danger Tip over Hazard 2 32700 Danger General Safety 2 33952 Danger Tip over Hazard 1 38149 Label Patents 1 40434 Label Lanyard Anchorage 3 Shading indicates decal is hidden from view i e under covers 26 Genie Z 80 60 Part No 82258 First Edition Third Printing Operator s Manual SSS SSS ey DECALS 32700 65269 38149 Serial Plate 31060 28161 82366 28158 28171 28160 27564 82268 or 28159 82269 31060 28161 40434 82296 43595 28177 82312 220 ae 27206 65269 65278 32700 28236 a 28176 28174 or 28235 65278 30080 etat 28165 28163 65278 or 44986 27206 27205 52966 or 52967 82403 AOS es q 28161 Z or 28177 or 82204 28181 98174 72169 28175 43595 or 28235 72168 43595 28164 82296 Part No 82258 Genie Z 80 60 27 Operator s Manual First Edition Third Printing Transport and Lifting Instructions Observe and Obey M The transport vehicle must be parked on a level surface M The transport vehicle must be secured to prevent rolling while the machine is being loaded M Be sure the vehicle capacity loading surfaces and ch
16. Manual Observe and use the circle and square markings and the color coded direction arrows on the platform controls and drive chassis for drive and steer functions Do not lower the boom unless the area below is clear of personnel and obstructions j O a iP B ex we bs 2 4 o Limit travel speed according to the condition of the ground surface congestion slope location of personnel and any other factors which may cause collision Do not operate a boom in the path of any crane unless the controls of the crane have been locked out and or precautions have been taken to prevent any potential collision No stunt driving or horseplay while operating a machine SAFETY RULES Component Damage Hazards Do not use any battery or charger greater than 12V DC to jump start the engine Do not use the machine as a ground for welding Explosion and Fire Hazards Do not start the engine if you smell or detect liquid petroleum gas LPG gasoline diesel fuel or other explosive substances Do not refuel the machine with the engine running Refuel the machine and charge the battery only in an open well ventilated area away from sparks flames and lighted tobacco Do not operate the machine in hazardous locations or locations where potentially flammable or explosive gases or particles may be present Part No 82258 Genie Z 80 60 Operator s Manual First Edition Third Printing SAFETY RULES Damaged Machine H
17. a firm level surface before raising the platform Do not use the platform controls to free a platform that is 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 Do not operate the machine in strong or gusty winds Do not increase the surface area of the platform or the load Increasing the area exposed to the wind will decrease machine stability Eas KE sN N A Use extreme care and slow speeds while driving the machine in the stowed position across uneven terrain debris unstable or slippery surfaces and near holes and drop offs Do not drive the machine on or near uneven terrain unstable surfaces or other hazardous conditions with the boom raised or extended SAFETY RULES Maximum allowable side force 150 Ibs ANSI amp CSA 667 N Maximum allowable 90 Ibs side force CE 400 N Do not push off or pull toward any object Aa outside of the platform e 7 Do not alter or disable qi LAS machine components that in any way affect N 7A safety and stability Do not replace items critical to machine stability with items of different weight or specification Do not modify or alter an aerial work platform Mounting attachments for holding tools or other materials onto the platform toeboards or guard rail system can increase the weight in the platfor
18. ains or straps are sufficient to withstand the machine weight See the serial plate for the machine weight M Be sure the turntable is secured with the turntable rotation lock before transporting Be sure to unlock the turntable for operation Free wheel Configuration for Winching Chock the wheels to prevent the machine from rolling 2WD models Release the non steer wheel brakes by turning over the drive hub disconnect caps Disengage 4WD models Release the wheel brakes by turning over all four drive hub disconnect caps Engage Be sure the winch line is properly secured to the drive chassis tie points and the path is clear of all obstructions Reverse the procedures described to re engage the brakes Note The pump free wheel valve should always remain closed 28 Genie Z 80 60 Part No 82258 First Edition Third Printing Operator s Manual Securing to Truck or Trailer for Transit Always use the turntable rotation lock pin each time the machine is transported Turn the key switch to the off position and remove the key before 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 Truck bed j n TRANSPORT AND LIFTING INSTRUCTIONS Securing the Platform Place a block under the rotator Do not allow the bl
