Terex Genie Z-60/37DC Operator's Manual
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Terex Genie Z-60/37DC Operator's Manual

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Operator's Manual
Z-60/37DC
Z-60/37FE
Serial Number Range
from Z6016N-101
CE
with
Maintenance
Information
Original Instructions
First Edition
Second Printing
Part No. 1270491

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Summary of Contents for Terex Genie Z-60/37DC

  • Page 1 Operator's Manual Serial Number Range Z-60/37DC from Z6016N-101 Z-60/37FE with Maintenance Information Original Instructions First Edition Second Printing Part No. 1270491...

  • Page 2: Table Of Contents

    Specifications ............62 Copyright © 2016 Terex Corporation First Edition: Second Printing, December 2016 Genie and "Z" are registered trademarks of Terex South Dakota, Inc. in the U.S.A. and many other countries. Complies with EC Directive 2006/42/EC See EC Declaration of Conformity Z-60/37DC •...

  • Page 3: Introduction

    First Edition • Second Printing Operator's Manual Introduction Introduction About this manual Intended Use Genie appreciates your choice of our machine for This machine is intended to be used only to lift your application. Our number one priority is user personnel, along with their tools and materials to safety, which is best achieved by our joint efforts.
  • Page 4 Operator's Manual First Edition • Second Printing Introduction Contacting the Manufacturer At times it may be necessary to contact Genie. When you do, be ready to supply the model number and serial number of your machine, along with your name and contact information. At minimum, Genie should be contacted for: Accident reporting Questions regarding product applications and...
  • Page 5 First Edition • Second Printing Operator's Manual Introduction Safety Sign Maintenance Replace any missing or damaged safety signs. Keep operator safety in mind at all times. Use mild soap and water to clean safety signs. Do not use solvent-based cleaners because they may damage the safety sign material.
  • Page 6 Operator's Manual First Edition • Second Printing Introduction Hazard Classification Decals on this machine use symbols, color coding and signal words to identify the following: Safety alert symbol—used to alert you to potential personal injury hazards. Obey all safety messages that follow this symbol to avoid possible injury or death.

  • Page 7: Symbol And Hazard Pictorials Definitions

    First Edition • Second Printing Operator's Manual Symbol and Hazard Pictorials Definitions Symbol and Hazard Pictorials Definitions Fire hazard Explosion hazard Explosion hazard Do not use ether or No smoking. other high energy No flame. starting aids on Stop engine. machines equipped with glow plugs.
  • Page 8 Operator's Manual First Edition • Second Printing Symbol and Hazard Pictorials Definitions Tie-down point Lifting point Platform tie-down Lifting & tie down Lanyard anchorage instructions instructions points Corrosive acid. Color Coded Direction Runaway Hazard Collision hazard Collision hazard Arrows Electrocution hazard Avoid contact Disconnect battery Voltage rating for...

  • Page 9: General Safety

    First Edition • Second Printing Operator's Manual General Safety General Safety Part No. 1270491 Z-60/37DC • Z-60/37FE...
  • Page 10 Operator's Manual First Edition • Second Printing General Safety Z-60/37DC • Z-60/37FE Part No. 1270491...
  • Page 11 First Edition • Second Printing Operator's Manual General Safety Part No. 1270491 Z-60/37DC • Z-60/37FE...
  • Page 12 Operator's Manual First Edition • Second Printing General Safety Z-60/37DC • Z-60/37FE Part No. 1270491...

  • Page 13: Personal Safety

    First Edition • Second Printing Operator's Manual Personal Safety Personal Safety Personal Fall Protection Personal fall protection equipment (PFPE) is required when operating this machine. Occupants 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 governmental rules regarding the use of personal protective equipment.

