Terex Genie Z-45XC, Operator'S Manual

Page 1: ...Operator s Manual Serial Number Range Z 45XC from Z4525XCF 101 AUS Australia with Maintenance Information First Edition First Printing Part No 1301594GT ...

Page 2: ...afety 10 Work Area Safety 11 Legend 20 Controls 21 Inspections 29 Operating Instructions 42 Transport and Lifting Instructions 50 Maintenance 53 Specifications 56 Copyright 2019 by Terex Corporation First Edition First Printing February 2020 Genie and Z are registered trademarks of Terex South Dakota Inc in the U S A and many other countries These machines comply with AS 1418 10 ...

Page 3: ...mped on 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 MEWP Familiarization with the MEWP must be given t...

Page 4: ...act 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 lift personnel i...

Page 5: ... 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 safety Stan...

Page 6: ...ns 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 Classification Decals on th...

Page 7: ... s manual Fire extinguisher Overhead obstruction Electrocution hazard Maintain required clearance Tip over hazard Manual force Tip over hazard Electrocution hazard Avoid contact Disconnect battery Lifting point Wind speed Weight of welder reduces capacity No smoking No flame Stop engine Explosion hazard Collision hazard Corrosive acid Wheel load Tire specifications No smoking Overhead obstruction ...

Page 8: ...y hazard Color coded direction arrows Voltage rating for power to platform Pressure rating for air line to platform Recovery procedure if tilt alarm sounds while elevated Platform uphill Lower primary Lower secondary Retract primary Platform downhill Retract primary Lower secondary Lower primary Access by trained and authorized personnel onlyl Emergency lowering Read the service manual Do not use ...

Page 9: ...dition First Printing Operator s Manual General Safety Part No 1301594GT Z 45 XC 7 General Safety 31060 219484 219484 114390 31060 114390 114258 114258 219484 1263543 31060 1267121 82377 82377 1267121 1263543 ...

Page 10: ...290332 1290332 218559 114397 1288849 28236 218559 1288849 28236 114390 114397 219487 219487 97579 82862 72875 Electrocution Hazard Contact with energized components can result in death or serious injury 82237 B DANGER Avoid contact with energized components 82237 82410 72875 82410 82237 82862 97579 31060 ...

Page 11: ...First Edition First Printing Operator s Manual General Safety Part No 1301594GT Z 45 XC 9 ...

Page 12: ...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 manufacturer ...

Page 13: ... 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 exceed the ...

Page 14: ...ty See the decals with the options and accessories If using accessories read understand and obey the decals instructions and manuals with the accessory Do not raise or extend the boom unless the machine is on a firm level surface Do not depend on the tilt alarm as a level indicator The tilt alarm sounds in the platform only when the machine is on a severe slope If the tilt alarm sounds when the pl...

Page 15: ...ine as a crane Do not push the machine or other objects with the boom Do not contact adjacent structures with the boom Do not tie the boom or platform to adjacent structures Do not place loads outside the platform perimeter Do not push off or pull toward any object outside of the platform Maximum allowable manual force AUS 90 lbs 400 N Do not alter or disable machine components that in any way aff...

Page 16: ...sport 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 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 ...

Page 17: ...ot 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 or o...

Page 18: ...bon monoxide poisoning Do not operate the machine with 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 a...

Page 19: ...and responsibilities manuals are complete legible and in the storage container located on the machine Component Damage Hazards Do not use any battery or charger greater than 12V to jump start the engine Do not use the machine as a ground for welding Do not operate the machine in locations where extremely high magnetic fields may be present Battery Safety Burn Hazards Batteries contain acid Always ...

Page 20: ...atform 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 maximum capacity of the panel cradles is 250 lbs 113 kg The weight of the panel cradles and the load in the panel cradles may limit the maximum number of occupants in platform to one person Secure the cradles to the pla...

Page 21: ...with movement of the platform with an overhanging load Do not cause a horizontal force or side load to machine by raising or lowering a fixed or overhanging load Electrocution Hazard Keep pipes away from all energized electrical conductors Welder Safety Read understand and obey all warnings and instructions provided with the welding power unit Do not connect weld leads or cables unless the welding...