19. azards Do not use a damaged or malfunctioning machine Conduct a thorough pre operation inspection of the machine and test all functions before each work shift Immediately tag and remove from service a damaged or malfunctioning machine Be sure all maintenance has been performed as specified in this manual and the appropriate service manual Be sure all decals are in place and legible Be sure that the operator s safety and responsibilities manuals are complete legible and in the storage container located in the platform Bodily Injury Hazard Do not operate the machine with a hydraulic oil or air leak An air leak or hydraulic leak can penetrate and or burn skin Always operate the machine in a well ventilated area to avoid carbon monoxide poisoning Decal Legend Genie product decals use symbols color coding and signal words to identify the following messages that follow this symbol to avoid possible injury or death Red used to indicate the ADANGER presence of an imminently hazardous situation which if not avoided will result in death or serious injury Safety alert symbol used to alert personnel to potential personal injury hazards Obey all safety Orange used to indicate the AWARNING presence of a potentially hazardous situation which if not avoided could result in death or serious injury Yellow with safety alert symbol ACAUTION used to indicate the presence of a potentially hazardous
20. button with indicator light 10 Diesel models Glow plug button with indicator light 11 Engine start button with indicator light 12 Drive select button with indicator lights Machine on incline symbol Low range operation for inclines eD Machine on level surface symbol High range operation for maximum drive speed 13 Steer mode select buttons with indicator lights 14 Engine idle rpm select button with indicator lights Rabbit amp Foot Switch foot switch activated high idle Turtle low idle Rabbit high idle Genie Z 80 60 Part No 82258 First Edition Third Printing Operator s Manual QO 00O Q CONTROLS ENGINE START eee RPM FUEL SELECT LOW FUEL STOP FAULT CHECK ENGINE POWER UP TO START DRIVE SPEED STEER MODE SELECT SELECT y a SECONDARY UP EXTEND SECONDARY BOOM DOWN RETRACT C 15 Used for optional equipment 16 Gasoline LPG models Gasoline LPG select button with indicator lights 17 Fault indicator light 18 Low fuel indicator light 19 Check engine indicator light 20 Red Emergency Stop button 21 Power indicator light me 530 DOWN to STOP EF 22 Dual axis proportional control handle for drive and steer functions OR Proportional control handle for drive function and thumb rocker for steer function 23 Single axis proportional co
21. d off To drive push the drive enable button and slowly move the drive steer control handle off center If the drive steer control handle is not moved within two seconds of pushing the drive enable button the drive function will not operate Release and push the drive enable button again Be aware that the machine may move in the opposite direction that the drive and steer controls are moved Always use the color coded direction arrows on the platform controls and the drive chassis to identify the direction the machine will travel Regulated Generator if equipped To operate the generator press the generator button The indicator light will come on and the engine will continue to run Plug power tools into the power to platform GFCI outlet To turn off the generator push the generator button The indicator light will turn off Engine Idle Select rpm Select the engine idle rpm by pressing the select button The indicator light next to the current setting will be on Rabbit and foot switch symbol foot switch activated high idle Turtle symbol low idle Rabbit symbol high idle 24 Genie Z 80 60 Part No 82258 First Edition Third Printing Operator s Manual Check Engine Light Light on and engine stopped Tag the machine and remove from service Light on and engine still running Contact service personnel within 24 hours Operating Envelope Indicator Lights The operating envelope
22. foot 30 cm per second immediately tag and remove the machine from service Test Auxiliary 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 76 Simultaneously press and hold the auxiliary power button and activate each function control handle toggle switch or button Note To conserve battery power test each function through a partial cycle Result All boom and steer functions should operate 20 Genie Z 80 60 Part No 82258 First Edition Third Printing Operator s Manual Do Not Operate Unless MI You learn and practice the principles of safe machine operation contained in this operator s manual 1 Avoid hazardous situations 2 Always perform a pre operation inspection 3 Always perform function tests prior to use 4 Inspect the workplace Know and understand the workplace inspection before going on to the next section 5 Only use the machine as it was intended Fundamentals The workplace inspection helps the operator 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 I