  • Page 14: Work Area Safety

    Operator's Manual First Edition • Second Printing Work Area Safety Work Area Safety Electrocution Hazards Keep away from the machine if it contacts This machine is not electrically insulated and will energized power lines. not provide protection from contact with or Personnel on the ground proximity to electrical current.
  • Page 15 First Edition • Second Printing Operator's Manual Work Area Safety Do not raise or extend the If the tilt alarm sounds boom unless the machine with the platform uphill: is on a firm, level surface. Lower the primary boom. Lower the secondary boom.
  • Page 16 Operator's Manual First Edition • Second Printing Work Area Safety Do not alter or disable machine components that in Use extreme care and any way affect safety and stability. slow speeds while driving the machine in the stowed Do not replace items critical to machine stability position across uneven with items of different weight or specification.
  • Page 17 First Edition • Second Printing Operator's Manual Work Area Safety Operation on Slopes Hazards Do not place or attach fixed or overhanging loads Do not drive the machine on a slope that exceeds to any part of this the maximum uphill, downhill or side slope rating of machine.
  • Page 18 Operator's Manual First Edition • Second Printing Work Area Safety Fall Hazards Collision Hazards Occupants must wear a Be aware of limited sight safety belt or harness in distance and blind spots accordance with when driving or operating. governmental regulations. Attach the lanyard to the anchor provided in the Be aware of the boom position and tailswing when...
  • Page 19 First Edition • Second Printing Operator's Manual Work Area Safety Observe and use the color-coded direction arrows Bodily Injury Hazard on the platform controls and drive chassis for drive Do not operate the machine with a hydraulic oil or and steer functions. air leak.
  • Page 20 Operator's Manual First Edition • Second Printing Work Area Safety Damaged Machine Hazards Battery Safety Do not use a damaged or malfunctioning machine. Burn Hazards Conduct a thorough pre-operation inspection of the Batteries contain acid. machine and test all functions before each work Always wear protective shift.
  • Page 21 First Edition • Second Printing Operator's Manual Work Area Safety Component Damage Hazard Panel Cradle Safety Do not use any battery charger greater than 48V to Read, understand and obey all warnings and charge the function batteries. instructions provided with the panel cradles. Both battery packs must be charged together.
  • Page 22 Operator's Manual First Edition • Second Printing Work Area Safety Lockout After Each Use Select a safe parking location—firm level surface, clear of obstruction and traffic. Retract and lower the boom to the stowed position. Rotate the turntable so that the boom is between the non-steer wheels.

  • Page 23: Legend

    First Edition • Second Printing Operator's Manual Legend Legend Platform controls Non-steer tire Platform Steer tire 10 Swing gate Power to charger 11 Lanyard anchorage points Ground controls 12 Sliding mid-rail Secondary boom 13 Foot switch Primary boom 14 Manual storage container Jib boom Part No.

  • Page 24: Controls

    Operator's Manual First Edition • Second Printing Controls Controls Ground Control Panel Primary boom up/down switch Function enable button Move the primary boom up/down switch up Press and hold the function enable button to and the boom will raise. Move the primary enable the functions on the ground control boom up/down switch down and the boom will panel to operate.
  • Page 25 First Edition • Second Printing Operator's Manual Controls LCD display 11 Jib boom up/down switch At machine start up the LCD screen displays Move the jib boom switch up and the jib boom pitch and roll angles of the machine, the will raise.
  • Page 26 Operator's Manual First Edition • Second Printing Controls Platform Control Panel Z-60/37DC • Z-60/37FE Part No. 1270491...
  • Page 27 First Edition • Second Printing Operator's Manual Controls Part No. 1270491 Z-60/37DC • Z-60/37FE...
  • Page 28 Operator's Manual First Edition • Second Printing Controls Primary boom extend/retract switch Platform Control Panel Move the primary boom Horn button extend/retract switch up and Press this button and the horn will sound. the primary boom will Release the button and the horn will stop. retract.
  • Page 29 First Edition • Second Printing Operator's Manual Controls Aircraft protection override switch (if equipped) 12 Drive enable indicator light Move and hold the aircraft protection override Light on indicates that the boom has moved switch to operate the machine when the just past either non-steer wheel and drive platform bumper is against an object.
  • Page 30 Operator's Manual First Edition • Second Printing Controls 17 Platform overload indicator light Light flashing indicates the platform is overloaded and no functions will operate. Remove weight until the light goes off. 18 Machine mode select switch: FE Models Move the switch to the left to select DC mode Move the switch to the right to select Hybrid mode 19 Proportional control handle for secondary...

