Terex Genie Z-60/37DC, Operator'S Manual

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

Page 2: ...rk Area Safety 12 Legend 21 Controls 22 Inspections 29 Operating Instructions 44 Transport and Lifting Instructions 55 Maintenance 58 Specifications 62 Copyright 2016 Terex Corporation First Edition S...

Page 3: ...Serial label located under cover Intended Use This machine is intended to be used only to lift personnel along with their tools and materials to an aerial work site Bulletin Distribution and Complianc...

Page 4: ...eporting Questions regarding product applications and safety Standards and regulatory compliance information Current owner updates such as changes in machine ownership or changes in your contact infor...

Page 5: ...3 Always perform function tests prior to use 4 Inspect the workplace 5 Only use the machine as it was intended You read understand and obey the manufacturer s instructions and safety rules safety and...

Page 6: ...ntial personal injury hazards Obey all safety messages that follow this symbol to avoid possible injury or death Indicates a hazardous situation which if not avoided will result in death or serious in...

Page 7: ...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 cleara...

Page 8: ...Arrows Runaway Hazard Collision hazard Collision hazard Electrocution hazard Avoid contact Disconnect battery Voltage rating for power to platform Pressure rating for air line to platform Recovery pro...

Page 9: ...First Edition Second Printing Operator s Manual General Safety Part No 1270491 Z 60 37DC Z 60 37FE 7 General Safety...

Page 10: ...Operator s Manual First Edition Second Printing General Safety 8 Z 60 37DC Z 60 37FE Part No 1270491...

Page 11: ...First Edition Second Printing Operator s Manual General Safety Part No 1270491 Z 60 37DC Z 60 37FE 9...

Page 12: ...Operator s Manual First Edition Second Printing General Safety 10 Z 60 37DC Z 60 37FE Part No 1270491...

Page 13: ...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...

Page 14: ...g 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 p...

Page 15: ...r both directions will not operate Identify the condition of the boom 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...

Page 16: ...400 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 r...

Page 17: ...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 do...

Page 18: ...form floor clear of debris Lower the platform entry mid rail or close the entry gate before operating Do not enter or exit the platform unless the machine is in the stowed position and the platform is...

Page 19: ...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 personne...

Page 20: ...on the machine Component Damage Hazards Do not use the machine as a ground for welding Do not use any battery or charger greater than 12V to jump start the engine Do not operate the machine in locati...

Page 21: ...aintenance free batteries each battery must weigh 56 7 kg Each battery pack including batteries must weigh a minimum of 567 kg Lifting Hazard Use a forklift to remove or install a battery pack Panel C...

Page 22: ...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...

Page 23: ...60 37DC Z 60 37FE 21 Legend 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 anchor...

Page 24: ...ary 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 switc...

Page 25: ...is in Hybrid mode 10 Machine mode select switch FE Models Move the switch to the left to select DC mode Move the switch to the right to select Hybrid mode 11 Jib boom up down switch Move the jib boom...

Page 26: ...Operator s Manual First Edition Second Printing Controls 24 Z 60 37DC Z 60 37FE Part No 1270491 Platform Control Panel...

Page 27: ...First Edition Second Printing Operator s Manual Controls Part No 1270491 Z 60 37DC Z 60 37FE 25...

Page 28: ...tch Move the primary boom extend retract switch up and the primary boom will retract Move the boom extend retract switch down and the primary boom will extend 6 Function speed control switch Move the...

Page 29: ...d the machine will steer to the right OR Move the control handle in the direction indicated by the blue arrow on the control panel and the machine will drive forward Move the control handle in the dir...

Page 30: ...d 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...

Page 31: ...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 maintenanc...

Page 32: ...aintenance section Check the following components or areas for damage improperly installed or missing parts and unauthorized modifications Electrical components wiring and electrical cables Hydraulic...

Page 33: ...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...

Page 34: ...h boom and platform 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 R...

Page 35: ...switch 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 wi...

Page 36: ...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...

Page 37: ...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 t...

Page 38: ...econdary boom raised or the primary boom extended exceeds 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 ful...

Page 39: ...4 5 Result The machine should stop once the machine reaches 4 5 of chassis tilt and the alarm should sound at the platform controls 77 Lower the primary boom to the stowed position or drive in the opp...

Page 40: ...r thumb rocker switch Note To conserve battery power test each function through a partial cycle Result All boom and steer functions should operate Drive functions should not operate with emergency pow...

Page 41: ...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 re...

Page 42: ...r Hazard Tilt Alarm 1 114249 Label Tip over Hazard Tires 4 114251 Label Explosion Hazard 2 Part No Decal Description Qty 114252 Label Tip over Hazard Limit Switches 3 114334 Label Electrocution Hazard...

Page 43: ...First Edition Second Printing Operator s Manual Inspections Part No 1270491 Z 60 37DC Z 60 37FE 41...

Page 44: ...114248 Label Tip over Hazard Tilt Alarm 1 114249 Label Tip over Hazard Tires 4 Part No Decal Description Qty 114251 Label Explosion Hazard 2 114252 Label Tip over Hazard Limit Switches 3 114334 Label...

Page 45: ...First Edition Second Printing Operator s Manual Inspections Part No 1270491 Z 60 37DC Z 60 37FE 43...

Page 46: ...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...

Page 47: ...d Emergency Stop button to the off position at the ground controls or the platform controls to stop all functions Repair any function that operates when either red Emergency Stop button is pushed in S...

Page 48: ...the engine If the engine fails to start after 15 seconds of cranking determine the cause and repair any malfunction Wait 60 seconds before trying to start again In cold conditions 6 C and below warm t...

Page 49: ...batteries to enable full use of the up functions To Steer 1 Press down the foot switch 2 Slowly move the drive control handle in the direction indicated by blue or yellow triangles OR press the thumb...

Page 50: ...rm is between the non steer wheels To determine the slope grade Measure the slope with a digital inclinometer OR use the following procedure You will need carpenter s level straight piece of wood at l...

Page 51: ...Machine on level surface symbol High range operation for maximum drive speed Function Speed Control 1 Move the switch to the left to decrease the function speeds for jib up down platform rotate and pr...

Page 52: ...ry boom Platform Overload Indicator Light Light flashing indicates the platform is overloaded and no functions will operate The platform control LCD screen will also display the following message PLAT...

Page 53: ...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...

Page 54: ...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 ADVIS...

Page 55: ...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 a...

Page 56: ...ough 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 ass...

Page 57: ...nt 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 t...

Page 58: ...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...

Page 59: ...es and straps or lines 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 l...

Page 60: ...ing symbols have been used in this 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 b...

Page 61: ...a Low 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...

Page 62: ...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 essent...

Page 63: ...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 machin...

Page 64: ...specific machine weight Maximum slope rating stowed position 4WD Platform downhill 45 24 Platform uphill 45 24 Side slope 25 14 Note Slope rating is subject to ground conditions with one person in the...

Page 65: ...Fuel tank capacity 75 7 liters Maximum slope rating stowed position 4WD Platform downhill 45 24 Platform uphill 45 24 Side slope 25 14 Note Slope rating is subject to ground conditions with one perso...

Page 66: ...l First Edition Second Printing Specifications 64 Z 60 37DC Z 60 37FE Part No 1270491 Z 60 37DC and Z 60 37FE Range of Motion Chart Z 60 37DC Z 60 37FE Part No 1270491 Operator s Manual First Edition...

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