Page 22: ...Z 45 XC Part No 1301594GT Legend 1 Foot switch 2 Manual storage container 3 Sliding mid rail 4 Lanyard anchorage points 5 Swing gate 6 Jib boom 7 Platform 8 Platform controls 9 Primary boom 10 Secondary boom 11 Ground controls 12 Steer tire 13 Non steer tire ...

Page 23: ... have one of these two styles of ground control panels The descriptions in this section and the instructions in the Function Test and Operating Instructions apply to both panels unless specifically noted 17 15 18 8 1 12 13 19 21 20 11 2 5 4 14 16 7 10 22 6 5 4 2 1 11 12 13 14 17 16 15 18 19 8 9 7 6 10 00009 9 00009 9 3 20 ...

Page 24: ...o the off position to stop all functions and turn the engine off Pull out the red Emergency Stop button to the on position to operate the machine 6 Gasoline LPG models Fuel select switch if equipped Move the fuel select switch to the gasoline position to select gasoline Move the fuel select switch to the LPG position to select LPG 7 Primary boom up down switch Move the primary boom up down switch ...

Page 25: ...ch down and the jib boom will lower 16 Platform level switch Move the platform level switch up and the level of the platform will raise Move the platform level switch down and the level of the platform will lower 17 Primary boom extend retract switch Move the primary boom extend retract switch to the right and the primary boom will retract Move the boom extend retract switch to the left and the pr...

Page 26: ...Operator s Manual First Edition First Printing Controls 24 Z 45 XC Part No 1301594GT Platform Control Panel ...

Page 27: ...First Edition First Printing Operator s Manual Controls Part No 1301594GT Z 45 XC 25 ...

Page 28: ...tes 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 6 Restricted range of motion indicator light if equipped Light on indicates that the range of motion is restricted 7 Unrestricted range of motion indicator light Light on indicates that the range of motion is unrestricted 8 Emergency lowering switch U...

Page 29: ...e control handle in 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 15 Drive speed select switch Machine on incline symbol Low range operation for inclines Machine on level surface symbol High range operatio...

Page 30: ...act switch up and the primary boom will retract Move the boom extend retract switch down and the primary boom will extend 24 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 control handle down and the primary boom will lower Move the control handle to the right and the turnt...

Page 31: ...n 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 unauthori...

Page 32: ...heck 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 Engine and related components Limit switches and horn Contact alarm if equipped Alarms ...

Page 33: ...e 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 may o...

Page 34: ...functions should operate 8 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 the Tilt Sensor 9 Turn the key switch to platform control Pull out the platform red Emergency Stop button to the on position 10 Open t...

Page 35: ...h and restart the engine Result The engine should start 23 Do not press down the foot switch and test each machine function Result No functions should operate Test Machine Functions 24 Press down the foot switch 25 Activate each machine function control handle or toggle switch Result All boom and platform functions should operate through a full cycle Test the Steering 26 Press down the foot switch...

Page 36: ...hassis 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 32 Press down the foot switch and lower the boom to the stowed position 33 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 anywhere ...

Page 37: ... immediately tag and remove the machine from service Test Drive Tilt Cutout 46 Press down the foot switch 47 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 48 Return to level ground and raise the primary boom to an out of stowed position approximately 10 above horizontal 49 Drive the machine on...

Page 38: ... 64 Drive the machine onto a slope where the 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 65 Retract the primary boom to the stowed position or drive in the opposite direction Result The machine should drive 66 Return to level ground and stow the boom 67 With the boom fully sto...

Page 39: ... 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 80 Activate the foot switch by pressing the foot switch down Result The contact alarm lights will flash and the machine horn will sound 81 Insert the actuator into the switch socket Result The lights and horn will turn off 82 Activate the foot switch by pre...

Page 40: ...ency Stop button to the on position 88 Press down the foot switch 89 Simultaneously hold the emergency power switch on and activate each function control handle or toggle 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 power ...

Page 41: ...ator 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 situation...

Page 42: ...und Control Panel 1 215526 Label Belt Routing MSG 425 1 215527 Instructions Ford Engine Specifications MSG 425 1 Part No Decal Description Qty 218053 Label ALC500 Board 1 218054 Label ALC500 Board 1 218529 Label ALC500 Board 1 218559 Danger Warning Tip over Crush Hazard 1 219484 Danger Tire Specification 4 219485 Notice Operating Instructions 1 219487 Label Platform Overload 1 219952 Label Emergen...

