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

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Operator's Manual
Z
-60 DC
®
Z
-60 FE
®
ANSI/CSA
North America
South America
Asia
with
Maintenance
Information
Original Instructions
Second Edition
First Printing
Part No. 1292373GT

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Summary of Contents for Terex Genie Z-60 DC

  • Page 1 Operator's Manual -60 DC ® ANSI/CSA North America -60 FE ® South America Asia with Maintenance Information Original Instructions Second Edition First Printing Part No. 1292373GT...

  • Page 2: Table Of Contents

    Specifications ............77 Copyright © 2016 Terex Corporation Second Edition: First Printing, April 2020 Genie and "Z" are registered trademarks of Terex South Dakota, Inc. in the U.S.A. and many other countries. These machines comply with ANSI/SAIA A92.20 CAN/CSA B354.6 -60 DC •...

  • Page 3: Introduction

    Second Edition • First Printing Operator's Manual Introduction Introduction About this manual Intended Use and Familiarization Guide Genie appreciates your choice of our machine for your application. Our number one priority is user The intended use of this machine is to lift personnel, safety, which is best achieved by our joint efforts.
  • Page 4 Second Edition • First Printing Operator's Manual Introduction Platform controls symbology and related Ground controls symbology and related machine movement: machine movement: Platform level swtich Platform level, jib boom up/down, primary boom extend/retract, primary boom Platform rotate switch up/down, and secondary boom retract/lower.
  • Page 5 Second Edition • First Printing Operator's Manual Introduction Bulletin Distribution and Contacting the Manufacturer Compliance At times it may be necessary to contact Genie. When you do, be ready to supply the model number Safety of product users is of paramount importance and serial number of your machine, along with your to Genie.
  • Page 6 Second Edition • First 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 7: Symbol And Hazard Pictorials Definitions

    Second Edition • First 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 Second Edition • First Printing Operator's Manual Symbol and Hazard Pictorials Definitions Wheel load Wind speed Maximum capacity Manual force Batteries used as counterweights 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...
  • Page 9 Second Edition • First Printing Operator's Manual Symbol and Hazard Pictorials Definitions Electrocution hazard Avoid contact Disconnect battery Voltage rating for Pressure rating for air power to platform line to platform Recovery procedure if tilt alarm sounds while elevated. Read the operator’s Platform uphill: Platform downhill: Read the service...

  • Page 10: General Safety

    Second Edition • First Printing Operator's Manual General Safety General Safety -60 DC • Z ® ® -60 FE Part No. 1292373GT...
  • Page 11 Second Edition • First Printing Operator's Manual General Safety -60 DC • Z ® ® Part No. 1292373GT -60 FE...
  • Page 12 Second Edition • First Printing Operator's Manual General Safety -60 DC • Z ® ® -60 FE Part No. 1292373GT...
  • Page 13 Second Edition • First Printing Operator's Manual General Safety -60 DC • Z ® ® Part No. 1292373GT -60 FE...
  • Page 14 Second Edition • First Printing Operator's Manual General Safety -60 DC • Z ® ® -60 FE Part No. 1292373GT...
  • Page 15 Second Edition • First Printing Operator's Manual General Safety -60 DC • Z ® ® Part No. 1292373GT -60 FE...
  • Page 16 Second Edition • First Printing Operator's Manual General Safety -60 DC • Z ® ® -60 FE Part No. 1292373GT...
  • Page 17 Second Edition • First Printing Operator's Manual General Safety -60 DC • Z ® ® Part No. 1292373GT -60 FE...
  • Page 18 Second Edition • First Printing Operator's Manual General Safety -60 DC • Z ® ® -60 FE Part No. 1292373GT...
  • Page 19 Second Edition • First Printing Operator's Manual General Safety -60 DC • Z ® ® Part No. 1292373GT -60 FE...