23. ge Phase to Phase Allow for platform movement electrical line 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 use the machine as a ground for welding unless the machine is equipped with the weld line to platform option and it is properly connected Tip over Hazards Occupants and equipment shall not exceed the maximum platform capacity Maximum platform capacity 500 Ibs 227 kg Maximum occupants 2 Do not raise or extend the boom unless the Feet Meters machine is on a firm level surface 0 to 300V Avoid Contact S 300V to 50KV 10 3 05 50KV to 200KV 15 4 60 200KV to 350KV 20 6 10 350KV to 500KV 25 7 62 500KV to 750KV 35 10 67 750KV to 1000KV 45 13 72 Do not depend on the tilt alarm as a level indicator The tilt alarm sounds in the platform only when the machine is on a severe slope 2 Genie Z 80 60 Part No 82258 First Edition Third Printing Operator s Manual If the tilt alarm sounds Do not extend rotate or raise the boom above horizontal Move the machine to a firm level surface before raising the platform If the tilt alarm sounds when the platform is raised use extreme caution to retract the boom and lower the platform Do not rotate the boom while lowering Move the machine to
24. ids 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 manual 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 14 Genie Z 80 60 Part No 82258 First Edition Third Printing Operator s Manual Do Not Operate Unless MI You learn and practice the principles of safe machine operation contained in this operator s manual 1 Avoid hazardous situations 2 Always perform a pre operation inspection 3 Always perform function tests prior to use Know and understand the function tests before going on to the next section 4 Inspect the workplace 5 Only use the machine as it was intended 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 only be made by a qualified service technician according to the manufacturer s specifications After repairs are completed the operator must Function Tests 1 Select a test area
25. ly move the appropriate function control handle or toggle switch or press the appropriate button according to the markings on the control panel To Steer 1 Press down the foot switch Models with 4 wheel steer 2 Select the steer mode by pressing a steer mode button The indicator light next to the current steer mode will be on All models 3 Slowly move the drive steer control handle in the direction lt indicated by the blue or yellow i 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 Part No 82258 Genie Z 80 60 23 Operator s Manual First Edition Third Printing OPERATING INSTRUCTIONS To Drive 1 Press down the foot switch _ y 2 Increase speed Slowly move the drive steer control handle in the direction indicated by the blue or yellow arrows Decrease speed Slowly move the drive steer control handle toward center Stop Return the drive steer control handle to center or release the foot switch Use the color coded direction arrows on the platform controls and the drive chassis to identify the direction the machine will travel Machine travel speed is restricted when the boom is raised or extended Drive Enable Light on indicates that the boom has moved past either circle end wheel and the drive function is turne
26. m and the surface area of the platform or the load Part No 82258 Genie Z 80 60 Operator s Manual First Edition Third Printing SAFETY RULES Do not place or attach overhanging loads to any part of this machine A Do not place ladders or scaffolds in the platform or against any part of this machine Do not use the machine on a moving or mobile surface or vehicle Be sure all tires are in good condition and lug nuts are properly tightened Fall Hazards Occupants must wear a safety belt or harness in accordance with governmental regulations Attach the lanyard to the anchorage point provided in the platform It is recommended that operators wear an approved hard hat when operating the machine Do not sit stand or climb on the platform guard rails Maintain a firm footing on the platform floor at all times si ss At L N gt A Do not climb down from the platform when raised Keep the platform floor clear of debris Lower the platform entry mid rail or close the entry gate before operating Collision Hazards Be aware of limited sight distance and blind spots when driving or operating Be aware of boom position and tailswing when rotating the turntable Check the work area for overhead obstructions or other possible hazards Be aware of crushing hazards when grasping the platform guard rail 4 Genie Z 80 60 Part No 82258 First Edition Third Printing Operator s