Page 43: ...849 214932 160516 114390 44981 28174 28235 219484 31060 1268192 219484 1268192 52475 114390 72086 52475 31788 1268192 219484 1268192 1263543 72086 52475 1278542 1278982 97602 52865 219485 219952 97865 825579 1280820 1280819 28158 28159 1283345 133278 826345 1278357 52607 1284534 82366 218529 218053 218054 1283744 28160 1268200 215527 823488 1288327 97548 1272242 38149 1283345 822131 215526 1263543...

Page 44: ...e 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 use a ...

Page 45: ...th optional cold start kits Attempting to start the engine when temperatures are below 0 F 18 C may require the use of a booster battery Gasoline LPG models In cold conditions 20 F 6 C and below the machine should be started on gasoline and warmed for 2 minutes then switched to LPG Warm engines can be started on LPG Emergency Stop Push in the red Emergency Stop button to the off position at the gr...

Page 46: ...form control 2 Pull out both ground and platform red Emergency Stop buttons to the on position 3 Gasoline LPG models Choose fuel by moving the fuel select switch to the desired position 4 Start the engine Do not press down the foot switch when starting the engine To Position Platform 1 Press down the foot switch 2 Slowly move the appropriate function control handle or toggle switch or press the ap...

Page 47: ... slope rating The term gradeability applies to the counterweight uphill configuration only Be sure the boom is below horizontal and the platform is between the circle end wheels Move the drive speed select switch to machine on incline symbol 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 wo...

Page 48: ...ctivated low idle Rabbit symbol Foot switch activated high idle Generator if equipped To start the generator move the generator toggle switch to the on position Plug a power tool into the power to platform GFCI outlet To turn off the generator move the generator toggle switch to the off position Note Machine functions will not operate while the generator is running and the foot switch is not press...

Page 49: ... light is on and the jib function is limited Restricted Range of Motion When the platform load is 661 1 000 lbs 301 454 kg Platform Capacity Selection with Aircraft Protection Range of motion is controlled automatically based on platform load Unrestricted Range of Motion When the platform load is less than 600 lbs 273 kg the restricted range of motion light is on Restricted Range of Motion When th...

Page 50: ...iate function control handle or toggle switch to move the machine away from aircraft components Contact Alarm if equipped The contact alarm is designed to alert ground personnel when an operator makes contact with the platform control panel interrupting boom movement sounding an alarm and flashing warning lights When the contact alarm cable is tripped the lift and drive functions are disabled at t...

Page 51: ...ch 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 52: ...cient 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 side s...

Page 53: ...fore transporting Inspect the entire machine for loose or unsecured items Securing the Chassis Use chains of ample load capacity Use a minimum of 4 chains or straps Adjust the rigging to prevent damage to the chains For diagram refer to the Lifting Instructions Securing the Platform Z 45 XC Make sure the jib and platform are in the stowed position Secure the platform with a nylon strap placed over...

Page 54: ...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 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 r...

Page 55: ...dure 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 Level Maintaining the proper engine oil level is essential to good engine performance and service life Operating the machine with an improp...

Page 56: ...l Type Low Sulfur Diesel LSD Deutz D2 9 L4 Engine Fuel Type Ultra 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 Daily checks allow the inspector to identify changes in oil level that might indicate the presence of hydraulic system problems 1 Be su...

Page 57: ...tial 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 hot or live circuits may result in death or serious injury Remove all rings watches and other jewelry Bodily injury hazard Batteries contain acid Avoid spilling or contacting battery acid Neutralize...

Page 58: ...ters Hydraulic pressure maximum boom functions 221 bar System voltage 12V Tire size 315 55 D20 foam filled Airborne noise emissions Sound pressure level at ground workstation 87 dBA Sound pressure level at platform workstation 82 dBA Guaranteed sound power level 105 dBA Total vibration value to which the hand arm system is subjected does not exceed 2 5 m s2 Highest root mean square value of weight...

Page 59: ...nting Operator s Manual Specifications Part No 1301594GT Z 45 XC 57 Z 45 XC Range of Motion Chart Z 45 XC Range of Motion Chart with Aircraft Protection Z 45 XC Part No 1301594GT Operator s Manual First Edition First Printing ...

Page 60: ......