Terex Genie Z-60DC Operator'S Manual Download Page 1

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Operator's Manual

Serial Number Range

-60DC

from

Z60H-2548

-60FE

with
Maintenance
Information

Original Instructions
Second Edition
First Printing
Part No. 1307261GT

Summary of Contents for Genie Z-60DC

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

Page 2: ...n 1 Symbol and Hazard Pictorials Definitions 5 General Safety 8 Personal Safety 13 Work Area Safety 14 Legend 23 Controls 24 Inspections 31 Operating Instructions 48 Transport and Lifting Instructions 60 Maintenance 63 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 ...

Page 3: ...assis Serial label located under cover Intended Use and Familiarization Guide The intended use of this machine is to lift personnel including tools and materials to an aerial work site Before operating the machine it s the operator s responsibility to read and understand this familiarization guide Each person must be trained to operate a Mobile Elevating Work Platform MEWP Familiarization with the...

Page 4: ... boom extend retract primary boom up down and secondary boom retract lower Turntable rotate and platform rotate Sequential functions and movement Drive and steer Interlocked functions Elevated drive speed Elevated drive in an off level condition Drive enable when the boom is rotated past the non steer wheels All platform and ground controls Limitations of use The intended use of this machine is to...

Page 5: ...he action indicated in a respective bulletin To view any open bulletins for your machine visit us on the web at www genielift com 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...

Page 6: ...d worksite regulations You read understand and obey all applicable governmental regulations You are properly trained to safely operate the machine 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 Hazard Classif...

Page 7: ...ns Fire hazard Explosion hazard Explosion hazard Do not use ether or other high energy starting aids on machines equipped with glow plugs No smoking No flame Stop engine Crush hazard No smoking Explosion hazard Electrocution hazard Maintain required clearance Tip over hazard Tip over hazard Grounded AC 3 wire only Replace damaged wires and cords Tire specifications ...

Page 8: ...t No 1307261GT Wheel load Wind speed Maximum capacity Manual force Batteries used as counterweights Tie down point Lifting point Platform tie down instructions Lifting tie down instructions Lanyard anchorage points Corrosive acid Color coded direction arrows Runaway hazard Collision hazard Overhead obstruction ...

Page 9: ...rm Pressure rating for air line to platform Recovery procedure if tilt alarm sounds while elevated Platform uphill 1 Lower primary 2 Lower secondary 3 Retract primary Platform downhill 1 Retract primary 2 Lower secondary 3 Lower primary Read the operator s manual Read the service manual Access by trained and authorized personnel only Emergency lowering Crush hazard Support the platform or boom dur...

Page 10: ...Operator s Manual Second Edition First Printing General Safety 8 Z 60 DC Z 60 FE Part No 1307261GT Gener al Safety ...

Page 11: ...Second Edition First Printing Operator s Manual General Safety Part No 1307261GT Z 60 DC Z 60 FE 9 ...

Page 12: ...Operator s Manual Second Edition First Printing General Safety 10 Z 60 DC Z 60 FE Part No 1307261GT ...

Page 13: ...Second Edition First Printing Operator s Manual General Safety Part No 1307261GT Z 60 DC Z 60 FE 11 ...

Page 14: ...Operator s Manual Second Edition First Printing General Safety 12 Z 60 DC Z 60 FE Part No 1307261GT ...

Page 15: ...hine 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 All PFPE must comply with applicable governmental regulations and must be inspected and used in accordance with the PFPE manufact...

Page 16: ...line sway or sag and beware 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 lines are shut off Do not operate the machine during lightning or storms Do not use the machine as a ground for welding Tip over Hazards Occupants equipment and materials shall not...

Page 17: ...oom on the slope as shown in the tilt alarm procedure Follow the steps to lower the boom before moving to a firm level surface Do not rotate the boom while lowering If the tilt alarm sounds with the platform uphill 1 Lower the primary boom 2 Lower the secondary boom 3 Retract the primary boom If the tilt alarm sounds with the platform downhill 1 Retract the primary boom 2 Lower the secondary boom ...