27. nspection Workplace Inspection Be aware of and avoid the following hazardous situations drop offs or holes bumps floor obstructions or debris overhead obstructions and high voltage conductors hazardous locations inadequate surface support to withstand all load forces imposed by the machine wind and weather conditions the presence of unauthorized personnel other possible unsafe conditions Part No 82258 Genie Z 80 60 21 Operator s Manual First Edition Third Printing Operating Instructions Do Not Operate Unless M You learn and practice the principles of safe machine operation contained in this operator s manual 1 Avoid hazardous situations 2 Always perform a pre operation inspection 3 Always perform function tests prior to use 4 Inspect the workplace 5 Only use the machine as it was intended 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 Using the machine for anything other than lifting personnel and tools 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 machine at different times in the same work shift they must all be qualified operators and are
28. ntrol handle for secondary boom up extend and down retract function 24 Single axis proportional control handle for primary boom extend retract function 25 Drive enable button with indicator light 26 Dual axis proportional control handle for primary boom up down and turntable rotate left right functions 27 Jib boom up down toggle switch Part No 82258 Genie Z 80 60 Operator s Manual First Edition Third Printing Pre operation Inspection Do Not Operate Unless M You learn and practice the principles of safe machine operation contained in this operator s manual 1 Avoid hazardous situations 2 Always perform a pre operation inspection Know and understand the pre operation inspection before going on to the next section 3 Always perform function tests prior to use 4 Inspect the workplace 5 Only use the machine as it was intended 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 The inspection 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
29. ock to contact the platform cylinder Secure the platform with a nylon strap placed over the jib knuckle Do not use excessive downward force when securing the boom section Part No 82258 Genie Z 80 60 29 Operator s Manual First Edition Third Printing TRANSPORT AND LIFTING INSTRUCTIONS Observe and Obey M Only qualified riggers should rig and lift the machine M Be sure the crane capacity loading surfaces and straps or lines are sufficient to withstand the machine weight See the serial plate for the 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 measurements on the pictures 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 turntable lifting point Adjust the rigging to prevent damage to the machine and to keep the machine level Turntable Chassis Lifting Lifting Point Points 2 O o1 i 2 CA Co saaki kiir FP mas 1 LNN E a 39 61 in 1m E i 34 18in 86 8 cm 30 Genie Z 80 60 Part No 82258 First Edition Third Printing Operator s Manual Specifications
30. ol handle in the direction indicated by the blue triangle on the control panel OR slowly move the drive steer control handle in the direction indicated by the blue triangle Result The steer wheels should turn in the direction that the blue triangles point on the drive chassis 5 Press the thumb rocker switch in the direction indicated by the yellow triangle on the control panel OR slowly move the drive steer handle in the direction indicated by the yellow triangle Result The steer wheels should turn in the direction that the yellow triangles point on the drive chassis 18 Genie Z 80 60 Part No 82258 First Edition Third Printing Operator s Manual Test Drive and Braking 52 Press down the foot switch 53 Slowly move the drive steer control handle in the direction indicated by the blue arrow 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 come to an abrupt stop 54 Slowly move the drive steer control handle in the direction indicated by the yellow arrow 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 yellow arrow points on the drive chassis then come to an abrupt stop Note The brakes must be able to hold the machine on an
31. om up down buttons 19 Secondary boom up extend and down retract buttons 20 Platform rotate left right buttons 21 Turntable rotate left right buttons Part No 82258 Genie Z 80 60 Operator s Manual First Edition Third Printing CONTROLS 0 000 OO g PLATFORM AUXILIARY Ke ROTATE HORN GENERATOR POWER GLOW PLUG ENGII 1 O p LOWER PRIMARY BOOM PLATFORM LEVEL MACHINE NOT LEVEL of z PLATFORM NOT LEVEL H PRIMARY BOOM UP DOWN Li E 4 mo P JIB BOOM 7 es i TURNTABLE ROTATE p go D TURNTABLE ROTAT DRIVE ENABLE OPERATION Light on indicates that boom has moved past a circle end tire and drive function is turned off To drive push drive enable button and slowly move drive control handle Machine may drive in opposite direction that drive and steer controls are moved Use color coded direction arrows on this panel and drive chassis to identify the direction machine will PRIMARY BOOM RETRACT 9 eet s travel primary BOOM EXTEND Platform Control Panel 1 Platform rotate toggle switch 2 Platform level toggle switch 3 Platform Not Level indicator light 4 Machine Not Level indicator light 5 Lower Primary Boom indicator light 6 notused 7 Hornbutton 8 Generator button with indicator light option 9 Auxiliary power