  • Page 20: Personal Safety

    Second Edition • First 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 21: Work Area Safety

    Second Edition • First Printing Operator's Manual 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 proximity Personnel on the ground or to electrical current.
  • Page 22 Second Edition • First 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 23 Second Edition • First Printing Operator's Manual Work Area Safety Use extreme care and slow Do not alter or disable machine components that in speeds while driving the any way affect safety and stability. machine in the stowed Do not replace items critical to machine stability position across uneven with items of different weight or specification.
  • Page 24 Second Edition • First Printing Operator's Manual Work Area Safety Operation on Slopes Hazards Do not place or attach fixed or overhanging loads to Do not drive the machine on a slope that exceeds any part of this machine. the maximum uphill, downhill or side slope rating of the machine.
  • Page 25 Second Edition • First Printing Operator's Manual 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 26 Second Edition • First Printing Operator's Manual Work Area Safety Bodily Injury Hazard Observe and use the color-coded direction arrows 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 27 Second Edition • First Printing Operator's Manual 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 28 Second Edition • First 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 29 Second Edition • First Printing Operator's Manual 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 30: Legend

    Second Edition • First Printing Operator's Manual Legend Legend Non-steer tire Platform controls Steer tire Platform Power to charger 10 Swing gate Ground controls 11 Lanyard anchorage points Secondary boom 12 Sliding mid-rail Primary boom 13 Foot switch Jib boom 14 Manual storage container -60 DC •...

  • Page 31: Controls

    Second Edition • First Printing Operator's Manual Controls Controls Ground Control Panel Function enable button Primary boom up/down switch Press and hold the function enable button to Move the primary boom up/down switch up and enable the functions on the ground control the boom will raise.
  • Page 32 Second Edition • First Printing Operator's Manual Controls Red Emergency Stop button LCD display Push in the red Emergency Stop button to the At machine start up the LCD screen displays off position to stop all functions and turn the pitch and roll angles of the machine, the engine off.
  • Page 33 Second Edition • First Printing Operator's Manual Controls 14 Turntable rotate switch 11 Jib boom up/down switch Move the turntable rotate switch up and the Move the jib boom switch up and the jib boom turntable will rotate to the right. Move the will raise.
  • Page 34 Second Edition • First Printing Operator's Manual Controls Platform Control Panel -60 DC • Z ® ® -60 FE Part No. 1292373GT...
  • Page 35 Second Edition • First Printing Operator's Manual Controls -60 DC • Z ® ® Part No. 1292373GT -60 FE...
  • Page 36 Second Edition • First Printing Operator's Manual 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 retract. Release the button and the horn will stop. Move the boom extend/retract switch down Platform level switch...
  • Page 37 Second Edition • First Printing Operator's Manual Controls Generator switch (if equipped) 11 Dual axis proportional control handle for drive and steer functions. Move the generator switch up to activate the generator. Move the switch down to turn off the Proportional control handle for drive function generator.
  • Page 38 Second Edition • First Printing Operator's Manual Controls 17 Platform overload indicator light 12 Drive enable indicator light Light flashing indicates the platform is Light on indicates that the boom has moved just overloaded. The engine will stop and no past either non-steer wheel and drive function functions will operate.