Page 18: ...0 N Do not alter or disable machine components that in any way affect safety and stability Do not replace items critical to machine stability with items of different weight or specification Do not replace factory installed tires with tires of different specification or ply rating Do not replace factory installed foam filled tires with air filled tires Wheel weight is critical to stability Do not u...

Page 19: ...oving or mobile surface or vehicle Be sure the tires are in good condition and the lug nuts tightened Operation on Slopes Hazards Do not drive the machine on a slope that exceeds the maximum uphill downhill or side slope rating of the machine Slope rating applies only to machines in the stowed position Maximum slope rating stowed position 4WD Platform downhill 45 24 Platform uphill 45 24 Side slop...

Page 20: ... Do not enter or exit the platform unless the machine is in the stowed position and the platform is at ground level Hazards related with the specific product application of exiting at height have been considered in the design of the machine for further information contact Genie see section Contacting the Manufacturer Collision Hazards Be aware of limited sight distance and blind spots when driving...

Page 21: ...th 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 cause serious injury Only trained maintenance personnel should access compartments Access by the operator is only advised when performing a pre operation inspection All compartments must remain closed and secured during operation When the engine is runni...

Page 22: ...ery or charger greater than 12V to jump start the engine Do not operate the machine in locations where extremely high magnetic fields may be present Battery Safety Burn Hazards Batteries contain acid Always wear protective clothing and eye wear when working with batteries Avoid spilling or contacting battery acid Neutralize battery acid spills with baking soda and water Do not expose the batteries...

Page 23: ...250 lbs 567 kg Lifting Hazard Use a forklift to remove or install a battery pack Panel Cradle Safety Read understand and obey all warnings and instructions provided with the panel cradles Do not exceed the rated platform capacity The combined weight of the cradles panels occupants tools and any other equipment must not exceed rated capacity The panel cradle assembly weighs 30 lbs 13 6 kg The maxim...

Page 24: ...ter Each 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 steer wheels 4 Turn the key switch to the off position and remove the key to secure from unauthorized use ...

Page 25: ... Z 60 DC Z 60 FE 23 Leg end 1 Non steer tire 2 Steer tire 3 Power to charger 4 Ground controls 5 Secondary boom 6 Primary boom 7 Jib boom 8 Platform controls 9 Platform 10 Swing gate 11 Lanyard anchorage points 12 Sliding mid rail 13 Foot switch 14 Manual storage container ...

Page 26: ...ction enable button Press and hold the function enable button to enable the functions on the ground control panel to operate 2 Secondary boom up down switch Move the secondary boom up down switch up and the secondary boom will raise Move secondary boom up down switch down and the secondary boom will lower 3 Primary boom up down switch Move the primary boom up down switch up and the boom will raise...

Page 27: ...hine 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 11 Jib boom up down switch Move the jib boom switch up and the jib boom will raise Move the jib boom switch down and the jib boom will lower 12 Platform level switch Move the platform level switch up and the level of the platform will raise Move the platform level swit...

Page 28: ...Operator s Manual Second Edition First Printing Controls 26 Z 60 DC Z 60 FE Part No 1307261GT Platform Control Panel ...

Page 29: ...Second Edition First Printing Operator s Manual Controls Part No 1307261GT Z 60 DC Z 60 FE 27 ...

Page 30: ... the switch to the left and the function speeds for jib up down platform rotate and primary boom extend retract will decrease Move the switch to the right and the function speeds for jib up down platform rotate and primary boom extend retract will increase Note Function speeds will increase or decrease by 5 each time the speed control switch is moved The speed control switch can also be held in ei...

Page 31: ...the direction indicated by the yellow arrow and the machine will drive backwards Press the left side of the thumb rocker and the machine will steer to the left Press the right side of the thumb rocker and the machine will steer to the right 12 Drive enable indicator light Light on indicates that the boom has moved just past either non steer wheel and drive function has been interrupted 13 Drive en...

Page 32: ...the right to select Hybrid mode 19 Proportional control handle for secondary boom up down function Move the control handle up and the secondary boom will raise Move the control handle down and the secondary boom will lower 20 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 will raise Move the c...

