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: 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
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.
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
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.
2 Genie Z-80/60 Part No. 82258
Operator's ManualFirst Edition · Third Printing
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.
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
Operator's ManualFirst Edition · Third Printing
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.
6 Genie Z-80/60 Part No. 82258
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
8 Genie Z-80/60 Part No. 82258
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
Operator's Manual First Edition · Third Printing
Pre-operation Inspection
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.
Do Not Operate Unless:
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.
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 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.
5 Only use the machine as it was intended.
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 perform a
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
Pre-operation Inspection
Operator's ManualFirst Edition · Third Printing
PRE-OPERATION INSPECTION
o
Be sure that the operator’s, safety and
responsibilities manuals are complete, legible
and in the storage container located in the
platform.
o
Be sure that all decals are legible and in place.
See Decals section.
o
Check for engine oil leaks and proper oil level.
Add oil if needed. See Maintenance section.
o
Check for hydraulic oil leaks and proper oil level.
Add oil if needed. See Maintenance section.
o
Check for engine coolant leaks and proper level
of coolant. Add coolant if needed. See
Maintenance section.
o
Check for battery fluid leaks and proper fluid
level. Add distilled water if needed. See
Maintenance section.
Check the following components or areas for
damage and improperly installed, loose or
missing parts:
o
Electrical components, wiring and
electrical cables
Check entire machine for:
o
Crack in welds or structural components
o
Dents or damage to machine
o
Be sure that all structural and other critical
components are present and all associated
fasteners and pins are in place and properly
tightened.
o
After you complete your inspection, be sure that
all compartment covers are in place and
latched.
o
Hydraulic hoses, fittings, cylinders and
manifolds
o
Fuel and hydraulic tanks
o
Drive and turntable motors and drive hubs
o
Boom and axle wear pads
o
Tires and wheels
o
Engine and related components
o
Limit switches and horn
o
Alarms and beacons (if equipped)
o
Nuts, bolts and other fasteners
o
Platform entry mid-rail or gate
Part No. 82258 Genie Z-80/60 11
Operator's Manual First Edition · Third Printing
Maintenance
Check the Engine Oil Level
Maintaining the proper engine oil level is essential
to good engine performance and service life.
Observe and Obey:
Only routine maintenance items specified in this
manual shall be performed by the operator.
Scheduled maintenance inspections shall be
completed by qualified service technicians,
according to the manufacturer's specifications
and the requirements specified in the
responsibilities manual.
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 ADD and
FULL marks on the dipstick.
Maintenance Symbols Legend
The following symbols have been
used in this manual to help
communicate the intent of the
instructions. When one or more of
the symbols appear at the
beginning of a maintenance
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.
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
Operator's ManualFirst Edition · Third Printing
MAINTENANCE
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 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.
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.
Electrocution hazard. Contact with
hot or live circuits may result in
death or serious injury. Remove all
rings, watches and other jewelry.
Bodily injury hazard. Batteries
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.
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
radiator are under pressure and
extremely hot. Use caution when
removing cap and adding fluids.
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 and a
corrosion preventative sealant will
help eliminate corrosion on the
battery terminals and cables.
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
Do Not Operate Unless:
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.
Operator's ManualFirst Edition · Third Printing
Function Tests
1 Select a test area 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.
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
perform a pre-operation inspection and function
tests again before putting the machine into service.
Part No. 82258 Genie Z-80/60 15
Test the Machine Functions
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
(if equipped) should sound while the boom is
lowering.
Operator's Manual First Edition · Third Printing
FUNCTION TESTS
Test Auxiliary Controls
9 Shut the engine off.
10 Pull out the red Emergency Stop 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
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
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
BOOM ANGLE is
displayed.
20 Push and hold the secondary boom up/extend
button.
Result: The secondary boom should raise and
the LCD screen should display:
0DEG
>0DEG
AT65DEG
AT 0 FT
>0 FT
>22 FT
The secondary boom should raise and then
extend. The secondary boom should not extend
until it is fully raised.
21 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
Operator's ManualFirst Edition · Third Printing
FUNCTION TESTS
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.
26 Locate and check the
hydraulic filter condition
indicator.
Result: The filter should
be operating with the
plunger in the green
area.
