Terex Genie Z-34/22DC, Operator'S Manual

Page 1: ...rator s Manual Serial Number Range Z 34 22N from Z34NF 17000 from Z34ND 1900 CE Z 34 22DC from Z34F 14000 with Maintenance Information Original Instructions Seventh Edition First Printing Part No 1297937GT ...

Page 2: ...d Pictorials Definitions 6 General Safety 8 Personal Safety 10 Work Area Safety 11 Legend 19 Controls 20 Inspections 22 Operating Instructions 36 Transport and Lifting Instructions 44 Maintenance 48 Specifications 50 Contents of EC Declaration of Conformity 53 Copyright 1996 Terex Corporation Seventh Edition First Printing February 2020 Genie and Z are registered trademarks of Terex South Dakota I...

Page 3: ...chassis 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 t...

Page 4: ...ry 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 ...

Page 5: ...tion of your machine be sure to comply with the action indicated in a respective bulletin 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 safe...

Page 6: ...n 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 prope...

Page 7: ...alert you to potential 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 injury Indicates a hazardous situation which if not avoided could result in death or serious injury Indicates a hazardous situation which if not avoided could result in minor or moderat...

Page 8: ...ot 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 Replace tires with tires of same specification Wheel load Wind speed Maximum capacity Side force Batterie...

Page 9: ...n 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 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...

Page 10: ...Operator s Manual Seventh Edition First Printing General Safety 8 Z 34 22N Z 34 22DC Part No 1297937GT Gener al Safety ...

Page 11: ...nth Edition First Printing Operator s Manual General Safety Part No 1297937GT Z 34 22N Z 34 22DC 9 These decals are model option or configuration specific These decals are installed on both sides of chassis ...

Page 12: ...achine 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 manufa...

Page 13: ... 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 exceed the maximum platform capacity Maximum platform ca...

Page 14: ... 3 Lower the primary boom Do not alter or disable the limit switches Do not drive over 0 7 mph 1 km h with the primary boom raised or extended or the secondary boom raised Do not use the platform controls to free a platform that is caught snagged or otherwise prevented from normal motion by an adjacent structure All personnel must be removed from the platform before attempting to free the platform...

Page 15: ...ace or attach fixed or overhanging loads to any part of this machine Do not place ladders or scaffolds in the platform or against any part of this machine Do not transport tools and materials unless they are evenly distributed and can be safely handled by person s in the platform Do not use the machine on a moving or mobile surface or vehicle Be sure the tires are in good condition and the lug nut...

Page 16: ...orm weight may reduce slope rating See Driving on a Slope in the Operating Instructions section Fall Hazards Occupants must wear a safety belt or harness in accordance with governmental regulations Attach the lanyard to the anchor provided in the platform Do not sit stand or climb on the platform guard rails Maintain a firm footing on the platform floor at all times Do not climb down from the plat...

Page 17: ... and governmental rules regarding use of personal protective equipment Observe and use the color coded direction arrows on the platform controls and drive chassis for drive and steer functions Do not lower the boom unless the area below is clear of personnel and obstructions Limit travel speed according to the condition of the ground surface congestion slope location of personnel and any other fac...

Page 18: ...ilated area away from sparks flames and lighted tobacco Do not operate the machine in hazardous locations or locations where potentially flammable or explosive gases or particles may be present Damaged Machine Hazards Do not use a damaged or malfunctioning machine Conduct a thorough pre operation inspection of the machine and test all functions before each work shift Immediately tag and remove fro...

Page 19: ... cable clamps with tools that may cause sparks Component Damage Hazard Do not use any battery charger greater than 48V to charge the batteries Both battery packs must be charged together Disconnect the battery pack plug before removing the battery pack Electrocution Hazard Connect the battery charger to a grounded AC 3 wire electrical outlet only Inspect daily for damaged cords cables and wires Re...

Page 20: ...duce the rated platform capacity and must be subtracted from the total platform load The contact alarm assembly weighs 10 lbs 4 5 kg Be sure the contact alarm is securely installed Lockout After 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 ...

Page 21: ... 34 22DC 19 Leg end 1 Non steer tire 2 Battery box 3 Steer tire 4 Power to charger between steer tires 5 Ground controls 6 Secondary boom 7 Primary boom 8 Jib boom 9 Platform controls 10 Platform 11 Lanyard anchorage points 12 Sliding mid rail 13 Manual storage container 14 Foot switch ...

