Terex Genie Z-45XC Operator's Manual
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Terex Genie Z-45XC Operator's Manual

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Operator's Manual
Z
-45XC
®
™
Serial Number Range
from Z4525XCF-101
AUS
Australia
with
Maintenance
Information
First Edition
First Printing
Part No. 1301594GT

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Summary of Contents for Terex Genie Z-45XC

  • Page 1 Operator's Manual Serial Number Range -45XC ® ™ from Z4525XCF-101 Australia with Maintenance Information First Edition First Printing Part No. 1301594GT...

  • Page 2: Table Of Contents

    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: Introduction

    First Edition • First Printing Operator's Manual Introduction Introduction About this manual Intended Use and Familiarization Guide Genie appreciates your choice of our machine for your application. Our number one priority is user The intended use of this machine is to lift safety, which is best achieved by our joint efforts.
  • Page 4 Operator's Manual First Edition • First Printing Introduction Platform controls symbology and related Ground controls symbology and related machine movement: machine movement: Platform level swtich Platform level, jib boom up/down, primary boom extend/retract, primary boom up/down, and secondary boom Platform rotate switch retract/lower.
  • Page 5 First Edition • First Printing Operator's Manual Introduction Bulletin Distribution and Contacting the Manufacturer Compliance At times it may be necessary to contact Genie. When you do, be ready to supply the model Safety of product users is of paramount number and serial number of your machine, along importance to Genie.
  • Page 6 Operator's Manual First Edition • First Printing 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.

  • Page 7: Symbol And Hazard Pictorials Definitions

    First Edition • First Printing Operator's Manual Symbol and Hazard Pictorials Definitions Symbol and Hazard Pictorials Definitions Crush hazard Keep away from Read the operator’s Fire extinguisher Overhead obstruction moving parts manual Electrocution hazard Maintain required Tip-over hazard Manual force Tip-over hazard clearance Electrocution hazard...
  • Page 8 Operator's Manual First Edition • First Printing Symbol and Hazard Pictorials Definitions Platform tie-down Lifting & tie down Lanyard anchorage Support the platform Tie-down point instructions instructions points or boom during maintenance Maximum capacity Runaway hazard Color coded direction Voltage rating for Pressure rating for air arrows power to platform...

  • Page 9: General Safety

    First Edition • First Printing Operator's Manual General Safety 31060 1267121 114390 114258 1263543 31060 General Safety 219484 82377 219484 1263543 82377 114390 31060 1267121 114258 219484 ® ™ Part No. 1301594GT -45 XC...
  • Page 10 Operator's Manual First Edition • First Printing General Safety 31060 114397 72875 219487 218559 82410 114390 1288849 1290332 82237 97579 82862 28236 82237 31060 72875 82410 DANGER Electrocution Hazard Contact with Avoid contact energized with energized components can components. result in death or serious injury.
  • Page 11 First Edition • First Printing Operator's Manual General Safety ® ™ Part No. 1301594GT -45 XC...

  • Page 12: Personal Safety

    Operator's Manual First Edition • First Printing Personal Safety Personal Safety Personal Fall Protection Personal fall protection equipment (PFPE) is required when operating this machine. 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.

