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Operator's Manual

Sixth Edition • Sixth Printing

Maintenance

58 Z-80/60

Part No. 226482

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 oil
level that might indicate the presence of hydraulic
system problems.

1

Be sure that 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 5 cm of the sight gauge.

3

Add oil as needed. Do not overfill.

Hydraulic oil specifications

Hydraulic oil type

Chevron Rando HD equivalent

Check the Batteries

Proper battery condition is essential to good
machine performance and operational safety.
Improper fluid levels or damaged cables and
connections can result in 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.

3

Be sure that the battery hold-down brackets
are in place and secure.

Note: Adding terminal protectors and a corrosion
preventative sealant will help eliminate the
corrosion on the battery terminals and cables.

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Содержание Z-80/60

Страница 1: ...Operator s Manual Serial Number Range Z 80 60 from 3158 AUS Australia with Maintenance Information Sixth Edition Sixth Printing Part No 226482...

Страница 2: ...times If you have any questions contact us Contact Us Internet www genielift com E mail awp techpub terex com Contents Introduction 1 Symbol and Hazard Pictorials Definitions 3 Personal Safety 5 Pers...

Страница 3: ...pervision running the machine 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...

Страница 4: ...ious injury Indicates a hazardous situation which if not avoided could result in death or serious injury Indicates a hazardous situation which if not avoided could result in minor or moderate injury I...

Страница 5: ...g No flame Stop engine Electrocution hazard Maintain required clearance Crush hazard Keep away from path of moving platform Fall hazard Keep off this surface Tip over hazard Tip over hazard Tip over h...

Страница 6: ...service manual Electrocution hazard Avoid contact Voltage rating for power to platform Pressure rating for air line to platform Access by trained and authorized personnel only Maximum capacity Manual...

Страница 7: ...Sixth Edition Sixth Printing Operator s Manual Personal Safety Part No 226482 Z 80 60 5 Personal Safety...

Страница 8: ...Operator s Manual Sixth Edition Sixth Printing Personal Safety 6 Z 80 60 Part No 226482...

Страница 9: ...chines equipped with glow plugs 97875 DANGER Explosion Burn Hazard Ignition of explosive gases or contact with corrosive acid will cause death burns or blindness 31788 C Keep all open flames and spark...

Страница 10: ...Operator s Manual Sixth Edition Sixth Printing Personal Safety 8 Z 80 60 Part No 226482...

Страница 11: ...upants must wear a safety belt or harness in accordance with governmental regulations Attach the lanyard to the anchor provided in the platform Operators must comply with employer job site and governm...

Страница 12: ...eware 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 li...

Страница 13: ...fy the condition of the boom on the slope as shown below Follow the steps to lower the boom before moving to a firm level surface Do not rotate the boom while lowering The recovery mode should be used...

Страница 14: ...the platform perimeter Do not push off or pull toward any object outside of the platform Maximum allowable manual force 400 N Do not alter or disable machine components that in any way affect safety a...

Страница 15: ...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 Opera...

Страница 16: ...oor clear of debris Lower the platform entry mid rail or close the entry gate before operating Do not enter or exit the platform unless the machine is in the stowed position and the platform is at gro...

Страница 17: ...n monoxide poisoning Do not operate the machine with a hydraulic oil or air leak An air leak or hydraulic leak can penetrate and or burn skin Improper contact with components under any cover will caus...

Страница 18: ...d responsibilities manuals are complete legible and in the storage container located on the machine Component Damage Hazards Do not use any battery or charger greater than 12V to jump start the engine...

Страница 19: ...movement of the platform with an overhanging load Do not cause a horizontal force or side load to machine by raising or lowering a fixed or overhanging load Electrocution Hazard Keep pipes away from...

Страница 20: ...ity and must be factored into the total platform load The welder power supply weighs 34 kg Do not operate the welder unless a fire extinguisher is immediately available for instant use per OSHA regula...

Страница 21: ...h 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 no...

Страница 22: ...80 60 Part No 226482 Legend 1 Circle end tire 2 Square end tire 3 Secondary boom 4 Ground controls 5 Primary boom 6 Lanyard anchorage points 7 Sliding mid rail 8 Manual storage container 9 Foot switc...

Страница 23: ...one of these two styles of ground control panel The descriptions in this section and the instructions in the Function Test and Operating Instructions apply to both panels unless specifically noted STO...

Страница 24: ...end Push the secondary boom down retract button and the secondary boom will retract and then lower 5 Primary boom up down buttons Press the primary boom up button and the boom will raise Press the pri...

Страница 25: ...e jib boom will raise Press the jib boom down button and the jib boom will lower 16 Primary boom extend retract buttons Press the primary boom extend button and the primary boom will extend Press the...

Страница 26: ...s 24 Z 80 60 Part No 226482 The Z 80 machines will have one of these two styles of platform control panel The descriptions in this section and the instructions in the Function Test and Operating Instr...

Страница 27: ...Sixth Edition Sixth Printing Operator s Manual Controls Part No 226482 Z 80 60 25 STOP 19 10 11 15 13 14 16 17 18 21 20 22 12 STOP 10 20 11 13 16 17 15 18 21 19 14 12 22...

Страница 28: ...or release the button to turn the generator off 8 Emergency Auxiliary power control with indicator light Use emergency auxiliary power if the primary power source engine fails Move and hold the switch...