  • Page 31: Inspections

    First Edition • Second Printing Operator's Manual Inspections Inspections 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: The inspection is designed to discover if anything is apparently wrong with a machine before the...
  • Page 32 Operator's Manual First Edition • Second Printing Inspections  Wear pads Pre-operation Inspection  Tires and wheels  Be sure that the operator’s, safety and  FE models: Engine and related responsibilities manuals are complete, legible components and in the storage container located in the platform.
  • Page 33 First Edition • Second Printing Operator's Manual Inspections 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 instructions to test all machine functions. A malfunctioning machine must never be used. If malfunctions are discovered, the machine must be Do Not Operate Unless: tagged and removed from service.
  • Page 34 Operator's Manual First Edition • Second Printing Inspections Test Emergency Controls At the Ground Controls FE Models: Select a test area that is firm, level and free of obstruction. 10 Turn the key switch to ground control. Turn the key switch to ground control. 11 Pull out the red Emergency Stop button to the on position.
  • Page 35 First Edition • Second Printing Operator's Manual Inspections Test the Tilt Sensor At the Platform Controls FE Models: 25 Turn the key switch to platform control. 17 Select a test area that is firm, level and free of 26 Pull out the red Emergency Stop button to the obstruction.
  • Page 36 Operator's Manual First Edition • Second Printing Inspections Test the Foot Switch Test Machine Functions DC Models: 39 Press down the foot switch. 32 Do not press down the foot switch. Test each 40 Activate each machine function control handle machine function.
  • Page 37 First Edition • Second Printing Operator's Manual Inspections Test Drive and Braking Test the Drive Enable System 44 Press down the foot switch. 47 Press down the foot switch and lower the boom to the stowed position. 45 Slowly move the drive control handle in the direction indicated by the blue arrow on the 48 Rotate the turntable until the primary boom control panel until the machine begins to move,...
  • Page 38 Operator's Manual First Edition • Second Printing Inspections Test Limited Drive Speed Test Drive Tilt Cutout 51 Press down the foot switch. 61 Press down the foot switch. 52 Raise the primary boom approximately 61 cm. 62 With the boom fully stowed, drive the machine onto a slope where the chassis pitch angle is 53 Slowly move the drive control handle to the full greater than 2.5°.
  • Page 39 First Edition • Second Printing Operator's Manual Inspections 69 Return to level ground and stow the boom. 77 Lower the primary boom to the stowed position or drive in the opposite direction. 70 With the boom fully stowed, drive the machine onto a slope where the chassis pitch angle is Result: The machine should drive.
  • Page 40 Operator's Manual First Edition • Second Printing Inspections Test the Oscillating Axle (if equipped) Test the Lift/Drive Select Function (if equipped) 86 Drive the right steer tire up onto a 15 cm block or curb. 93 Press down the foot switch. Result: The three remaining tires should stay 94 Move the drive control handle off center and in firm contact with the ground.
  • Page 41 First Edition • Second Printing Operator's Manual Inspections Workplace Inspection Checklist Be aware of and avoid the following hazardous situations:  drop-offs or holes  bumps, floor obstructions or debris  sloped surfaces Do Not Operate Unless:  unstable or slippery surfaces ...
  • Page 42 1269255 Danger – Tip-over Hazard, Batteries 52967 Cosmetic – 4 x 4 1269258 Label – Slope Rating, Z-60/37 65278 Caution – No Step 1269259 Cosmetic – Genie Z-60/37DC 72086 Label – Lifting Point 1269261 Cosmetic – Z-60/37DC 82481 Label – Battery/Charger Safety 1272242 Label –...
  • Page 43 First Edition • Second Printing Operator's Manual Inspections Part No. 1270491 Z-60/37DC • Z-60/37FE...
  • Page 44 Operator's Manual First Edition • Second Printing Inspections Inspection for Decals with Part No. Decal Description Symbols Z-60/37FE 114251 Label – Explosion Hazard 114252 Label – Tip-over Hazard, Limit Switches Use the pictures on the next page to verify that all 114334 Label –...
  • Page 45 First Edition • Second Printing Operator's Manual Inspections Part No. 1270491 Z-60/37DC • Z-60/37FE...

