Terex Genie Z-33 Operator's Manual
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Terex Genie Z-33 Operator's Manual

Terex Genie Z-33 Operator's Manual

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Operator's Manual
Z
-33
®
DC Power
Front Matter
from Z3318M-2801
CE
with
Maintenance
Information
Original Instructions
First Edition
Second Printing
Part No. 1257143GT

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Summary of Contents for Terex Genie Z-33

  • Page 1 Operator's Manual ® from Z3318M-2801 DC Power with Maintenance Information Original Instructions First Edition Second Printing Part No. 1257143GT Front Matter...

  • Page 2: Table Of Contents

    NG31 6BH Copyright © 2014 Terex Corporation First Edition: Second Printing, April 2022 Genie and "Z" are registered trademarks of Terex South Dakota, Inc. in the U.S.A. and many other countries. Complies with EC Directive 2006/42/EC See EC Declaration of Conformity Supply of Machinery (Safety) Regulations 2008 ®...

  • Page 3: Introduction

    First Edition • Second 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 • Second Printing Introduction Platform controls symbology and related Ground controls symbology and related machine movement: machine movement: Platform level Platform level, Primary boom extend/retract, Primary boom up/down, Secondary boom up/down Primary boom up/down Turntable rotate Turntable rotate Sequential functions and movement: Drive and steer.
  • Page 5 First Edition • Second 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 • Second 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 • Second Printing Operator's Manual Symbol and Hazard Pictorials Definitions Symbol and Hazard Pictorials Definitions Crush hazard Explosion hazard Collision hazard Collision hazard Runaway hazard Tip-over hazard Tip-over hazard Raise platform on Electrocution hazard Maintain required firm, level surface clearance Color coded direction Maximum capacity...
  • Page 8 Operator's Manual First Edition • Second Printing Symbol and Hazard Pictorials Definitions Recovery procedure if tilt alarm sounds while elevated. No smoking. Read the operator’s Platform uphill: Platform downhill: Wheel load No flame. manual 1 Lower primary. 1 Retract primary. Stop engine.

  • Page 9: General Safety

    First Edition • Second Printing Operator's Manual General Safety General Safety Part No. 1257143GT ®...
  • Page 10 Operator's Manual First Edition • Second Printing General Safety ® Part No. 1257143GT...
  • Page 11 First Edition • Second Printing Operator's Manual General Safety Part No. 1257143GT ®...

  • Page 12: Personal Safety

    Operator's Manual First Edition • Second 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 • Second Printing Operator's Manual Work Area Safety Tip-over Hazards Work Area Safety Electrocution Hazards Occupants, equipment and materials shall not This machine is not electrically insulated and will exceed the maximum platform capacity or the not provide protection from contact with or maximum platform capacity of the platform proximity to electrical current.
  • Page 14 Operator's Manual First Edition • Second Printing Work Area Safety Do not depend on the tilt alarm as a level indicator. Do not raise the boom The tilt alarm sounds in the platform only when the when wind speeds may machine is on a severe slope.
  • Page 15 First Edition • Second Printing Operator's Manual Work Area Safety Do not push off or pull Do not place or attach toward any object outside fixed or overhanging loads of the platform. to any part of this machine. Maximum allowable manual force: 400 N Do not alter or disable machine components that Do not place ladders or...
  • Page 16 Operator's Manual First Edition • Second Printing Work Area Safety Operation on Slopes Hazards Fall Hazards Do not drive the machine on a slope that exceeds Occupants must wear a the maximum uphill, downhill or side slope rating safety belt or harness in of the machine.
  • Page 17 First Edition • Second Printing Operator's Manual Work Area Safety Collision Hazards Observe and use the color-coded direction arrows on the platform controls and drive chassis for drive and steer functions. Be aware of limited sight distance and blind spots Do not lower the boom when driving or operating.
  • Page 18 Operator's Manual First Edition • Second Printing Work Area Safety Bodily Injury Hazard Damaged Machine Hazards Do not operate the machine with a hydraulic oil or Do not use a damaged or malfunctioning machine. air leak. An air leak or hydraulic leak can penetrate Conduct a thorough pre-operation inspection of and/or burn skin.
  • Page 19 First Edition • Second Printing Operator's Manual Work Area Safety Battery Safety Component Damage Hazard Do not use any battery charger greater than 48V Burn Hazards to charge the function batteries. Batteries contain acid. Both battery packs must be charged together. Always wear protective clothing and eye wear when Disconnect the battery pack plug before removing...
  • Page 20 Operator's Manual First Edition • Second Printing Work Area Safety Contact Alarm Safety Read, understand and obey all warnings and instructions provided with the contact alarm. Do not exceed the rated platform capacity. The weight of the contact alarm assembly will reduce the rated platform capacity and must be subtracted from the total platform load.