  • Page 39: Inspections

    Second Edition • First 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 40 Second Edition • First Printing Operator's Manual Inspections Pre-operation Inspection  Wear pads  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 41 Second Edition • First 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 42 Second Edition • First Printing Operator's Manual Inspections Test Machine Functions At the Ground Controls Do not push and hold the function enable Select a test area that is firm, level and free of button. Attempt to activate each boom and hazards.
  • Page 43 Second Edition • First Printing Operator's Manual Inspections Test Auxiliary Controls Test the Tilt Sensor FE Models: FE Models: 10 Turn the key switch to ground control. 17 Select a test area that is firm, level and free of hazards. 11 Pull out the red Emergency Stop button to the on position.
  • Page 44 Second Edition • First Printing Operator's Manual Inspections Test the Foot Switch At the Platform Controls DC Models: 25 Turn the key switch to platform control. 32 Do not press down the foot switch. Test each 26 Pull out the red Emergency Stop button to the machine function.
  • Page 45 Second Edition • First Printing Operator's Manual Inspections Test Machine Functions Test Drive and Braking 39 Press down the foot switch. 44 Press down the foot switch. 40 Activate each machine function control handle 45 Slowly move the drive control handle in the or toggle switch.
  • Page 46 Second Edition • First Printing Operator's Manual Inspections Test the Drive Enable System Test Limited Drive Speed 47 Press down the foot switch and lower the boom 51 Press down the foot switch. to the stowed position. 52 Raise the primary boom approximately 2 ft / 48 Rotate the turntable until the primary boom 61 cm.
  • Page 47 Second Edition • First Printing Operator's Manual Inspections 70 With the boom fully stowed, drive the machine Test Drive Tilt Cutout onto a slope where the chassis pitch angle is 61 Press down the foot switch. greater than 4.5°. 62 With the boom fully stowed, drive the machine Result: The machine should continue to drive.
  • Page 48 Second Edition • First Printing Operator's Manual Inspections 77 Return to level ground and extend the primary Test the Oscillating Axle (if equipped) boom approximately 1.6 ft / 0.5 m. 85 Drive the right steer tire up onto a 6 in/15 cm 78 Drive the machine onto a slope where the block or curb.
  • Page 49 Second Edition • First Printing Operator's Manual Inspections Test the Lift/Drive Select Function (if Test the Contact Alarm (if equipped) equipped) 94 Do not activate the foot switch and press on the contact alarm cable to release the actuator 92 Press down the foot switch. from the switch socket.
  • Page 50 Second Edition • First Printing Operator's Manual Inspections Test Aircraft Protection Package (if equipped) Note: Two people may be required to perform this test. 101 Extend the primary boom approximately 1 ft/30 cm. 102 Move the yellow bumper at the bottom of the platform 4 inches/10 cm in any direction.
  • Page 51 Second Edition • First 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 52 Second Edition • First Printing Operator's Manual Inspections Inspection for Decals with Words Part No. Decal Description Danger – Tip-over Hazard, 500 lbs / Z-60DC 218550 227 kg Use the pictures on the next page to verify that all Danger, Warning – Tip-over, Crush 218559 decals are legible and in place.
  • Page 53 Second Edition • First Printing Operator's Manual Inspections -60 DC • Z ® ® Part No. 1292373GT -60 FE...
  • Page 54 Second Edition • First Printing Operator's Manual Inspections Inspection for Decals with Words Part No. Decal Description Danger, Warning – Tip-over, Crush Z-60FE 218559 Hazard Use the pictures on the next page to verify that all Label – Platform Overload 219487 decals are legible and in place.
  • Page 55 Second Edition • First Printing Operator's Manual Inspections -60 DC • Z ® ® Part No. 1292373GT -60 FE...
  • Page 56 Second Edition • First Printing Operator's Manual Inspections Inspection for Decals with Part No. Decal Description Label – Tip-over Hazard, CE Symbols Z-60DC 219954 Label – Platform Overload 219956 Use the pictures on the next page to verify that all Label –...
  • Page 57 Second Edition • First Printing Operator's Manual Inspections -60 DC • Z ® ® Part No. 1292373GT -60 FE...
  • Page 58 Second Edition • First Printing Operator's Manual Inspections Inspection for Decals with Part No. Decal Description Label – Tip-over Hazard, CE Symbols Z-60FE 219954 Label – Platform Overload 219956 Use the pictures on the next page to verify that all Label –...
  • Page 59 Second Edition • First Printing Operator's Manual Inspections -60 DC • Z ® ® Part No. 1292373GT -60 FE...

