Terex Z60H-3000 Operator's Manual
  1. Manuals
  2. Brands
  3. Terex Manuals
  4. Boom Lifts
  5. Z60H-3000
  6. Operator's manual
Terex Z60H-3000 Operator's Manual

Terex Z60H-3000 Operator's Manual

Hide thumbs
Table of Contents

Advertisement

Quick Links

Download this manual
Operator's Manual
Z
-60 DC
®
Z
-60 FE
®
Serial Number Range
from Z60H-3000
from Z60M-1000
CE
with
Maintenance
Information
Original Instructions
Third Edition
Second Printing
Part No. 1312306GT

Advertisement

Table of Contents
loading
Need help?

Need help?

Do you have a question about the Z60H-3000 and is the answer not in the manual?

Questions and answers

Related Manuals for Terex Z60H-3000

Summary of Contents for Terex Z60H-3000

  • Page 1 Operator's Manual Serial Number Range -60 DC ® from Z60H-3000 from Z60M-1000 -60 FE ® with Maintenance Information Original Instructions Third Edition Second Printing Part No. 1312306GT...

  • Page 2: Table Of Contents

    NG31 6BH Copyright © 2016 Terex Corporation Third Edition: Second Printing, April 2022 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 Supply of Machinery (Safety) Regulations 2008 ®...

  • Page 3: Introduction

    Third Edition • Second 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 safety, which is best achieved by our joint efforts.
  • Page 4 Operator's Manual Third Edition • Second Printing 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 Third Edition • Second 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 Operator's Manual Third Edition • Second Printing 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

    Third 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 Third Edition • Second Printing 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 and tie down Lanyard anchorage instructions instructions points Corrosive acid. Color coded direction Runaway hazard Collision hazard...
  • Page 9 Third Edition • Second 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. Platform uphill: Platform downhill: Read the operator’s Read the service...

  • Page 10: General Safety

    Operator's Manual Third Edition • Second Printing General Safety General Safety Z-60 DC/FE ® -60 DC • Z ® -60 FE Part No. 1312306GT...
  • Page 11 Third Edition • Second Printing Operator's Manual General Safety Z-60 DC Part No. 1312306GT ® -60 DC • Z ® -60 FE...
  • Page 12 Operator's Manual Third Edition • Second Printing General Safety Z-60 DC ® -60 DC • Z ® -60 FE Part No. 1312306GT...
  • Page 13 Third Edition • Second Printing Operator's Manual General Safety Z-60 FE Part No. 1312306GT ® -60 DC • Z ® -60 FE...
  • Page 14 Operator's Manual Third Edition • Second Printing General Safety Z-60 FE ® -60 DC • Z ® -60 FE Part No. 1312306GT...

  • Page 15: Personal Safety

    Third 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 16: Work Area Safety

    Operator's Manual Third 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 17 Third 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 18 Operator's Manual Third Edition • Second Printing 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 Third 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 machine.
  • Page 20 Operator's Manual Third 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 21 Third Edition • Second 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 Operator's Manual Third 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 Batteries contain acid. the machine and test all functions before each Always wear protective work shift.
  • Page 23 Third Edition • Second Printing Operator's Manual Work Area Safety Panel Cradle Safety Electrocution/Burn Hazards 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 Operator's Manual Third 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 25: Legend

    Third Edition • Second 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 Part No.

  • Page 26: Controls

    Operator's Manual Third Edition • Second Printing 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 Third 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 28 Operator's Manual Third Edition • Second Printing Controls Platform Control Panel ® -60 DC • Z ® -60 FE Part No. 1312306GT...
  • Page 29 Third Edition • Second Printing Operator's Manual Controls Part No. 1312306GT ® -60 DC • Z ® -60 FE...
  • Page 30 Operator's Manual Third Edition • Second Printing Controls Platform Control Panel Function speed control switch 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 Third Edition • Second 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 Operator's Manual Third Edition • Second Printing 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