Page 22: ...station is selected the platform controls are inoperable including the E stop switch Ground Control Panel 1 Secondary boom up down switch 2 Turntable rotate switch 3 Platform rotate switch 4 Platform level switch 5 Primary boom extend retract switch 6 Auxiliary power switch 7 Key switch for platform off ground selection 8 Hour meter 9 Red Emergency Stop button 10 10A breaker for control electrical...

Page 23: ...te switch if equipped 9 Battery charge indicator and or low voltage interrupt option 10 Machine not level indicator light if equipped 11 Proportional control handle for drive function and thumb rocker for steer function 12 Platform overload indicator light if equipped 13 Function Override Aircraft Protection Package if equipped 14 Boom function speed controller 15 Jib boom up down switch 16 Second...

Page 24: ...pection 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 una...

Page 25: ...ized modifications Electrical components wiring and electrical cables Hydraulic power unit reservoir hoses fittings cylinders and manifolds Drive and turntable motors and drive hubs Wear pads Tires and wheels Limit switches and horn Contact alarm if equipped Beacons and alarms if equipped Nuts bolts and other fasteners Platform entry mid rail or gate Platform load cell Lanyard anchorage points Che...

Page 26: ...nly 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...

Page 27: ...tform functions should operate 7 Hold the function enable switch to either side and activate each boom and platform function toggle switch Result All boom and platform functions should operate through a full cycle Test the Tilt Sensor 8 Turn the key switch to platform control Pull out the platform red Emergency Stop button to the on position 9 Open the control panel side turntable cover and locate...

Page 28: ...he direction indicated on the control panel Test Machine Functions 22 Press down the foot switch 23 Activate each machine function control handle or toggle switch Result All boom and platform functions should operate through a full cycle Note Control the speed of boom functions by adjusting the boom function speed controller Drive and steer functions are not affected by the boom function speed con...

Page 29: ...n the drive 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 30 Press down the foot switch and lower the boom to the stowed position 31 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...

Page 30: ...osition If 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 Z 34N Z 34 DC 44 Press down the foot switch 45 With the boom fully stowed drive the machine onto a slope where the chassis roll angle is greater than 4 5 Result The machine should continue to drive...

Page 31: ...chassis roll angle is greater than 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 60 Lower the primary boom to the stowed position or drive in the opposite direction Result The machine should drive 61 Return to level ground and extend the primary boom approximately 1 6 ft 0 5 m 62 Drive the machine onto a slope wh...

Page 32: ...or toggle switch Result All boom and steer functions should operate Test the Contact Alarm if equipped 74 Do not activate the foot switch and press on the contact alarm cable to release the actuator from the switch socket Result The contact alarm lights will not flash and the machine horn will not sound 75 Activate the foot switch by pressing the foot switch down Result The contact alarm lights wi...

Page 33: ...t All machine functions should operate 1 actuator 2 contact alarm cable 3 flashing alarm 4 switch socket Test Auxiliary Power 81 Pull out the red Emergency Stop button to the on position 82 Press down the foot switch 83 Simultaneously hold the auxiliary power switch on and activate each function control handle or toggle switch Note To conserve battery power test each function through a partial cyc...

Page 34: ...ce the principles of safe machine operation contained in this operator s manual 1 Avoid hazardous situations 2 Always perform a pre operation inspection 3 Always perform function tests prior to use 4 Inspect the workplace Know and understand the workplace inspection before going on to the next section 5 Only use the machine as it was intended ...

Page 35: ...ity 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 situations drop offs or holes bumps floor obstructions or debris sloped surfaces unstable or slippery surfaces overhead obstructions and high voltage conductors hazardous locations inadequate surf...

Page 36: ...el Tip over Hazard Tilt Alarm 1 Part No Decal Description Qty 114249 Label Tip over Hazard Tires 4 114252 Label Tip over Hazard Limit Switches 7 114334 Label Electrocution Hazard Plug 1 114343 Label Emergency Lowering 1 133067 Label Electrocution Hazard 3 133286 Label Power to Charger Universal 1 139587 Label Wheel Load Z 34 22 DC 4 139590 Label Wheel Load Z 34 22N 4 219954 Label Tip over Hazard C...

Page 37: ...Seventh Edition First Printing Operator s Manual Inspections Part No 1297937GT Z 34 22N Z 34 22DC 35 ...

Page 38: ...It 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 t...

Page 39: ...ound or platform control 2 Pull out the red Emergency Stop button to the on position 3 Press down the foot switch when operating the auxiliary controls from the platform 4 Simultaneously hold the auxiliary power switch on and activate the desired function The drive functions will not operate with emergency power Operation from Ground 1 Be sure both battery packs are connected before operating the ...