32. on hazard Contact with AWARNING hot or live circuits may result in death or serious injury Remove all rings watches and other jewelry Bodily injury hazard Batteries AWARNING contain acid Avoid spilling or contacting battery acid Neutralize battery acid spills with baking soda and water 1 Put on protective clothing and eye wear 2 Be sure that the battery cable connections are tight and free of corrosion 3 Be sure that the battery hold down bar is in place and secure 4 Remove the battery vent caps 5 Check the battery acid level If needed replenish with distilled water to the bottom of the battery fill tube Do not overfill 6 Install the vent caps Adding terminal protectors anda corrosion preventative sealant will help eliminate corrosion on the battery terminals and cables Check the Engine Coolant Level Liquid Cooled Models Maintaining the engine coolant at the proper level is essential to engine service life An 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 problems 1 Check the fluid level in the coolant recovery tank Add fluid as needed Result The fluid level should be in the NORMAL range Bodily injury hazard Fluids in the AWARNING radiator are under pressure and extremely hot Use caution when removing cap and adding flu
33. p button to the on position 11 Simultaneously push and hold the auxiliary power button and push each boom function button Note To conserve battery power test each function through a partial cycle Result All boom functions should operate Test the Tilt Sensor 12 Push one of the LCD screen buttons until 4 ll TURNTABLE LEVEL SENSOR X DIRECTION appears Result The LCD screen should display the angle in degrees 13 Push one of the LCD screen buttons until TURNTABLE LEVEL SENSOR Y DIRECTION appears Result The LCD screen should display the angle in degrees 14 Push one of the LCD screen buttons until PLATFORM LEVEL SENSOR DEGREES appears Result The LCD screen should display the angle in degrees Test the Operating Envelope 15 Push one of the LCD screen buttons shown until PRI 4 4l BOOM ANGLE is displayed 16 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 68 The primary boom should stop when the screen reads 68 degrees 17 Lower the primary boom 18 Simultaneously push the LCD screen buttons shown to activate status mode 19 Push one of the LCD screen buttons shown until SEC 4 el BOOM ANGLE is displayed 20 Push and hold the secondary boom up extend button
34. situation which if not avoided may cause minor or moderate injury Yellow without safety alert symbol used to indicate the presence of a potentially hazardous situation which if not avoided may result in property damage CAUTION Green used to indicate operation or maintenance information 6 Genie Z 80 60 Part No 82258 First Edition Third Printing Operator s Manual Controls NIZI NIZ NZ NZ NZI ZNI IAN IZNIQIZNI IZNI TREDE Ya oe 0 o UNS ge 2 o STOP COCO AUXILIARY POWER HIGH SPEED FUNCTION ENABLE LOW SPEED FUNCTION ENABLE x SYSTEM fN 20 AMP 0000 OGO O O Q ALARM Ground Control Panel Boom down button Boom extend retract buttons Boom up button Engine speed select button LCD screen control buttons Gasoline LPG select button LCD readout screen Red Emergency Stop button Diesel models Glow plug button 10 Key switch for off ground platform selection 11 Engine start button OAN DOA RWNDY 12 Auxiliary power button 13 High speed function enable button 14 Low speed function enable button 15 20A circuit breaker for system circuit 16 Alarm 17 Platform level up down buttons 18 Jib bo
35. that is firm level and free of obstruction At the Ground Controls 2 Turn the key switch to ground control 3 Pull out the red Emergency Stop button to the on position Result The LCD screen will come on and display no error messages The beacon if equipped should flash Note In cold climates the LCD readout screen will need to warm up before the display appears 4 Start the engine See Operating Instructions section Test Emergency Stop 5 Push in the red Emergency Stop button to the off position Result The engine should turn off and no functions should operate 6 Pull out the red Emergency Stop button to the on position and restart the engine Test the Machine Functions 7 Donotpress 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 if equipped should sound while the boom is perform a pre operation inspection and function lowering tests again before putting the machine into service Part No 82258 Genie Z 80 60 15 Operator s Manual First Edition Third Printing FUNCTION TESTS Test Auxiliary Controls 9 Shut the engine off 10 Pull out the red Emergency Sto