  • Page 13: Work Area Safety

    First Edition • First Printing Operator's Manual Work Area Safety Work Area Safety Electrocution Hazards Keep away from the machine if it contacts This machine is not electrically insulated and will energized power lines. not provide protection from contact with or Personnel on the ground proximity to electrical current.
  • Page 14 Operator's Manual First Edition • First Printing Work Area Safety If the platform load is greater than 664 lbs/301 kg, Do not depend on the tilt alarm as a level indicator. or 604 lbs/274 kg with Aircraft Protection Package The tilt alarm sounds in the platform only when the do not move the platform into the unrestricted machine is on a severe slope.
  • Page 15 First Edition • First Printing Operator's Manual Work Area Safety Do not tie the boom or platform to adjacent Do not raise the boom structures. when wind speeds may exceed 28 mph/12.5 m/s. Do not place loads outside the platform perimeter. If wind speeds exceed 28 mph/12.5 m/s when Do not push off or pull...
  • Page 16 Operator's Manual First Edition • First Printing Work Area Safety Do not modify or alter an aerial work platform Operation on Slopes Hazards without prior written permission from the Do not drive the machine on a slope that exceeds manufacturer. Mounting attachments for holding the maximum uphill, downhill or side slope rating of tools or other materials onto the platform, toeboards, or guard rail system can increase the...
  • Page 17 First Edition • First Printing Operator's Manual Work Area Safety Fall Hazards Collision Hazards Occupants must wear a Be aware of limited sight safety belt or harness in distance and blind spots accordance with when driving or operating. governmental regulations. Attach the lanyard to the anchor provided in the Be aware of the boom position and tailswing when...
  • Page 18 Operator's Manual First Edition • First Printing Work Area Safety Bodily Injury Hazard Observe and use the color-coded direction arrows on the platform controls and drive chassis for drive Always operate the machine in a well-ventilated and steer functions. area to avoid carbon monoxide poisoning. Do not lower the boom Do not operate the machine with a hydraulic oil or unless the area below is...
  • Page 19 First Edition • First Printing Operator's Manual Work Area Safety Damaged Machine Hazards Battery Safety Do not use a damaged or malfunctioning machine. Burn Hazards Conduct a thorough pre-operation inspection of the Batteries contain acid. machine and test all functions before each work Always wear protective shift.
  • Page 20 Operator's Manual First Edition • First Printing Work Area Safety Contact Alarm Safety Panel Cradle Safety Read, understand and obey all warnings and Read, understand and obey all warnings and instructions provided with the contact alarm. instructions provided with the panel cradles. Do not exceed the rated platform capacity.
  • Page 21 First Edition • First Printing Operator's Manual Work Area Safety Pipe Cradle Safety Welder Safety Read, understand, and obey all warnings and Read, understand and obey all warnings and instructions provided with the pipe cradles. instructions provided with the welding power unit. Do not exceed the rated platform capacity.

  • Page 22: Legend

    Operator's Manual First Edition • First Printing Legend Legend Foot switch Platform controls Manual storage container Primary boom Sliding mid-rail 10 Secondary boom Lanyard anchorage points 11 Ground controls Swing gate 12 Steer tire Jib boom 13 Non-steer tire Platform ®...

  • Page 23: Controls

    First Edition • First Printing Operator's Manual Controls Controls The Z-45/25 XC machines will 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.
  • Page 24 Operator's Manual First Edition • First Printing Controls Gasoline/LPG models: Fuel select switch, if Ground Control Panel equipped Diesel models: Oil pressure light Move the fuel select switch to the gasoline Light on and engine stopped: Tag the machine position to select gasoline. Move the fuel and remove from service.
  • Page 25 First Edition • First Printing Operator's Manual Controls 12 Turntable rotate switch 17 Primary boom extend/retract switch Move the turntable rotate switch to the right Move the primary boom extend/retract switch and the turntable will rotate to the right. Move to the right and the primary boom will retract.
  • Page 26 Operator's Manual First Edition • First Printing Controls Platform Control Panel ® ™ -45 XC Part No. 1301594GT...
  • Page 27 First Edition • First Printing Operator's Manual Controls ® ™ Part No. 1301594GT -45 XC...
  • Page 28 Operator's Manual First Edition • First Printing Controls Platform overload indicator light Platform Control Panel Light flashing indicates the platform is Horn button overloaded. The engine will stop and no Press this button and the horn will sound. functions will operate. Remove weight until the Release the button and the horn will stop.
  • Page 29 First Edition • First Printing Operator's Manual Controls 12 Work light switch (if equipped) 15 Drive speed select switch Move the work light switch up to activate the Machine on incline symbol: Low range lights. Move the work light switch down to turn operation for inclines.
  • Page 30 Operator's Manual First Edition • First Printing Controls 24 Dual axis proportional control handle for 21 Models with LCD screen: Engine shut-down primary boom up/down and turntable rotate indicator light left/right functions Light on indicates that the engine has shut Move the control handle up down.