    Third 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 34 Operator's Manual Third Edition • Second Printing 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 Third 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 36 Operator's Manual Third Edition • Second Printing 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 Third Edition • Second Printing Operator's Manual Inspections At the Platform Controls Test the Tilt Sensor 17 Select a test area that is firm, level and free of 20 Turn the key switch to platform control. hazards. 21 Pull out the red Emergency Stop button to the 18 Turn the key switch to ground control.
  • Page 38 Operator's Manual Third Edition • Second Printing Inspections Test the Foot Switch Test Machine Functions DC Models: 34 Press down the foot switch. 27 Do not press down the foot switch. Test each 35 Activate each machine function control handle machine function.
  • Page 39 Third Edition • Second Printing Operator's Manual Inspections Test Drive and Braking Test the Drive Enable System 39 Press down the foot switch. 42 Press down the foot switch and lower the boom to the stowed position. 40 Slowly move the drive control handle in the direction indicated by the blue arrow on the 43 Rotate the turntable until the primary boom control panel until the machine begins to...
  • Page 40 Operator's Manual Third Edition • Second Printing Inspections Test Limited Drive Speed Test Drive Tilt Cutout 46 Press down the foot switch. 56 Press down the foot switch. 47 Raise the primary boom approximately 2 ft / 57 With the boom fully stowed, drive the machine 61 cm.
  • Page 41 Third Edition • Second Printing Operator's Manual Inspections 65 With the boom fully stowed, drive the machine 72 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 Operator's Manual Third Edition • Second Printing Inspections Test the Oscillating Axle (if equipped) Test the Lift/Drive Select Function (if enabled) 80 Drive the right steer tire up onto a 6 in/15 cm block or curb. 87 Press down the foot switch. Result: The three remaining tires should stay 88 Move the drive control handle off center and in firm contact with the ground.
  • Page 43 Third Edition • Second Printing Operator's Manual Inspections 94 Insert the actuator into the switch socket. Test the Contact Alarm (if equipped) Result: The lights and horn will turn off. 89 Do not activate the foot switch and press on the contact alarm cable to release the actuator 95 Operate each machine function.
  • Page 44 Operator's Manual Third Edition • Second Printing Inspections Test Aircraft Protection Package (if equipped) Note: Two people may be required to perform this test. 96 Extend the primary boom approximately 1 ft/30 cm. 97 Move the yellow bumper at the bottom of the platform 4 inches/10 cm in any direction.
  • Page 45 Third 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 46 Operator's Manual Third Edition • Second Printing Inspections Inspection for Decals with Part No. Decal Description Symbols Z-60DC 1269246 Label – Transport/Lifting** 1269255 Danger – Tip-over Hazard, Batteries Use the pictures on the next page to verify that all 1269258 Label – Slope Rating, Z-60 decals are legible and in place.
  • Page 47 Third Edition • Second Printing Operator's Manual Inspections Z-60 DC Part No. 1312306GT ® -60 DC • Z ® -60 FE...
  • Page 48 Operator's Manual Third Edition • Second Printing Inspections Inspection for Decals with Part No. Decal Description Symbols Z-60FE 1265451 Platform Control Panel 1269245 Label – Emergency Lowering Use the pictures on the next page to verify that all 1269246 Label – Transport/Lifting** decals are legible and in place.
  • Page 49 Third Edition • Second Printing Operator's Manual Inspections Z-60 FE Part No. 1312306GT ® -60 DC • Z ® -60 FE...

  • Page 50: Operating Instructions

    Operator's Manual Third 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 51 Third Edition • Second 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 Operator's Manual Third Edition • Second Printing 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 Third Edition • Second 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 Operator's Manual Third Edition • Second Printing 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 Third Edition • Second Printing Operator's Manual Operating Instructions Machine Not Level Indicator Light Tilt Sensor Activation Settings If the tilt alarm sounds when the Model Parallel to boom Perpendicular to structure boom structure platform is raised, the Machine Not Level indicator light will come on Z-60 DC 4.5°...
  • Page 56 Operator's Manual Third Edition • Second Printing Operating Instructions Function Speed Control Contact Alarm (if equipped) The contact alarm is designed to alert ground Move the switch to the personnel when an operator makes contact with left to decrease the the platform control panel, interrupting boom function speeds for jib movement, sounding an alarm and flashing...
  • Page 57 Third Edition • Second Printing Operator's Manual Operating Instructions Aircraft Protection Package (if equipped) Panel Cradle Assembly Apply the warning decal to the front of each If the platform bumper comes panel cradle (if needed). into contact with an object, the machine will shut down and no Install rubber bumper 1 in the panel cradle functions will operate.
  • Page 58 Operator's Manual Third 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 from contact with the platform rails. Installation of Strap Open the clamp and install it around a vertical platform rail tube.
  • Page 59 Third Edition • Second 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 60 Operator's Manual Third Edition • Second Printing Operating Instructions Dry Battery Filling and Charging After Each Use Instructions Select a safe parking location—firm level surface, clear of obstruction and traffic. This procedure applies to flooded lead acid batteries only. Retract and lower the boom to the stowed position.

  • Page 61: Transport And Lifting Instructions

    Third Edition • Second Printing Operator's Manual Transport and Lifting Instructions Transport and Lifting Instructions  Be sure the turntable is secured with the turntable rotation lock before transporting. Be sure to unlock the turntable for operation.  Do not drive the machine on a slope that exceeds the uphill, downhill or side slope rating.
  • Page 62 Operator's Manual Third Edition • Second Printing Transport and Lifting Instructions Securing to Truck or Trailer for Securing the Chassis 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 63 Third 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 64: Maintenance

    Operator's Manual Third Edition • Second Printing Maintenance Check the Engine Oil Level Maintenance 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 65 Third 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 66 Operator's Manual Third 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 67 Third Edition • Second Printing Operator's Manual Maintenance Scheduled Maintenance Maintenance performed commissioning, 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 and maintenance manuals for this machine.

  • Page 68: Specifications

    Operator's Manual Third Edition • Second Printing 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 69 Third Edition • Second 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 70 Operator's Manual Third Edition • Second Printing 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 71 Third Edition • Second 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>...
  • Page 72 Operator's Manual Third Edition • Second Printing Specifications Z®-60 DC • Z®-60 FE Part No. 1312306GT Operator's Manual Third Edition • Second Printing ® -60 DC • Z ® -60 FE Part No. 1312306GT...

This manual is also suitable for:

Genie z-60 feGenie z-60 dcZ60m-1000

Table of Contents