36. to the list on the next page and check each of the items and locations for modifications damage or loose or missing parts A damaged or modified machine must never be used If damage or any variation from factory delivered condition is discovered the machine must be tagged and removed from service Repairs to the machine may only be made by a qualified service technician according to the manufacturer s specifications After repairs are completed the operator must performa pre operation inspection again before going on to the function tests Scheduled maintenance inspections shall be performed by qualified service technicians according to the manufacturer s specifications and the requirements listed in the responsibilities manual 10 Genie Z 80 60 Part No 82258 First Edition Third Printing OO _______ EX Pre operation Inspection QO Be sure that the operator s safety and responsibilities manuals are complete legible and in the storage container located in the platform Be sure that all decals are legible and in place See Decals section Check for engine oil leaks and proper oil level Add oil if needed See Maintenance section Check for hydraulic oil leaks and proper oil level Add oil if needed See Maintenance section Check for engine coolant leaks and proper level of coolant Add coolant if needed See Maintenance section Check for battery fluid leaks and proper fluid level Add distilled
37. ual to help communicate the intent of the instructions When one or more of the symbols appear at the beginning of amaintenance procedure it conveys the meaning below Indicates that 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 HEA 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 Check the oil level with the engine off 1 Check the engine oil dipstick Add oil as needed GM models Result The oil level should be within the app and FULL marks on the dipstick Deutz models Result The oil level should be within the two marks on the dipstick Perkins models Result The oil level should be within the two notches on the dipstick GM 3 0L EFI Engine Oil viscosity requirements below 0 F 17 8 C 5W 30 above 0 F 17 8 C 10W 30 Only use engine oils labeled For Gasoline Engines by the American Petroleum Institute API Units ship with 10W 30 12 Genie Z 80 60 Part No 82258 First Edition Third Printing Operator s Manual Deutz F4L 913 Engine Engine oil viscosity requirements below 60 F 15 5 C 5W 30 synthetic 10 F to 90 F 23 C to
38. water if needed See Maintenance section Check the following components or areas for damage and improperly installed loose or missing parts a Electrical components wiring and electrical cables 4 Hydraulic hoses fittings cylinders and manifolds a Fuel and hydraulic tanks a Drive and turntable motors and drive hubs 4 Boom and axle wear pads a Tires and wheels a Engine and related components a Limit switches and horn a Alarms and beacons if equipped a Nuts bolts and other fasteners a Platform entry mid rail or gate Operator s Manual PRE OPERATION INSPECTION Check entire machine for a Crack in welds or structural components 4 Dents or damage to machine Be sure that all structural and other critical components are present and all associated fasteners and pins are in place and properly tightened After you complete your inspection be sure that all compartment covers are in place and latched Part No 82258 Genie Z 80 60 11 Operator s Manual First Edition Third Printing Maintenance Observe and Obey m Only routine maintenance items specified in this manual shall be performed by the operator f Scheduled maintenance inspections shall be completed by qualified service technicians according to the manufacturer s specifications and the requirements specified in the responsibilities manual Maintenance Symbols Legend The following symbols have been used in this man
39. y slope it is able to climb Test the Oscillate Axle oscillating axle equipped models 55 Start the engine from the platform controls 56 Drive the right square end tire up onto a 6 inch 15 2 cm block or curb Result The three remaining tires should stay in FUNCTION TESTS Test the Drive Enable System 59 Press down the foot switch and lower the booms to the stowed position 60 Rotate the turntable until the primary boom moves past one of the circle end tires Result The drive enable indicator light should come on while the boom is anywhere in the range shown 61 Move the drive steer control handle off center Result No drive function should operate 62 Push the drive enable button and slowly move the drive steer control handle off center Result The drive function should operate Note When the drive enable system is in use the machine may drive in the opposite direction that the drive and steer control handle is moved Use the color coded direction arrows on the platform controls and the drive chassis to identify the direction of Blue travel d If the drive steer control firm contact with the ground handle is not moved within Yellow F two seconds of pushing the 57 sh Hate e tire up onto a 6 inch drive enable button the drive e OOE SEIT function will not operate Result The three remaining tires should stay in firm contact with the ground 58 Drive both square end tires
Download Pdf Manuals
Related Search