  • Page 31: Inspections

    First Edition • First Printing Operator's Manual Inspections Inspections Pre-operation Inspection Fundamentals It is the responsibility of the operator to perform a pre-operation inspection and routine maintenance. The pre-operation inspection is a visual inspection performed by the operator prior to each work shift. Do Not Operate Unless: The inspection is designed to discover if anything is apparently wrong with a machine before the...
  • Page 32 Operator's Manual First Edition • First Printing Inspections  Contact alarm (if equipped) Pre-operation Inspection  Alarms and beacons (if equipped)  Be sure that the operator’s, safety, and  Generator (if equipped) responsibilities manuals are complete, legible and in the storage container located in the ...
  • Page 33 First Edition • First Printing Operator's Manual Inspections 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 Do Not Operate Unless: tagged and removed from service.
  • Page 34 Operator's Manual First Edition • First Printing Inspections Test the Tilt Sensor At the Ground Controls Turn the key switch to Select a test area that is firm, level and free of platform control. Pull out the hazards. platform red Emergency Turn the key switch to ground control.
  • Page 35 First Edition • First Printing Operator's Manual Inspections Test Machine Functions At the Platform Controls 24 Press down the foot switch. Test Emergency Stop 25 Activate each machine function control handle 15 Turn the key switch to platform control and or toggle switch.
  • Page 36 Operator's Manual First Edition • First Printing Inspections Test Drive and Braking Test the Drive Enable System 29 Press down the foot switch. 32 Press down the foot switch and lower the boom to the stowed position. 30 Slowly move the drive control handle in the direction indicated by the blue arrow on the 33 Rotate the turntable until the primary boom control panel until the machine begins to move,...
  • Page 37 First Edition • First Printing Operator's Manual Inspections Test Limited Drive Speed Test Drive Tilt Cutout 36 Press down the foot switch. 46 Press down the foot switch. 37 Raise the primary boom approximately 2 ft / 47 With the boom fully stowed, drive the machine 61 cm.
  • Page 38 Operator's Manual First Edition • First Printing Inspections 56 Return to level ground and raise the secondary 65 Retract the primary boom to the stowed boom to an out of stowed position position or drive in the opposite direction. (approximately 15° above horizontal). Result: The machine should drive.
  • Page 39 First Edition • First Printing Operator's Manual Inspections Test Aircraft Protection Package Test the Contact Alarm (if equipped) (if equipped) 79 Do not activate the foot switch and press on the contact alarm cable to release the actuator Note: Two people may be required to perform this from the switch socket.
  • Page 40 Operator's Manual First Edition • First Printing Inspections Test Emergency Power 86 Shut the engine off. 87 Pull out the red Emergency 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.
  • Page 41 First Edition • First Printing Operator's Manual Inspections Workplace Inspection Checklist Be aware of and avoid the following hazardous situations:  drop-offs or holes  bumps, floor obstructions, or debris  sloped surfaces Do Not Operate Unless:  unstable or slippery surfaces ...
  • Page 42 Operator's Manual First Edition • First Printing Inspections Inspection for Decals with Words Part No. Decal Description 218053 Label – ALC500 Board Use the pictures on the next page to verify that all 218054 Label – ALC500 Board decals are legible and in place. 218529 Label –...
  • Page 43 First Edition • First Printing Operator's Manual Inspections 1280819 31060 114390 114258 1283744 82366 219485 825579 1274536 1280820 219952 218529 1283345 218053 219484 218054 1268192 1283744 72086 52475 1278542 1278982 114397 1267121 219487 219484 1268192 72086 218559 28160 52475 1263543 114390 1268200 1288849...