Page 33: ...ction is 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 procedures are required Only routine maintenance items specified in this manual may be performed by the operator Refer to the list on the next page and check each of the items If damage or any unaut...

Page 34: ... if needed See Maintenance section Check the following components or areas for damage improperly installed or missing parts and unauthorized modifications Electrical components wiring and electrical cables Hydraulic hoses fittings cylinders and manifolds Fuel and hydraulic tanks Drive and turntable motors and drive hubs Wear pads Tires and wheels FE models Engine and related components Limit switc...

Page 35: ...y use the 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 instructions to test all machine functions A malfunctioning machine must never be used If malfunctions are discovered the machine must be tagged and removed from service Repairs to the machine m...

Page 36: ...form function toggle switch Result No boom and platform functions should operate 9 Press and hold the function enable button and activate each boom and platform function toggle switch Result All boom and platform functions should operate through a full cycle The descent alarm should sound while the boom is lowering Test Auxiliary Controls FE Models 10 Turn the key switch to ground control 11 Pull ...

Page 37: ...ch to ground control 24 Pull out the red Emergency Stop button to the on position Result At machine start up the ground control meter displays pitch and roll angles of the machine and the alarm will beep 4 seconds At the Platform Controls 25 Turn the key switch to platform control 26 Pull out the red Emergency Stop button to the on position 27 FE models Start the engine See Operating Instructions ...

Page 38: ...est each machine function Result No functions should operate Test Machine Functions 39 Press down the foot switch 40 Activate each machine function control handle or toggle switch Result All boom and platform functions should operate through a full cycle Test the Steering 41 Press down the foot switch 42 Press the thumb rocker switch on top of the drive control handle in the direction indicated by...

Page 39: ...ve chassis then come to an abrupt stop Note The brakes must be able to hold the machine on any slope it is able to climb Test the Drive Enable System 47 Press down the foot switch and lower the boom to the stowed position 48 Rotate the turntable until the primary boom moves past one of the non steer wheels Result The drive enable indicator light should come on and remain on while the boom is anywh...

Page 40: ...the drive speed with the primary or secondary boom raised or the primary boom extended exceeds 1 ft 30 cm per second immediately tag and remove the machine from service Test Drive Tilt Cutout 61 Press down the foot switch 62 With the boom fully stowed drive the machine onto a slope where the chassis pitch angle is greater than 4 5 Result The machine should continue to drive 63 Return to level grou...

Page 41: ...top once the machine reaches 2 5 of chassis tilt and the alarm should sound at the platform controls 76 Lower the primary boom to the stowed position or drive in the opposite direction Result The machine should drive 77 Return to level ground and extend the primary boom approximately 1 6 ft 0 5 m 78 Drive the machine onto a slope where the chassis roll angle is greater than 2 5 Result The machine ...

Page 42: ...the red Emergency Stop button to the off position 89 Pull out the red Emergency Stop button to the on position 90 Press down the foot switch 91 Simultaneously move and hold the auxiliary power switch and activate each function control handle toggle switch or thumb rocker switch Note To conserve battery power test each function through a partial cycle Result All boom and steer functions should oper...

Page 43: ...he machine horn will sound 96 Insert the actuator into the switch socket Result The lights and horn will turn off 97 Activate the foot switch by pressing the foot switch down and press on the contact alarm cable to release the actuator from the switch socket Result The contact alarm lights will flash and the machine horn will sound 98 Operate each machine function Result All machine functions shou...

Page 44: ...d the primary boom approximately 1 ft 30 cm 102Move the yellow bumper at the bottom of the platform 4 inches 10 cm in any direction 103Activate each function control handle or toggle switch Result No boom and steer functions should operate 104Move and hold the aircraft protection override switch 105Activate each function control handle or toggle switch Result All boom and steer functions should op...

Page 45: ...operator 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 remember the workplace hazards then watch for and avoid them while moving setting up and operating the machine Workplace Inspection Checklist Be aware of and avoid the following hazardous situa...

