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

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Operator's Manual
Z
-60DC
®
Z
-60FE
®
Serial Number Range
from Z60H-2548
CE
with
Maintenance
Information
Original Instructions
Second Edition
First Printing
Part No. 1307261GT

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Summary of Contents for Terex Genie Z-60DC

  • Page 1 Operator's Manual Serial Number Range -60DC ® from Z60H-2548 -60FE ® with Maintenance Information Original Instructions Second Edition First Printing Part No. 1307261GT...

  • Page 2: Table Of Contents

    Specifications ............67 Copyright © 2016 Terex Corporation First Edition: First Printing, September 2020 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 -60 DC •...

  • Page 3: Introduction

    Second Edition • First Printing Operator's Manual Introduction Intr oducti on 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 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 Safety of product users is of paramount number and serial number of your machine, along importance 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 H az ard Pictorials Definiti ons Fire hazard Explosion hazard Explosion hazard Do not use ether or No smoking. other high energy No flame. Stop engine. starting aids on 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 Gener al Safety -60 DC • Z ® ® -60 FE Part No. 1307261GT...
  • Page 11 Second Edition • First Printing Operator's Manual General Safety -60 DC • Z ® ® Part No. 1307261GT -60 FE...
  • Page 12 Second Edition • First Printing Operator's Manual General Safety -60 DC • Z ® ® -60 FE Part No. 1307261GT...
  • Page 13 Second Edition • First Printing Operator's Manual General Safety -60 DC • Z ® ® Part No. 1307261GT -60 FE...
  • Page 14 Second Edition • First Printing Operator's Manual General Safety -60 DC • Z ® ® -60 FE Part No. 1307261GT...

  • Page 15: Personal Safety

    Second Edition • First Printing Operator's Manual Personal Safety Pers onal 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.

  • Page 16: Work Area Safety

    Second Edition • First Printing Operator's Manual Work Area Safety Wor k Ar ea 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 17 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 18 Second Edition • First Printing Operator's Manual Work Area Safety Use extreme care and Do not alter or disable machine components that slow speeds while driving in any way affect safety and stability. the machine in the stowed Do not replace items critical to machine stability position across uneven with items of different weight or specification.
  • Page 19 Second Edition • First 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 machine.
  • Page 20 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 21 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 22 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 Batteries contain acid. the machine and test all functions before each Always wear protective work shift.
  • Page 23 Second Edition • First Printing Operator's Manual Work Area Safety Electrocution/Burn Hazards Panel Cradle Safety Connect the battery charger to a Read, understand and obey all warnings and grounded, AC 3-wire electrical instructions provided with the panel cradles. outlet only. Do not exceed the rated platform capacity.
  • Page 24 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 25: Legend

    Second Edition • First Printing Operator's Manual Legend Leg end 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 26: Controls

    Second Edition • First Printing Operator's Manual Controls Controls The ground control station is to be used as a means to raise the platform for storage purposes and for function tests. The ground control station can be used in the event of an emergency to rescue an incapacitated person in the platform.
  • Page 27 Second Edition • First 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 28 Second Edition • First Printing Operator's Manual Controls Platform Control Panel -60 DC • Z ® ® -60 FE Part No. 1307261GT...
  • Page 29 Second Edition • First Printing Operator's Manual Controls -60 DC • Z ® ® Part No. 1307261GT -60 FE...
  • Page 30 Second Edition • First Printing Operator's Manual Controls Function speed control switch Platform Control Panel Move the switch to the left and the function Horn button speeds for jib up/down, platform rotate and Press this button and the horn will sound. primary boom extend/retract will decrease.
  • Page 31 Second Edition • First Printing Operator's Manual Controls 11 Dual axis proportional control handle for drive 12 Drive enable indicator light and steer functions. Light on indicates that the boom has moved just past either non-steer wheel and drive Proportional control handle for drive function function has been interrupted.
  • Page 32 Second Edition • First Printing Operator's Manual Controls 17 Platform overload indicator light Light flashing indicates the platform is overloaded. The engine will stop and no functions will operate. Remove weight until the light goes off and then restart the engine. 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...

