Genie Z-80, Z-60 User Manual

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Operator’s Manual

First Edition

Third Printing

with Maintenance Information

Part No. 82258

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 ..............................................................

1

Controls .....................................................................

7

Pre-operation Inspection ...........................................

10

Maintenance .............................................................

12

Function Tests ..........................................................

15

Workplace Inspection ................................................

21

Operating Instructions ...............................................

22

Decals ......................................................................

26

Transport and Lifting Instructions ..............................

28

Specifications ...........................................................

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 92.5-1992.

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:

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.

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

You are properly trained to safely operate the machine.

Part No. 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.

Maintain safe distances from electrical power lines and apparatus in accordance with applicable governmental regulations and the following chart.

Voltage

 

Minimum Safe

Phase to Phase

Approach Distance

 

Feet

Meters

 

 

0 to 300V

Avoid Contact

 

 

 

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

 

 

 

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 lbs

227 kg

 

 

Maximum occupants

2

 

 

Do not raise or extend the boom unless the machine is on a firm, level surface.

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 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.

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 lbs

- ANSI & CSA

667 N

 

 

Maximum allowable

90 lbs

side force - CE

400 N

 

 

Do not push off or pull toward any object outside of the platform.

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 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 platform and the surface area of the platform or the load.

Part No. 82258

Genie Z-80/60

3

Operator's Manual

First Edition · Third Printing

 

 

 

 

SAFETY RULES

Do not place or attach overhanging loads to any part of this machine.

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.

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 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.

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

5

Operator's Manual

First Edition · Third Printing

 

 

 

 

SAFETY RULES

Damaged Machine Hazards

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:

Safety alert symbol—used to alert personnel to potential personal injury hazards. Obey all safety messages that follow this symbol to avoid possible injury or death.

Red—used to indicate the presence of an imminently hazardous situation which, if not avoided, will result in death or serious injury.

Orange—used to indicate the presence of a potentially hazardous situation which, if not avoided, could result in death or serious injury.

Yellow with safety alert symbol— used to indicate the presence of a potentially hazardous 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.

Green—used to indicate operation or maintenance information.

6

Genie Z-80/60

Part No. 82258

First Edition · Third Printing

Operator's Manual

 

 

 

 

Controls

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

Ground Control Panel

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

1

Boom down button

12

Auxiliary power button

2

Boom extend/retract buttons

13

High speed function enable button

3

Boom up button

14

Low speed function enable button

4

Engine speed select button

15

20A circuit breaker for system circuit

5

LCD screen control buttons

16

Alarm

6

Gasoline/LPG select button

17

Platform level up/down buttons

7

LCD readout screen

18

Jib boom up/down buttons

8

Red Emergency Stop button

 

 

 

19 Secondary boom up/extend and

9

Diesel models: Glow plug button

 

 

 

 

 

 

down/retract buttons

10

Key switch for off/ground/platform selection

20

Platform rotate left/right buttons

11

Engine start button

21

Turntable rotate left/right buttons

Part No. 82258

Genie Z-80/60

7

Genie Z-80, Z-60 User Manual

Operator's Manual

First Edition · Third Printing

 

 

 

 

CONTROLS

1

2

3

4

5

6

7

8

9

10

27

Platform Control Panel

1Platform rotate toggle switch

2Platform level toggle switch

3Platform Not Level indicator light

4Machine Not Level indicator light

5Lower Primary Boom indicator light

6not used

7Horn button

26

25

8Generator button with indicator light (option)

9Auxiliary power button with indicator light

10Diesel models: Glow plug button with indicator light

11Engine start button with indicator light

12Drive select button with indicator lights:

Machine on incline symbol: Lowrange

operation for inclines

15

24

Machine on level surface symbol: High range operation for maximum drive speed

13Steer mode select buttons with indicator lights

14Engine idle (rpm) select button with indicator lights:

·Rabbit & Foot Switch: foot switch activated high idle

·Turtle: low idle

·Rabbit: high idle

8

Genie Z-80/60

Part No. 82258

First Edition · Third Printing

Operator's Manual

 

 

 

 

CONTROLS

11

12

13

14

23

15Used for optional equipment

16Gasoline/LPG models: Gasoline/LPG select button with indicator lights

17Fault indicator light

18Low fuel indicator light

19Check engine indicator light

20Red Emergency Stop button

21Power indicator light

15

16

17

18

19

20

22

21

22Dual axis proportional control handle for drive and steer functions

OR Proportional control handle for drive function and thumb rocker for steer function

23Single axis proportional control handle for secondary boom up/extend and down/retract function

24Single axis proportional control handle for primary boom extend/retract function

25Drive enable button with indicator light

26Dual axis proportional control handle for primary boom up/down and turntable rotate left/right functions

27Jib boom up/down toggle switch

Part No. 82258

Genie Z-80/60

9

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