  • Page 44: Operating Instructions

    Operator's Manual First Edition • First Printing Operating Instructions Operating Instructions Fundamentals The Operating Instructions section provides instructions for each aspect of machine operation. It is the operator’s responsibility to follow all the safety rules and instructions in the operator’s, safety, and responsibilities manuals.
  • Page 45 First Edition • First Printing Operator's Manual Operating Instructions Starting the Engine Emergency Stop At the ground controls, turn the key switch to Push in the red Emergency Stop button to the off the desired position. position at the ground controls or the platform controls to stop all machine functions and turn the Be sure both ground and platform control red engine off.
  • Page 46 Operator's Manual First Edition • First Printing Operating Instructions Operation from Ground Operation from Platform Turn the key switch to ground control. Turn the key switch to platform control. Pull out the red Emergency Stop button to the Pull out both ground and platform red on position.
  • Page 47 First Edition • First Printing Operator's Manual Operating Instructions To Drive To determine the slope grade: Press down the foot switch. Measure the slope with a digital inclinometer OR use the following procedure. Increase speed: Slowly move the control handle off center. You will need: Decrease speed: Slowly move the control ...
  • Page 48 Operator's Manual First Edition • First Printing Operating Instructions Drive Enable Generator (if equipped) Light on indicates that the boom To start the generator, move has moved just past either the generator toggle switch to non-steer wheel and the drive the on position.
  • Page 49 First Edition • First Printing Operator's Manual Operating Instructions Platform Capacity Selection Platform Capacity Selection with Aircraft Protection Range of motion is controlled automatically based on platform load. Range of motion is controlled automatically based on platform load. Unrestricted Range of Motion: When the platform load is less than 661 lbs - Unrestricted Range of Motion: When 1,000 lbs/301 - 454 kg, the restricted...
  • Page 50 Operator's Manual First Edition • First Printing Operating Instructions Platform Overload Indicator Light Contact Alarm (if equipped) The contact alarm is designed to alert ground Light flashing indicates the personnel when an operator makes contact with platform is overloaded. The the platform control panel, interrupting boom engine will stop and no movement, sounding an alarm and flashing...
  • Page 51 First Edition • First Printing Operator's Manual Operating Instructions After Each Use Select a safe parking location—firm level surface, clear of obstruction and traffic. Retract and lower the boom to the stowed position. Rotate the turntable so that the boom is between the non-steer wheels.

  • Page 52: Transport And Lifting Instructions

    Reverse the procedures described to re-engage machine weight. See the inspections section the brakes. for the serial label location. Note: Towing the Genie Z-45XC is not recommended. If the machine must be towed, do not exceed 2 mph / 3.2 km/h. ®...
  • Page 53 First Edition • First Printing Operator's Manual Transport and Lifting Instructions Securing the Platform - Z-45 XC Securing to Truck or Trailer for Transit Make sure the jib and platform are in the stowed position. Always use the turntable rotation lock pin each Secure the platform with a nylon strap placed over time the machine is transported.
  • Page 54 Operator's Manual First Edition • First Printing Transport and Lifting Instructions 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. Observe and Obey: Attach the rigging only to the designated lifting points on the machine.

  • Page 55: Maintenance

    First Edition • First Printing Operator's Manual Maintenance Maintenance 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 improper oil level Observe and Obey: can damage engine components.
  • Page 56 Operator's Manual First Edition • First Printing Maintenance Diesel Fuel Requirements Check the Hydraulic Oil Level Satisfactory engine performance is dependent on Maintaining the hydraulic oil at the proper level is the use of a good quality fuel. The use of a good essential to machine operation.
  • Page 57 First Edition • First Printing Operator's Manual Maintenance Check the Engine Coolant Level – Check the Batteries Liquid Cooled Models Proper battery condition is essential to good machine performance and operational safety. Maintaining the engine coolant at the proper level Improper fluid levels or damaged cables and is essential to engine service life.

  • Page 58: Specifications

    Operator's Manual First Edition • First Printing Specifications Specifications Z-45 XC Platform dimensions, 6 foot 183 cm x 76 cm Platform leveling self-leveling Height, working maximum 15.86 m Platform rotation 160° Height, platform maximum 13.86 m AC outlet in platform standard Height, stowed maximum 2.25 m...
  • Page 59 First Edition • First Printing Operator's Manual Specifications Z-45 XC Range of Motion Chart Z-45 XC Range of Motion Chart with Aircraft Protection ® -45 XC™ Part No. 1301594GT Operator's Manual First Edition • First Printing ® ™ Part No. 1301594GT -45 XC...

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Z4525xcf-101

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