Page 46: ... Electrocution Hazard 3 133205 Label Electrocution Burn Hazard 2 133286 Label Power to Charger Universal 1 Part No Decal Description Qty 219954 Label Tip over Hazard CE 1 219956 Label Platform Overload 1 219958 Label Tip over Crush Hazard 1 1256425 Label Danger Electrocution Hazard 1 1263542 Label Compartment Access 2 1265361 Label Battery Charger Indicator 1 1265450 Ground Control Panel 1 1265451...

Page 47: ...Second Edition First Printing Operator s Manual Inspections Part No 1307261GT Z 60 DC Z 60 FE 45 ...

Page 48: ...it Switches 3 114334 Label Electrocution Hazard Plug 1 133067 Label Electrocution Hazard 3 133205 Label Electrocution Burn Hazard 2 133286 Label Power to Charger 1 Part No Decal Description Qty 219954 Label Tip over Hazard CE 1 219956 Label Platform Overload 1 219958 Label Tip over Crush Hazard 1 1256425 Label Danger Electrocution Hazard 1 1263542 Label Compartment Access 2 1265361 Label Battery C...

Page 49: ...Second Edition First Printing Operator s Manual Inspections Part No 1307261GT Z 60 DC Z 60 FE 47 ...

Page 50: ... is the 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 their tools and materials to an aerial work site is unsafe and dangerous Only trained and authorized personnel should be permitted to operate a machine If more than one operator is expected to ...

Page 51: ...he platform 4 Simultaneously hold the auxiliary power switch to either side and activate the desired function FE Models Starting the Engine From the ground control panel 1 Turn the key switch to ground control 2 Be sure both ground and platform control red Emergency Stop buttons are pulled out to the on position 3 Move the machine mode select switch to hybrid mode 4 Push the function enable button...

Page 52: ... is removed from the platform Operation from Platform Note When operating the machine from the platform the following foot switch messages may appear on the platform control LCD screen FOOT SWITCH POWER UP FAULT RELEASE FOOT SWITCH AND REPOWER FOOT SWITCH MUST BE APPLIED BEFORE FUNCTION IS ACTIVATED FOOT SWITCH TIMED OUT RELEASE FOOT SWITCH TO RESET If any of these messages appear follow the messa...

Page 53: ...e displayed on the platform control LCD screen DRIVE SPEED REDUCED DUE TO SLOPE Note In very hot environments operators may notice slower drive and or charging performance This is the machine protecting itself from the effects of heat and is a functional design of the machine Driving on a slope Determine the uphill downhill and side slope ratings for the machine and determine the slope grade Maxim...

Page 54: ...hes 3 6 m Rise 12 inches 0 3 m 12 in 144 in 0 083 x 100 8 3 grade 0 3 m 3 6 m 0 083 x 100 8 3 grade If the slope exceeds the maximum slope or side slope rating then the machine must be winched or transported up or down the slope See Transport and Lifting section Drive Enable Light on indicates that the boom has moved just past either non steer wheel and the drive function has been interrupted To d...

Page 55: ...imary boom 2 Lower the secondary boom 3 Retract the primary boom If the tilt alarm sounds with the platform downhill 1 Retract the primary boom 2 Lower the secondary boom 3 Lower the primary boom Tilt Sensor Activation Settings Model Parallel to boom structure Perpendicular to boom structure Z 60 DC 4 5 2 5 Z 60 FE 4 5 2 5 When the Machine On Incline indicator light is on and the tilt alarm sounds...

Page 56: ...ch is moved The speed control switch can also be held in either direction to increase or decrease function speed AC Inverter if equipped The inverter supplies power to the platform when external AC power is removed Plug the power to platform cable on the machine into the the inverter power cable Move the inverter switch up to activate the inverter Move the switch down to turn off the inverter All ...

Page 57: ...sistance may be needed These notifications will continue until the system is reset 1 The contact alarm cable is tripped releasing the actuator from the switch socket 2 Insert the actuator into the switch socket to turn off flashing lights and audio alarm 1 actuator 2 contact alarm cable 3 flashing alarm 4 switch socket Aircraft Protection Package if equipped If the platform bumper comes into conta...