  • Page 60: Operating Instructions

    Second Edition • First Printing Operator's Manual 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 61 Second Edition • First Printing Operator's Manual Operating Instructions Machine Operation FE Models: Starting the Engine FE models can be operated with or without the From the ground control panel: engine running. Turn the key switch to ground control. Turn the key switch to ground or platform Be sure both ground and platform control red control.
  • Page 62 Second Edition • First Printing Operator's Manual Operating Instructions Operation from Ground Operation from Platform Turn the key switch to ground control. Note: When operating the machine from the platform, the following foot switch messages may Pull out the red Emergency Stop button to the appear on the platform control LCD screen.
  • Page 63 Second Edition • First Printing Operator's Manual Operating Instructions To Steer To Drive Press down the foot switch. Press down the foot switch. Slowly move the drive control handle in the Increase speed: Slowly move the control direction indicated by blue or yellow triangles handle off center.
  • Page 64 Second Edition • First Printing Operator's Manual 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 65 Second Edition • First Printing Operator's Manual Operating Instructions Drive Enable Machine Not Level Indicator Light Light on indicates that the boom If the tilt alarm sounds when the has moved just past either platform is raised, the Machine Not non-steer wheel and the drive Level indicator light will come on function has been interrupted.
  • Page 66 Second Edition • First Printing Operator's Manual Operating Instructions Tilt Sensor Activation Settings Function Speed Control Model Parallel to boom Perpendicular to Move the switch to the left structure boom structure to decrease the function speeds for jib up/down, Z-60 DC 4.5°...
  • Page 67 Second Edition • First Printing Operator's Manual Operating Instructions Contact Alarm (if equipped) Aircraft Protection Package (if equipped) The contact alarm is designed to alert ground If the platform bumper comes personnel when an operator makes contact with the into contact with an object, the platform control panel, interrupting boom machine will shut down and no movement, sounding an alarm and flashing warning...
  • Page 68 Second Edition • First 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 69 Second Edition • First Printing Operator's Manual Operating Instructions Installation of Padding Install the 2 pieces of padding on the platform rails. Position the padding to protect the panels from contact with the platform rails. Installation of Strap Open the clamp and install it around a vertical platform rail tube.
  • Page 70 Second Edition • First Printing Operator's Manual 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 71 Second Edition • First 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 72: Transport And Lifting Instructions

    See the serial label for the brakes. machine weight. See the inspections section Note: Towing the Genie Z-60 DC or the Z-60 FE is for the serial label location. not recommended. If the machine must be towed, do not exceed 2 mph / 3.2 km/h.
  • Page 73 Second Edition • First Printing Operator's Manual Transport and Lifting Instructions Securing the Chassis Securing to Truck or Trailer for Transit Use chains of ample load capacity. Always use the turntable rotation lock pin each time Use a minimum of 6 chains. the machine is transported.
  • Page 74 Second Edition • First 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 75: Maintenance

    Second Edition • First Printing Operator's Manual Maintenance Maintenance Check the Engine Oil Level Maintaining the proper engine oil level is essential to good engine performance and service life. Observe and Obey: Operating the machine with an improper oil level can damage engine components.
  • Page 76 Second Edition • First 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 77 Second Edition • First Printing Operator's Manual 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 is Improper fluid levels or damaged cables and essential to engine service life.
  • Page 78 Second Edition • First 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 79: Specifications

    Second Edition • First Printing Operator's Manual Specifications Specifications Model Z-60 DC Maximum slope rating, stowed position, 4WD Height, working maximum 65 ft 7 in 20 m Platform downhill 45% 24° Height, platform maximum 59 ft 7 in 18.16 m Platform uphill 45% 24°...
  • Page 80 Second Edition • First Printing Operator's Manual Specifications Model Z-60 FE Maximum slope rating, stowed position, 4WD Height, working maximum 65 ft 7 in 20 m Platform downhill 45% 24° Height, platform maximum 59 ft 7 in 18.16 m Platform uphill 45% 24°...
  • Page 81 Second Edition • First Printing Operator's Manual Specifications Z-60 DC and Z-60 FE Range of Motion Chart Max Height Max Reach 80 ft 24.4 m -10 ft -3 m 70 ft 21.3 m 0 ft 60 ft 18.3 m 10 ft 50 ft 15.2 m 20 ft...

This manual is also suitable for:

Genie z-60 feGenie z-60 de

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