  • Page 33: Inspections

    Second Edition • First Printing Operator's Manual Inspections Ins pections 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 34 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 35 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 36 Second Edition • First Printing Operator's Manual Inspections At the Ground Controls Test Auxiliary Controls FE Models: Select a test area that is firm, level and free of hazards. 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 37 Second Edition • First 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 hazards.
  • Page 38 Second Edition • First Printing Operator's Manual 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 39 Second Edition • First 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...
  • Page 40 Second Edition • First Printing Operator's Manual 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 2 ft / 62 With the boom fully stowed, drive the machine 61 cm.
  • Page 41 Second Edition • First Printing Operator's Manual Inspections 70 With the boom fully stowed, drive the machine 77 Return to level ground and extend the primary onto a slope where the chassis pitch angle is boom approximately 1.6 ft / 0.5 m. greater than 4.5°.
  • Page 42 Second Edition • First Printing Operator's Manual Inspections Test the Oscillating Axle (if equipped) Test the Lift/Drive Select Function (if equipped) 85 Drive the right steer tire up onto a 6 in/15 cm block or curb. 92 Press down the foot switch. Result: The three remaining tires should stay 93 Move the drive control handle off center and in firm contact with the ground.
  • Page 43 Second Edition • First Printing Operator's Manual Inspections 98 Operate each machine function. Test the Contact Alarm (if equipped) Result: All machine functions should not 94 Do not activate the foot switch and press on operate. the contact alarm cable to release the actuator from the switch socket.
  • Page 44 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 45 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 46 Second Edition • First Printing Operator's Manual Inspections Inspection for Decals with Part No. Decal Description Symbols Z-60DC Label – Tip-over Hazard, CE 219954 Label – Platform Overload 219956 Use the pictures on the next page to verify that all Label –...
  • Page 47 Second Edition • First Printing Operator's Manual Inspections -60 DC • Z ® ® Part No. 1307261GT -60 FE...
  • Page 48 Second Edition • First Printing Operator's Manual Inspections Inspection for Decals with Part No. Decal Description Symbols Z-60FE Label – Tip-over Hazard, CE 219954 Label – Platform Overload 219956 Use the pictures on the next page to verify that all Label –...
  • Page 49 Second Edition • First Printing Operator's Manual Inspections -60 DC • Z ® ® Part No. 1307261GT -60 FE...

  • Page 50: Operating Instructions

    Second Edition • First Printing Operator's Manual Operating Instructions Operati ng Instr ucti ons 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 51 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 52 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 53 Second Edition • First Printing Operator's Manual Operating Instructions To Steer Driving on a slope Press down the foot switch. Determine the uphill, downhill and side slope ratings for the machine and determine the slope Slowly move the drive control handle in the grade.
  • Page 54 Second Edition • First Printing Operator's Manual Operating Instructions To determine the slope grade: Drive Enable Measure the slope with a digital inclinometer OR Light on indicates that the boom use the following procedure. has moved just past either non- steer wheel and the drive You will need: function has been interrupted.
  • Page 55 Second Edition • First Printing Operator's Manual Operating Instructions Machine Not Level Indicator Light Tilt Sensor Activation Settings Model Parallel to boom Perpendicular to If the tilt alarm sounds when the structure boom structure platform is raised, the Machine Not Level indicator light will come on 4.5°...
  • Page 56 Second Edition • First Printing Operator's Manual Operating Instructions Function Speed Control Platform Overload Indicator Light Light flashing indicates the Move the switch to the platform is overloaded. The left to decrease the engine will stop and no function speeds for jib functions will operate.
  • Page 57 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 into contact with an object, the the platform control panel, interrupting boom machine will shut down and no movement, sounding an alarm and flashing...
  • Page 58 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 59 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 60 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 61 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 62: Transport And Lifting Instructions

    Second Edition • First Printing Operator's Manual Transport and Lifting Instructions Trans port and Lifti ng Instr ucti ons  Be sure the turntable is secured with the turntable rotation lock before transporting. Be sure to unlock the turntable for operation. ...
  • Page 63 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 Use a minimum of 6 chains. time the machine is transported.
  • Page 64 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 65: Maintenance

    Second Edition • First Printing Operator's Manual Maintenance Maintenanc e 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 66 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 67 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 Improper fluid levels or damaged cables and is essential to engine service life.
  • Page 68 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 69: Specifications

    Second Edition • First Printing Operator's Manual Specifications Specific ati ons 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 70 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 71 Second Edition • First Printing Operator's Manual Specifications Z-60 DC and Z-60 FE Range of Motion Max Height Max Reach Chart 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...
  • Page 72 Second Edition • First Printing Operator's Manual Specifications Contents of EC Declaration of Conformity <Manufacturer’s name> hereby declares that the machinery described below complies with the provisions of the following Directives: 1. EC Directive 2006/42/EC, Machinery Directive, under consideration of harmonized European standard EN280 as described in EC type-examination certificate <variable field>...

This manual is also suitable for:

Genie z-60feZ60h-2548

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