Page 58: ...sembly 1 Apply the warning decal to the front of each panel cradle if needed 2 Install rubber bumper 1 in the panel cradle base See the illustration 3 Secure the bumper with 2 high profile lock nuts and 2 washers Panel Cradle Installation 1 Insert the hook piece through the slots in the panel cradle base 2 Hook the panel cradle to the bottom platform tube in the desired location 3 Install rubber b...

Page 59: ...l platform rail tube 2 Insert a bolt with a washer through one 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 end plate should be able to slide on the platform rail Panel Cradle Operation 1 Secure both panel cradles to the platform 2 Place the load s...

Page 60: ...th distilled water to the bottom of the fill tube Do not overfill If the batteries are not charged weekly the following message will appear on the platform control LCD screen FULL PLUG IN CHARGE ADVISED WEEKLY FOR BEST BATTERY LIFE 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...

Page 61: ...er Each 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 steer wheels 4 Turn the key switch to the off position and remove the key to secure from unauthorized use ...

Page 62: ...e sufficient to withstand the machine weight Genie lifts are very heavy relative to their size See the serial label for the machine weight See the inspections section for the serial label location 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...

Page 63: ...ition and remove the key before transporting Inspect the entire machine for loose or unsecured items Securing the Chassis Use chains of ample load capacity Use a minimum of 6 chains Adjust the rigging to prevent damage to the chains For diagram refer to the Lifting Instructions Securing the Platform Make sure the jib and platform are in the stowed position Secure the platform with a nylon strap pl...

Page 64: ...ines are sufficient to withstand the machine weight See the serial label for the machine weight 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 Attach the rigging only to the designated lifting points on the machine Adjust the rigging to preve...

Page 65: ...is manual to help communicate the intent of the instructions When one or more of the symbols appear at the beginning of a maintenance procedure it conveys the meaning below Indicates that 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 Engine Oil ...

Page 66: ... Sulfur Diesel ULSD 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 sig...

Page 67: ...evel in the coolant recovery tank Add fluid as needed Result The fluid level should be at the FULL mark on the tank or visible in the sight gauge 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...

Page 68: ...uarterly 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: ...F 40 C to 49 C Low end of temperature range requires the use of special hydraulic and engine oils Maximum slope rating stowed position 4WD Platform downhill 45 24 Platform uphill 45 24 Side slope 25 14 Maximum allowable chassis inclination Parallel to boom structure 2 5 Perpendicular to boom structure 4 5 Note Slope rating is subject to ground conditions with one person in the platform and adequat...

Page 70: ...erature range requires the use of special hydraulic and engine oils Fuel tank capacity 20 gallons 75 7 liters Maximum slope rating stowed position 4WD Platform downhill 45 24 Platform uphill 45 24 Side slope 25 14 Maximum allowable chassis inclination Parallel to boom structure 2 5 Perpendicular to boom structure 4 5 Note Slope rating is subject to ground conditions with one person in the platform...

Page 71: ...Z 60 DC and Z 60 FE Range of Motion Chart Max Height Max Reach 1 80 ft 24 4 m 11 10 ft 3 m 2 70 ft 21 3 m 12 0 ft 0 m 3 60 ft 18 3 m 13 10 ft 3 m 4 50 ft 15 2 m 14 20 ft 6 1 m 5 40 ft 12 2 m 15 30 ft 9 1 m 6 30 ft 9 1 m 16 40 ft 12 2 m 7 20 ft 6 1 m 17 50 ft 15 2 m 8 10 ft 3 m 9 0 ft 0 m 10 10 ft 3 m ...

Page 72: ...engine only Test Report This machine has been tested and passed the following categories per EN 280 2013 A1 2015 clause 6 3 prior to entering the market 1 BRAKES Brakes working properly in forward and reverse 2 OVERLOAD Overload tested at XXX rated load 3 FUNCTIONAL Smooth operation at XXX rated load 4 FUNCTIONAL All safety devices working correctly 5 FUNCTIONAL Speeds set within permitted specifi...

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