Test the Tilt Sensor Alarm
29 Push 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
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.
Part No. 82258 Genie Z-80/60 17
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.
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 squareend (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
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.
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 control 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.
44 Press down the foot switch.
18 Genie Z-80/60 Part No. 82258
51 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.
Operator's ManualFirst Edition · Third Printing
FUNCTION TESTS
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 any 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.
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.
Result: The three remaining tires should stay in
firm contact with the ground.
57 Drive the left square-end tire up onto a 6 inch /
15.2 cm block or curb.
If the drive/steer control
handle is not moved within
two seconds of pushing the
drive enable button, the drive
function will not operate.
Yellow
Result: The three remaining tires should stay in
firm contact with the ground.
58 Drive both square-end tires 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 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
Do Not Operate Unless:
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.
Operator's ManualFirst Edition · Third Printing
Workplace Inspection
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
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.
Part No. 82258 Genie Z-80/60 21
Operator's Manual First Edition · Third Printing
Operating Instructions
Starting the Engine
1 At the ground controls, turn the key switch to
the desired position.
2 Be sure both the ground and platform control red
Emergency Stop buttons are pulled out to the
Do Not Operate Unless:
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.
on position.
3 Gasoline/LPG models: Choose fuel by pressing
the fuel select button.
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.
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.
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 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.
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.
22 Genie Z-80/60 Part No. 82258
Operator's ManualFirst Edition · Third Printing
OPERATING INSTRUCTIONS
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.
Operation from Platform
1 Turn the key switch to platform control.
2 Pull out 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 Slowly 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.
To Position Platform
1 Push and hold a function enable/
speed select button.
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.
Part No. 82258 Genie Z-80/60 23
All models:
3 Slowly move the drive/steer
control handle in the direction
indicated by the 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.
Operator's Manual First Edition · Third Printing
OPERATING INSTRUCTIONS
To Drive
1 Press down the foot switch.
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 turned off.
To drive, push the drive enable button and slowly
move the drive/steer control handle off center.
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
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.
24 Genie Z-80/60 Part No. 82258
Operator's ManualFirst Edition · Third Printing
OPERATING INSTRUCTIONS
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 indicator lights will come on
to notify the operator that a function has been
interrupted and/or an action is required by the
operator.
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.
Stopping the Engine
Push in the red Emergency Stop button and turn
the key switch to the off position.
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 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.
Platform Not Level indicator
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.
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.
Part No. Description Quantity
27204 Arrow - Blue 1
27205 Arrow - Yellow 1
27206 Triangle - Blue 2
27207 Triangle - Yellow 2
27564 Danger - Electrocution Hazard 2
28158 Label - Unleaded 1
28159 Label - Diesel 1
28160 Label - LPG 1
28161 Warning - Crushing Hazard 3
28163 Notice - Max. Side Force, 150 lbs / 667 N,
ANSI & CSA 1
28164 Notice - Hazardous Materials 1
28165 Notice - Footswitch 1
28171 Label - No Smoking 1
28174 Label - Power to Platform, 230V 2
28175 Caution - Compartment Access 1
28176 Notice - Missing Manuals 1
Part No. Description Quantity
43595 Danger - Tip-over Hazard, Tires 4
44986 Notice - Max. Manual Force,
90 lbs / 400 N, CE 1
52966 Cosmetic - 4 x 2 1
52967 Cosmetic - 4 x 4 1
65269 Notice - Operating Instructions 2
65278 Caution - No Step 4
72168 Notice - Starter Battery 1
72169 Notice - Controls Battery 1
82202 Notice - Engine Specifications, Perkins 1
82203 Notice - Engine Specifications, GM 1
82204 Notice - Engine Specifications, Deutz 1
82268 Cosmetic - Genie Z-80/60 1
82269 Ground Control Panel 1
82281 Platform Control Panel 1
82296 Notice - Tire Specifications 4
82312 Cosmetic - Z-80 1
28177 Warning - Collision Hazard 2
28181 Warning - No Step or Ride 1
28235 Label - Power to Platform, 115V 2
28236 Warning - Failure To Read . . . 1
30080 Notice - Max. Capacity, 500 lbs / 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
82366 Label - Chevron Rykon 1
82403 Label - Fuse and Relay Panel Layout 1
Shading indicates decal is hidden from view, i.e.
under covers
26 Genie Z-80/60 Part No. 82258
Operator's ManualFirst Edition · Third Printing
DECALS
Part No. 82258 Genie Z-80/60 27
Operator's Manual First Edition · Third Printing
Transport and Lifting Instructions
Free-wheel Configuration for
Winching
Chock the wheels to prevent the machine from
rolling.
