Operator's Manual Serial Number Range Z-60/37DC from Z6016N-101 ANSI/CSA North America Z-60/37FE South America Asia with Maintenance Information First Edition First Printing Part No. 1270490 Operator's Manual First Edition • First Printing F ront Matter Contents Introduction ........................................................... 1 Symbol and Hazard Pictorials Definitions ............. 5 General Safety ...................................................... 7 Personal Safety ................................................... 15 Work Area Safety ................................................ 16 Legend ................................................................ 25 Controls ............................................................... 26 Inspections .......................................................... 33 Operating Instructions ......................................... 50 Transport and Lifting Instructions ....................... 60 Maintenance ....................................................... 63 Specifications ...................................................... 67 Copyright © 2016 Terex Corporation First Edition: First Printing, January 2016 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/SIA A92.5 CAN B.354.4 Z-60/37DC (cid:129) Z-60/37FE Part No. 1270490 First Edition (cid:129) First Printing Operator's Manual Introduction Introduction About this manual Intended Use Genie appreciates your choice of our machine for This machine is intended to be used only to lift your application. Our number one priority is user personnel, along with their tools and materials to safety, which is best achieved by our joint efforts. an aerial work site. This book is an operation and daily maintenance manual for the user or operator of a Genie Bulletin Distribution and machine. Compliance This manual should be considered a permanent part of your machine and should remain with the Safety of product users is of paramount machine at all times. If you have any questions, importance to Genie. Various bulletins are used by contact Genie. Genie to communicate important safety and product information to dealers and machine owners. Product Identification The information contained in the bulletins is tied to The machine serial number is located on the serial specific machines using the machine model and label. serial number. Serial number Serial label Distribution of bulletins is based on the most stamped on chassis (located under cover) current owner on record along with their associated dealer, so it is important to register your machine and keep your contact information up to date. To ensure safety of personnel and the reliable continued operation of your machine, be sure to comply with the action indicated in a respective bulletin. Part No. 1270490 Z-60/37DC (cid:129) Z-60/37FE 1 Operator's Manual First Edition (cid:129) First Printing Introduction 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 regarding product applications and safety Standards and regulatory compliance information Current owner updates, such as changes in machine ownership or changes in your contact information. See Transfer of Ownership, below. Transfer of Machine Ownership Taking a few minutes to update owner information will ensure that you receive important safety, maintenance and operating information that applies to your machine. Please register your machine by visiting us on the web at www.genielift.com or by calling us toll free at 1-800-536-1800. 2 Z-60/37DC (cid:129) Z-60/37FE Part No. 1270490 First Edition (cid:129) 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. Danger Failure to obey the instructions and safety rules in this manual will result in death or serious injury. Do Not Operate Unless:  You learn and practice the principles of safe machine operation contained in this operator’s manual. 1 Avoid hazardous situations. Know and understand the safety rules before going on to the next section. 2 Always perform a pre-operation inspection. 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 operator’s manuals and machine decals.  You read, understand and obey employer’s safety rules and worksite regulations.  You read, understand and obey all applicable governmental regulations.  You are properly trained to safely operate the machine. Part No. 1270490 Z-60/37DC (cid:129) Z-60/37FE 3 Operator's Manual First Edition (cid:129) First Printing Introduction Hazard Classification Decals on this machine use symbols, color coding and signal words to identify the following: Safety alert symbol—used to alert you to potential personal injury hazards. Obey all safety messages that follow this symbol to avoid possible injury or death. DANGER Indicates a hazardous situation which, if not avoided, will result in death or serious injury. WARNING Indicates a hazardous situation which, if not avoided, could result in death or serious injury. CAUTION Indicates a hazardous situation which, if not avoided, could result in minor or moderate injury. NOTICE Indicates a property damage message. 4 Z-60/37DC (cid:129) Z-60/37FE Part No. 1270490 First Edition (cid:129) 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. Crush hazard No smoking Explosion hazard Electrocution hazard Maintain required clearance Tip-over hazard Tip-over hazard Grounded AC Replace damaged Replace tires with 3-wire only wires and cords tires of same specification. Wheel load Wind speed Maximum capacity Side force Batteries used as counterweights Part No. 1270490 Z-60/37DC (cid:129) Z-60/37FE 5 Operator's Manual First Edition (cid:129) First Printing Symbol and Hazard Pictorials Definitions 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 Collision hazard Arrows 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 Access by trained 1 Lower primary. 1 Retract primary. manual manual and authorized 2 Lower secondary. 2 Lower secondary. personnel only 3 Retract primary. 3 Lower primary. 6 Z-60/37DC (cid:129) Z-60/37FE Part No. 1270490 First Edition (cid:129) First Printing Operator's Manual General Safety General Safety Part No. 1270490 Z-60/37DC (cid:129) Z-60/37FE 7 Operator's Manual First Edition (cid:129) First Printing General Safety 8 Z-60/37DC (cid:129) Z-60/37FE Part No. 1270490