Genie Z-80, Z-60 User Manual

Operator’s Manual

with Maintenance Information

First Edition

Third Printing

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: [e-mail]

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

Operator's ManualFirst Edition · Third Printing

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.

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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

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.

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.

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SAFETY RULES

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.

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.

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.

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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.

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SAFETY RULES

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.

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.

No stunt driving or horseplay while operating a
machine.

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.

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Operator's ManualFirst Edition · Third Printing

Controls

Ground Control Panel

1 Boom down button
2 Boom extend/retract buttons
3 Boom up button
4 Engine speed select button
5 LCD screen control buttons
6 Gasoline/LPG select button
7 LCD readout screen
8 Red Emergency Stop button
9 Diesel models: Glow plug button
10 Key switch for off/ground/platform selection
11 Engine start button

Part No. 82258 Genie Z-80/60 7

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 boom up/down buttons
19 Secondary boom up/extend and

down/retract buttons
20 Platform rotate left/right buttons
21 Turntable rotate left/right buttons

Operator's Manual First Edition · Third Printing

CONTROLS

1

2

43

65

7

8

9 10

27

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 not used
7 Horn button

26

8 Generator button with

indicator light (option)

9 Auxiliary power 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

1525

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 & Foot Switch: foot
switch activated high idle

· Turtle: low idle

· Rabbit: high idle

operation for inclines

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24

Operator's ManualFirst Edition · Third Printing

CONTROLS

11 14 16 1817 20

12 13 15

19

22 21

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

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

23

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

control handle for secondary
boom up/extend and
down/retract function

Part No. 82258 Genie Z-80/60 9