  • Page 46: Operating Instructions

    Operator's Manual First Edition • Second Printing Operating Instructions Operating Instructions 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.
  • Page 47 First Edition • Second Printing Operator's Manual Operating Instructions Machine Operation Emergency Power FE models can be operated with or without the Use emergency power if the primary power source engine running. fails. Turn the key switch to ground or platform Turn the key switch to ground or platform control.
  • Page 48 Operator's Manual First Edition • Second Printing Operating Instructions FE Models: Starting the Engine Operation from Ground From the ground control panel: Turn the key switch to ground control. Turn the key switch to ground control. Pull out the red Emergency Stop button to the on position.
  • Page 49 First Edition • Second Printing Operator's Manual Operating Instructions To Steer Operation from Platform Press down the foot switch. Note: When operating the machine from the platform, the following foot switch messages may Slowly move the drive control handle in the appear on the platform control LCD screen.
  • Page 50 Operator's Manual First Edition • Second Printing Operating Instructions To determine the slope grade: Driving on a slope Measure the slope with a digital inclinometer OR Determine the uphill, downhill and side slope use the following procedure. ratings for the machine and determine the slope grade.
  • Page 51 First Edition • Second Printing Operator's Manual Operating Instructions Drive Enable Function Speed Control Light on indicates that the boom Move the switch to the has moved just past either left to decrease the non-steer wheel and the drive function speeds for jib function has been interrupted.
  • Page 52 Operator's Manual First Edition • Second Printing Operating Instructions Machine Not Level Indicator Light Platform Overload Indicator Light If the tilt alarm sounds when the Light flashing indicates the platform is raised, the Machine Not platform is overloaded and no Level indicator light will come on functions will operate.
  • Page 53 First Edition • Second Printing Operator's Manual Operating Instructions After Each Use Select a safe parking location—firm level surface, clear of obstruction and traffic. Retract and lower the boom to the stowed position. Rotate the turntable so that the boom is between the non-steer wheels.
  • Page 54 Operator's Manual First Edition • Second Printing Operating Instructions FE Models: Charging Batteries with Engine Running the engine will automatically charge the batteries. The engine will automatically shut off when the battery charge cycle reaches 85%. After the charge cycle reaches 85% the platform Battery and Charger Instructions control panel LCD screen will display the following message, HYBRID CHARGE COMPLETE.
  • Page 55 First Edition • Second Printing Operator's Manual Operating Instructions Panel Cradle Assembly Dry Battery Filling and Charging Instructions Apply the warning decal to the front of each panel cradle (if needed). This procedure applies to flooded lead acid Install rubber bumper 1 in the panel cradle batteries only.
  • Page 56 Operator's Manual First Edition • Second Printing Operating Instructions Installation of Padding Install the 2 pieces of padding on the platform rails. Position the padding to protect the panels rubber bumper 2 from contact with the platform rails. Installation of Strap rubber Open the clamp and install it around a vertical bumper 1...

  • Page 57: Transport And Lifting Instructions

    See the serial label for the the brakes. machine weight. See the inspections section for the serial label location. Note: Towing the Genie Z-60/37DC or the Z-60/37FE is not recommended. If the machine must be towed, do not exceed 3.2 km/h. Part No. 1270491...
  • Page 58 Operator's Manual First Edition • Second Printing Transport and Lifting Instructions Securing the Chassis Securing to Truck or Trailer for Transit Use chains of ample load capacity. Use a minimum of 6 chains. Always use the turntable rotation lock pin each time the machine is transported.
  • Page 59 First Edition • Second Printing Operator's Manual Transport and Lifting Instructions Lifting Instructions Fully lower and retract the boom. Fully lower the jib. Remove all loose items on the machine. Determine the center of gravity of your machine using the table and the picture on this page. Observe and Obey: Attach the rigging only to the designated lifting points on the machine.

  • Page 60: Maintenance

    Operator's Manual First Edition • Second Printing Maintenance Maintenance Check the Engine Oil Level Maintaining the proper engine oil level is essential to good engine performance and service life. Operating the machine with an improper oil level Observe and Obey: can damage engine components.
  • Page 61 First Edition • Second Printing Operator's Manual Maintenance Diesel Fuel Requirements Check the Hydraulic Oil Level Satisfactory engine performance is dependent on Maintaining the hydraulic oil at the proper level is the use of a good quality fuel. The use of a good essential to machine operation.
  • Page 62 Operator's Manual First Edition • Second Printing Maintenance Check the Engine Coolant Level – Check the Batteries Liquid Cooled Models Proper battery condition is essential to good machine performance and operational safety. Maintaining the engine coolant at the proper level Improper fluid levels or damaged cables and is essential to engine service life.
  • Page 63 First Edition • Second Printing Operator's Manual Maintenance 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.

  • Page 64: Specifications

    Operator's Manual First Edition • Second Printing Specifications Specifications Model Z-60/37DC Maximum slope rating, stowed position, 4WD Height, working maximum 20 m Platform downhill 45% 24° Height, platform maximum 18.16 m Platform uphill 45% 24° Height, stowed maximum 2.54 m Side slope 25% 14°...
  • Page 65 First Edition • Second Printing Operator's Manual Specifications Model Z-60/37FE Maximum slope rating, stowed position, 4WD Height, working maximum 20 m Platform downhill 24° Height, platform maximum 18.16 m Platform uphill 24° Height, stowed maximum 2.54 m Side slope 14° Horizontal reach, maximum 11.15 m Note: Slope rating is subject to ground conditions with...
  • Page 66 Operator's Manual First Edition • Second Printing Specifications Z-60/37DC and Z-60/37FE Range of Motion Chart Z-60/37DC • Z-60/37FE Part No. 1270491 Operator's Manual First Edition • Second Printing Z-60/37DC • Z-60/37FE Part No. 1270491...
  • Page 67 www.genielift.com...

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Genie z-60/37fe

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