2WD models: Release
Observe and Obey:
The transport vehicle must be parked on a level
surface.
The transport vehicle must be secured to
prevent rolling while the machine is being
loaded.
Be sure the vehicle capacity, loading surfaces
and chains or straps are sufficient to withstand
the machine weight. See the serial plate 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.
the non-steer wheel
brakes by turning over
the drive hub
disconnect caps.
4WD models: Release
the wheel brakes by
turning over all four
drive hub disconnect
caps.
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.
Disengage
Engage
Note: The pump free-wheel valve should always
remain closed.
28 Genie Z-80/60 Part No. 82258
Operator's ManualFirst Edition · Third Printing
TRANSPORT AND LIFTING INSTRUCTIONS
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
Securing the Platform
Place a block under the rotator. Do not allow the
block 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
Lifting Instructions
Fully lower and retract both the primary and
secondary booms. Remove all loose items on the
machine.
Rotate the turntable 90 degrees.
Observe and Obey:
Only qualified riggers should rig and lift the
machine.
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.
Turntable
Lifting
Point
Points (2)
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.
Chassis
Lifting
39.61 in / 1 m
34.18 in
86.8 cm
30 Genie Z-80/60 Part No. 82258
56 in
1.42 m
Operator's ManualFirst Edition · Third Printing
Specifications
Z-80/60
Height, working maximum 86 ft 26.2 m
Height, platform maximum 80 ft 24.4 m
Height, stowed maximum 9 ft 10 in 3 m
Horizontal reach maximum 60 ft 18.3 m
Width 8 ft 2 in 2.5 m
Length, stowed 37 ft 11.3 m
Length, stowed for transport 30 ft 9.1 m
Maximum load capacity 500 lb 227 kg
Wheelbase 9 ft 4 in 2.8 m
Ground clearance 12 in 30.5 cm
Turning radius, outside
2 wheel steer 24 ft 7 in 7.5 m
4 wheel steer 15 ft 2 in 4.6 m
Turning radius, inside
2 wheel steer 14 ft 6 in 4.4 m
4 wheel steer 7 ft 2.1 m
Turntable rotation (degrees) 360° continuous
Turntable tailswing,
secondary boom lowered 10 ft 10 in 3.3 m
Controls 12V DC proportional
Platform dimensions, 6 foot 72 in x 30 in
(length x width) 1.8 m x 76 cm
Platform dimensions, 8 foot 96 in x 36 in
(length x width) 2.4 m x 91 cm
Platform leveling self-leveling
Platform rotation 160°
AC outlet in platform standard
Hydraulic pressure (maximum) 3200 psi
(boom functions) 220 bar
Tire size 18-625, 16 ply FF
Gradeability, 4WD, stowed 50 %
Gradeability, 2WD, stowed 30 %
Fuel tank capacity 40 gallons 151 liters
Weight See Serial Plate
(Machine weights vary with option configurations)
Airborne noise emissions 80 dB
Maximum sound level at normal operating workstations
(A-weighted)
Floor Loading Information
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
Drive speed, 0.7 mph 1.1 km/h
raised or extended 40 ft/40 sec 12.2 m/40 sec
GVW+Rated Load 38,000 lbs 17,237 kg
Axle load, maximum 27,813 lbs 12,616 kg
Wheel load, maximum 13,530 lbs 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.
Continuous improvement of our products is a Genie
policy. Product specifications are subject to change
without notice or obligation.
Part No. 82258 Genie Z-80/60 31
2
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
10 ft / 3 m
0 ft / 0 m
10 ft / 3 m
10 ft / 3 m
0 ft / 0 m
10 ft / 3 m
20 ft / 6.1 m
30 ft / 9.1 m
40 ft / 12.2 m
50 ft / 15.2 m
60 ft / 18.3 m
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.
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