  • Page 21: Legend

    First Edition • Second Printing Operator's Manual Legend Legend Foot switch Secondary boom Manual storage container Ground controls Sliding mid-rail 10 Power to charger (between tires) Lanyard anchorage points 11 Steer tire Platform 12 Battery box Platform controls 13 Non-steer tire Primary boom Part No.

  • Page 22: Controls

    Operator's Manual First Edition • Second Printing Controls Controls The ground control station is to be used as a means to raise the platform for storage purposes and for function tests. The ground control station can be used in the event of an emergency to rescue an incapacitated person in the platform.
  • Page 23 First Edition • Second Printing Operator's Manual Controls Key switch for platform/off/ground selection Ground Control Panel Turn the key switch to the platform position Platform level switch and the platform controls will operate. Turn the key switch to the off position and the machine Move the platform level will be off.
  • Page 24 Operator's Manual First Edition • Second Printing Controls Platform Control Panel Horn button LCD display Secondary boom up/down button 10 Drive enable switch Platform level switch 11 Boom function speed controller Platform overload indicator light 12 Dual axis proportional control handle for primary boom up/down and turntable rotate left/right Machine not level indicator light functions...
  • Page 25 First Edition • Second Printing Operator's Manual Controls Platform Control Panel Proportional control handle for drive function and thumb rocker for steer function Horn button Move the control handle in the direction Press this button and the horn will sound. indicated by the blue arrow on the control Release the button and the horn will stop.
  • Page 26 Operator's Manual First Edition • Second Printing Controls 14 Auxiliary power switch 12 Dual axis proportional control handle for primary boom up/down and turntable rotate Use auxiliary power if the primary power left/right functions source (engine) fails. Simultaneously hold the auxiliary power switch Move the control handle up to either side and activate the desired function.

  • Page 27: Inspections

    First Edition • Second 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 28 Operator's Manual First Edition • Second Printing Inspections Pre-operation Inspection  Nuts, bolts and other fasteners  Ground strap  Be sure that the operator’s manual is  Platform entry mid-rail or gate complete, legible and in the storage container located in the platform.
  • Page 29 First Edition • Second 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 30 Operator's Manual First Edition • Second Printing Inspections At the Ground Controls Test the Tilt Sensor Select a test area that is firm, level and free of Pull out the platform red Emergency Stop hazards. button to the on position. Turn the key switch to platform control.
  • Page 31 First Edition • Second Printing Operator's Manual Inspections At the Platform Controls Test Machine Functions 21 Press down the foot switch. 14 Turn the key switch to platform control. 22 Activate each machine function control handle 15 Pull out the platform red Emergency Stop or toggle switch.
  • Page 32 Operator's Manual First Edition • Second Printing Inspections Test Drive and Braking Test the Drive Enable System 26 Press down the foot switch. 29 Press down the foot switch and lower the boom to the stowed position. 27 Slowly move the drive control handle in the direction indicated by the blue arrow on the 30 Rotate the turntable until the primary boom control panel until the machine begins to...
  • Page 33 First Edition • Second Printing Operator's Manual Inspections Test Limited Drive Speed 42 Retract and lower the boom to the stowed position. 33 Press down the foot switch. If the drive speed with the primary or secondary 34 Raise the primary boom approximately boom raised or the primary boom extended 3 ft/91 cm.
  • Page 34 Operator's Manual First Edition • Second Printing Inspections Test the Lift/Drive Select Function 57 Return to level ground and extend the primary boom approximately 1.6 ft/0.5 m. 50 Press down the foot switch. 58 Drive the machine onto a slope where the 51 Move the drive control handle off center and chassis pitch angle is greater than 2.5°.
  • Page 35 First Edition • Second Printing Operator's Manual Inspections 65 With the boom fully stowed, drive the machine 73 With the boom fully stowed, drive the machine onto a slope where the chassis pitch angle is onto a slope where the chassis roll angle is greater than 2.5°.
  • Page 36 Operator's Manual First Edition • Second Printing Inspections 81 Operate each machine function. Test the Contact Alarm (if equipped) Result: All machine functions should not 77 Do not activate the foot switch and press on operate. the contact alarm cable to release the actuator from the switch socket.
  • Page 37 First Edition • Second 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 Do Not Operate Unless:  sloped surfaces  unstable or slippery surfaces ...
  • Page 38 Operator's Manual First Edition • Second Printing Inspections Decal Inspection Part No. Decal Description 1278542 Instructions – Contact Alarm Use the pictures on this page to verify that all 1278982 Label – Actuator Switch Socket decals are legible and in place. Below is a numerical list with quantities and descriptions.
  • Page 39 First Edition • Second Printing Operator's Manual Inspections 1261929 1257157 72867 114427 52475 72086 1272242 1258500 114249 114252 1257156 1261930 114249 1258982 72086 52475 1281175 72086 1258982 1263542 133067 82487 1258499 27207 114345 82481 219958 27207 219956 27204 1261869 133286 133067 114334 44981...