Page 40: ...the markings on the control panel To Steer 1 Press down the foot switch 2 Turn the steer wheels with the thumb rocker switch located on the top of the control handle Use the color coded direction triangles on the platform controls and the drive chassis to identify the direction the wheels will turn To Drive 1 Press down the foot switch 2 Increase speed Slowly move the control handle off center Dec...

Page 41: ...heels 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 least 3 feet 1 m long tape measure Lay the piece of wood on the slope At the downhill end lay the level on the top edge of the piece of wood and lift the end until the piece of wood is level While holding the piece of wood level m...

Page 42: ...rupt if equipped Machines equipped with Low Voltage Interrupt will lose primary and secondary boom up functions from the platform when batteries are low Machine Not Level Indicator Light If the tilt alarm sounds when the platform is raised use extreme caution The machine not level indicator light will come on and the drive function in one or both directions will not operate Identify the condition ...

Page 43: ...om lowering process explained in the previous procedure Platform Overload Indicator Light Light flashing indicates the platform is overloaded and no functions will operate Remove weight from the platform until the light goes off Aircraft Protection Package if equipped If the platform bumpers come into contact with aircraft components the machine will shut down and no functions will operate 1 Start...

Page 44: ... alerting others that assistance 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 After Each Use 1 Select a safe parking location firm le...

Page 45: ... distilled water to cover the plates Do not overfill prior to the charge cycle 2 Replace the battery vent caps 3 Connect the battery charger to a grounded AC circuit 4 The charger will indicate when the battery is fully charged 5 Check the battery acid level when the charging cycle is complete Replenish with distilled water to the bottom of the fill tube Do not overfill Dry Battery Filling and Cha...

Page 46: ...ed mobile elevating work platform operators should move the machine on or off the truck The transport vehicle must be parked on a level surface The transport vehicle must be secured to prevent rolling while the machine is being loaded Be sure the vehicle capacity loading surfaces and chains or straps are sufficient to withstand the machine weight Genie lifts are very heavy relative to their size S...

Page 47: ...e from rolling 2 Apply the non steer wheel brakes by turning over the drive hub disconnect caps Towing the Genie Z 34 DC or the Genie Z 34N is not recommended If the machine must be towed do not exceed 2 mph 3 2 km h Securing to Truck or Trailer for Transit Always chock the machine wheels in preparation for transport Turn the key switch to the off position and remove the key before transporting In...

Page 48: ... Securing the Platform Make sure the jib and platform are in the stowed position Place a block under the edge of the platform beneath the platform entry Secure the platform with a nylon strap placed over the platform mount near the platform rotator see below Do not use excessive downward force when securing the boom section ...

Page 49: ...t 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 There are four lifting points on the chassis ...

Page 50: ...enance 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 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 c...

Page 51: ...oda and water Perform this test after fully charging the battery 1 Put on protective clothing and eye wear 2 Be sure that the battery cable connections are tight and free of corrosion Standard Batteries 3 Remove the battery vent caps 4 Check the battery acid level of each battery If needed replenish with distilled water to the bottom of the battery fill tube Do not overfill 5 Install the vent caps...

Page 52: ...um boom functions 3200 psi 221 bar System voltage 48V Tire size solid rubber 22 x 7 x 17 75 in Highest root mean square value of weighted acceleration to which the whole body is subjected does not exceed 0 5 m s2 Weight Machine weights vary with option configurations See serial label for specific machine weight Maximum slope rating stowed position Platform downhill 35 19 Platform uphill 20 11 Side...

Page 53: ... 3200 psi 221 bar System voltage 48V Tire size Foam filled only 9 14 5 LT Highest root mean square value of weighted acceleration to which the whole body is subjected does not exceed 0 5 m s2 Weight Machine weights vary with option configurations See serial label for specific machine weight Maximum slope rating stowed position Platform downhill 30 17 Platform uphill 20 11 Side slope 25 14 Note Slo...

Page 54: ...Z 34 22N Z 34 22DC Part No 1297937GT Range of Motion Chart Max Height Max Reach 1 35 ft 10 6 m 9 0 ft 0 m 2 30 ft 9 1 m 10 5 ft 1 5 m 3 25 ft 7 6 m 11 10 ft 3 m 4 20 ft 6 1 m 12 15 ft 4 6 m 5 15 ft 4 6 m 13 20 ft 6 1 m 6 10 ft 3 m 14 25 ft 7 6 m 7 5 ft 1 5 m 8 0 ft 0 m ...

Page 55: ...al combustion 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 per...

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