Страница 29: ...axis proportional control handle for drive and steer functions OR Proportional control handle for drive function and thumb rocker for steer function Move the control handle in the direction indicated...

Страница 30: ...ly move the drive control handle off center 25 Dual axis proportional control handle for primary boom up down and turntable rotate left right functions Move the control handle up and the primary boom...

Страница 31: ...s 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 proce...

Страница 32: ...ck air filled tires for proper tire pressure Add air if needed See Maintenance section Check the following components or areas for damage improperly installed or missing parts and unauthorized modific...

Страница 33: ...he machine as it was intended Function Test Fundamentals The function tests are designed to discover any malfunctions before the machine is put into service The operator must follow the step by step i...

Страница 34: ...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 t...

Страница 35: ...d until it is fully raised 21 Press 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...

Страница 36: ...le switch or button Result All functions should operate through a full cycle Test the Steering models with 4 wheel steer 37 Select square end blue arrow steer Push the square end blue arrow steer butt...

Страница 37: ...ngles point on the drive chassis 48 Slowly move the 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...

Страница 38: ...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...

Страница 39: ...e foot switch 68 Raise the primary boom to 10 above horizontal 69 Slowly move the drive control handle to the full drive position Result The maximum achievable drive speed with the primary boom raised...

Страница 40: ...ld the switch or push and hold the button Activate each function control handle toggle switch or thumb rocker switch Note To conserve battery power test each function through a partial cycle Result Al...

Страница 41: ...r 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...

Страница 42: ...4 82268 Cosmetic Genie Z 80 60 1 82269 Ground Control Panel 1 82281 Platform Control Panel 1 Part No Decal Description Qty 82296 Danger Label Tire Specifications Foam 4 82312 Cosmetic Z 80 60 1 82366...

Страница 43: ...Sixth Edition Sixth Printing Operator s Manual Inspections Part No 226482 Z 80 60 41...

Страница 44: ...operator s responsibility to follow all the safety rules and instructions in the operator s safety and responsibilities manuals Using the machine for anything other than lifting personnel along with t...

Страница 45: ...Start the engine Push the button or move the switch If the engine fails to start or dies the restart delay with disable the start switch for 3 seconds All models If the engine fails to start after 15...

Страница 46: ...d or platform control 2 Pull out the red Emergency Stop button to the on position 3 Press down the foot switch when using the controls from the platform 4 Activate the emergency controls Move and hold...

Страница 47: ...indicator light next to the current steer mode will be on All models 3 Slowly move the drive control handle in the direction indicated by blue or yellow triangles OR press the thumb rocker switch loc...

Страница 48: ...e drive setting Move the switch or push the button until the light next to the machine on incline symbol is on To determine the slope grade Measure the slope with a digital inclinometer OR use the fol...

Страница 49: ...ll travel Generator if equipped To operate the generator press the generator button or move the switch The indicator light will come on the engine will continue to run Plug a power tool into the power...

Страница 50: ...s or by using the platform level recovery toggle switch in the procedure above Once the platform level reaches 15 degrees the only way to recover is to use the Service Recovery key switch on the side...

Страница 51: ...l envelope A trained operator on the ground will need to lower the platform from the ground controls Please see the Service Bypass Recovery Key Switch section in the service manual LCD Screen if equip...

Страница 52: ...and Obey Pipe cradles must be installed on the inside of the platform Pipe cradles must not obstruct the platform controls or the platform entrance The bottom of the pipe cradle tube must rest on the...

Страница 53: ...cradles may limit the maximum number of occupants in the platform Maximum Pipe Cradle Capacity All models 90 7 kg Pipe Cradle Assembly Weight 9 5 kg Panel Cradle Assembly 1 Apply the warning decal to...

Страница 54: ...e side of the clamp 3 Install the strap assembly end plate onto the bolt 4 Insert the bolt through the other side of the clamp 5 Secure with a washer and a nut Do not over tighten The strap assembly e...

Страница 55: ...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 non...

Страница 56: ...e the vehicle capacity loading surfaces and chains or straps are sufficient to withstand the machine weight Genie lifts are very heavy relative to their size See the serial label for the machine weigh...

Страница 57: ...ransporting 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...

Страница 58: ...ng 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...

Страница 59: ...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 Check the...

Страница 60: ...ulic oil type Chevron Rando HD equivalent Check the Batteries Proper battery condition is essential to good machine performance and operational safety Improper fluid levels or damaged cables and conne...

Страница 61: ...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 Check the Tire Pr...

Страница 62: ...Diesel LSD Perkins 804D 33 Engine Fuel Type Low Sulfur Diesel LSD Perkins 404D 22T Engine Fuel Type Low Sulfur Diesel LSD Continental TME27 Engine Fuel Type Low Sulfur Diesel LSD Deutz BF4L Engine Fue...

Страница 63: ...2 5 m s2 Highest root mean square value of weighted acceleration to which the whole body is subjected does not exceed 0 5 m s2 Weight 17 010 kg Machine weights vary with option configurations See ser...

Страница 64: ...Operator s Manual Sixth Edition Sixth Printing Specifications 62 Z 80 60 Part No 226482 Z 80 60 Range of Motion Z 80 60 Part No 226482 Operator s Manual Sixth Edition Sixth Printing...

Страница 65: ...Distributed By www genielift com...

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