  • Page 40: Operating Instructions

    Operator's Manual First Edition • Second 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 manual.
  • Page 41 First Edition • Second Printing Operator's Manual Operating Instructions Emergency Stop Operation from Ground Push in the red Emergency Stop button to the off Turn the key switch to ground control. position at the ground controls or the platform Pull out the red Emergency Stop button to the controls to stop all functions.
  • Page 42 Operator's Manual First Edition • Second Printing Operating Instructions Operation from Platform To Drive Press down the foot switch. Turn the key switch to platform control. Increase speed: Slowly move the control Pull out the red Emergency Stop button to the handle off center.
  • Page 43 First Edition • Second Printing Operator's Manual Operating Instructions Driving on a slope To determine the slope grade: Determine the uphill, downhill and side slope Measure the slope with a digital inclinometer OR ratings for the machine and determine the slope use the following procedure.
  • Page 44 Operator's Manual First Edition • Second Printing Operating Instructions Tilt Sensor Activation Settings Drive Enable Light on indicates that the boom Model Chassis Angle Chassis Angle has moved just past either non- (side to side) (front to back) steer wheel and the drive 4.5°...
  • Page 45 First Edition • Second Printing Operator's Manual Operating Instructions Machine Not Level Indicator Light Platform Overload Indicator Light If the tilt alarm sounds when the Light flashing indicates the platform is raised, the Machine Not platform is overloaded and no Level indicator light will come on functions will operate.
  • Page 46 Operator's Manual First Edition • Second Printing Operating Instructions 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.
  • Page 47 First Edition • Second Printing Operator's Manual Operating Instructions Standard Batteries Remove the battery vent caps and check the battery acid level. If necessary, add only enough distilled water to cover the plates. Do not overfill prior to the charge cycle. Replace the battery vent caps.
  • Page 48 Operator's Manual First Edition • Second Printing Operating Instructions Dry Battery Filling and Charging After Each Use Instructions Select a safe parking location—firm level surface, clear of obstruction and traffic. Remove the battery vent caps and Lower the boom to the stowed position. permanently remove the plastic seal from the battery vent openings.

  • Page 49: Transport And Lifting Instructions

    First Edition • Second Printing Operator's Manual Transport and Lifting Instructions Transport and Lifting Instructions  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 slope rating.
  • Page 50 Operator's Manual First Edition • Second Printing Transport and Lifting Instructions Securing to Truck or Trailer for Securing the Platform Transit Make sure the jib and platform are in the stowed position. Always use the turntable rotation lock pin each time the machine is transported.
  • Page 51 First Edition • Second Printing Operator's Manual Transport and Lifting Instructions Lifting Instructions Fully lower and retract the boom. Fully lower the jib. Remove all loose items on the machine. Use the turntable rotation lock to secure the turntable. Observe and Obey: Determine the center of gravity of your machine using the table and the picture on this page.

  • Page 52: Maintenance

    Operator's Manual First Edition • Second Printing Maintenance Maintenance 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 Observe and Obey: checks allow the inspector to identify changes in oil level that might indicate the presence of ...
  • Page 53 First Edition • Second Printing Operator's Manual Maintenance Check the Batteries Scheduled Maintenance Maintenance performed quarterly, annually and every two years must be completed by a person trained and qualified to perform maintenance on Proper battery condition is essential to good this machine according to the procedures found in machine performance and operational safety.

  • Page 54: Specifications

    Operator's Manual First Edition • Second Printing Specifications Specifications Airborne noise emissions Model ® Sound pressure level at ground workstation < 70 dBA Height, working maximum 39 ft 4 in 12 m Sound pressure level at platform workstation < 70 dBA Height, platform maximum 32 ft 10 in 10 m...
  • Page 55 First Edition • Second Printing Operator's Manual Specifications Range of Motion Chart Max Height Max Reach 35 ft 10.6 m 0 ft 30 ft 9.1 m 5 ft 1.5 m 25 ft 7.6 m 10 ft 20 ft 6.1 m 15 ft 4.6 m 15 ft...
  • Page 56 Operator's Manual First Edition • Second Printing Specifications Contents of EC Declaration of Conformity <Manufacturer’s name> hereby declares that the machinery described below complies with the provisions of the following Directives: 1. EC Directive 2006/42/EC, Machinery Directive, under consideration of harmonized European standard EN280 as described in EC type-examination certificate <variable field>...
  • Page 57 First Edition • Second Printing Operator's Manual Specifications Contents of UK Declaration of Conformity <Manufacturer’s name> hereby declares that the machinery described below complies with the provisions of the following Legislation: 1. Supply of Machinery (Safety) Regulations 2008 (SI 2008/1597) as amended (SI 2011/1043, SI 2011/2157, SI 2019/696) under consideration of designated standard EN280 as described in type- examination certificate <variable field>...

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