Terex Genie Z331815M-101 Operator's Manual
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Terex Genie Z331815M-101 Operator's Manual

Terex Genie Z331815M-101 Operator's Manual

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1.
Operator's Manual
Z-33/18
DC Power
Serial number range
From Z331815M-101
to Z331816M- 1299
From Z3318M-1300
ANSI/CSA
North America
South America
Asia
with
Maintenance
Information
Original Instructions
First Edition
Second Printing
Part No. 1257144GT

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Summary of Contents for Terex Genie Z331815M-101

  • Page 1 Operator's Manual Serial number range Z-33/18 From Z331815M-101 ANSI/CSA to Z331816M- 1299 North America DC Power South America Asia From Z3318M-1300 with Maintenance Information Original Instructions First Edition Second Printing Part No. 1257144GT...

  • Page 2: Table Of Contents

    Bleicheplatz 2 First Edition: Second Printing, August 2018 8200 Schaffhausen Switzerland Genie and "Z" are registered trademarks of Terex South Dakota, Inc. in the U.S.A. and many other countries. Technical Assistance Service These machines comply with Telephone: +39 075 9418129 ANSI/SIA 92.5...

  • Page 3: Introduction

    First Edition • Second Printing Operator's Manual 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.
  • Page 4 Operator's Manual First Edition • Second 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...
  • Page 5 First Edition • Second Printing Operator's Manual Introduction 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.
  • 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 Crush hazard Explosion hazard Collision hazard Collision hazard Runaway Hazard Tip-over hazard Tip-over hazard Raise platform on Electrocution Maintain required firm, level surface hazard clearance 12.5 m/sec 12.5 m/sec 12.5 m/sec 12.5 m/sec 12.5 m/sec...
  • 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 Platform uphill: Platform downhill: Wheel load No flame operator’s 1 Lower primary 1 Retract primary Stop engine manual 2 Lower secondary 2 Lower secondary...

  • Page 9: General Safety

    First Edition • Second Printing Operator's Manual General Safety Safety Signs and Locations 31060 114390 Tip-over Hazard Altering or disabling limit switches can result in machine tip-over. Machine tip-over will result in death or serious injury. Do not alter or disable limit switch(s).
  • Page 10 Operator's Manual First Edition • Second Printing General Safety Safety Signs and Locations 1280819 1261933 31060 128 819 114390 31787 31788 1261933 52865 528 5 1261934 218559 1262132 114390 Tip-over Hazard 1261934 Tipping over the machine will result in death or serious injury. 114397 Maximum 28236...
  • Page 11 First Edition • Second Printing Operator's Manual General Safety Safety Signs and Locations 114252 133067 114334 82481 114345 82481 D 114249 114252 82481 114345 133067 114252 114249 114334 114249 Part No. 1257144GT Z-33/18...
  • Page 12 Operator's Manual First Edition • Second Printing General Safety Safety Signs and Locations 114249 133067 114252 82487 114345 82481 114249 1258501 219958 219956 1261869 114248 1258501 12.5 m/sec 133067 219956 82487 1261869 200 kg 219956 A 114249 30% (17°) < = 20% (11°) 200 kg 25% (14°)

  • Page 13: Personal Safety

    First Edition • Second Printing Operator's Manual 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 14: Work Area Safety

    Operator's Manual First Edition • Second Printing Work Area Safety Electrocution Hazards Tip-over Hazards This machine is not electrically insulated and will not Occupants, equipment and materials shall not provide protection from contact with or proximity to exceed the maximum platform capacity or the electrical current.
  • Page 15 First Edition • Second Printing Operator's Manual Work Area Safety If the tilt alarm sounds while the boom is lowered: Do not raise the boom when do not extend, rotate or raise the boom above wind speeds may exceed horizontal. Move the machine to a firm, level 12.5 m/s.
  • Page 16 Operator's Manual First Edition • Second Printing Work Area Safety Do not tie the boom or platform to adjacent Do not place ladders or structures. scaffolds in the platform or against any part of this Do not place loads outside the platform perimeter. machine.
  • Page 17 First Edition • Second Printing Operator's Manual Work Area Safety Do not climb down from Operation on Slopes Hazards the platform when raised. Do not drive the machine on a slope that exceeds the maximum uphill, downhill or side slope rating of the machine.
  • Page 18 Operator's Manual First Edition • Second Printing Work Area Safety Be aware of crushing Bodily Injury Hazard hazards when grasping the platform guard rail. Do not operate the machine with a hydraulic oil or air leak. An air leak or hydraulic leak can penetrate and/or burn skin.
  • Page 19 First Edition • Second Printing Operator's Manual Work Area Safety Lockout After Each Use Damaged Machine Hazards 1 Select a safe parking location–firm level surface, clear of obstruction and traffic. Do not use a damaged or malfunctioning machine. 2 Retract and lower the boom to the stowed Conduct a thorough pre-operation inspection of position.
  • Page 20 Operator's Manual First Edition • Second Printing Work Area Safety Component Damage Hazards Battery Safety Do not use any battery charger greater than 48V Burn Hazards to charge the batteries. Both battery packs must be charged together. Batteries contain acid Always wear protective Disconnect the battery pack plug before removing clothing and eye wear when...

  • Page 21: Legend

    First Edition • Second Printing Operator's Manual Legend 1 Foot switch 8 Secondary boom 2 Manual storage container 9 Ground controls 3 Sliding mid-rail 10 Power to charger (between tires) 4 Lanyard anchorage point 11 Steer tire 5 Platform 12 Battery box 6 Platform controls 13 Non-steer tire 7 Primary boom...

  • Page 22: Controls

    Operator's Manual Operator's Manual First Edition • Second Printing Controls 00009.9 Ground Control Panel 1 Platform level switch 10 Emergency lowering switch 2 Turntable rotate switch 11 Hour meter 3 Primary boom extend/retract switch 4 Primary boom up/down switch 5 Not used 6 Key switch for platform/off/ground selection 7 Red Emergency Stop button 8 Secondary boom up/down switch...
  • Page 23 First Edition • Second Printing Operator's Manual Operator's Manual Controls Ground Control Panel 7 Red Emergency Stop button 1 Platform level switch Push in the red Emergency Stop button to the off position to stop all functions. Pull out the red Move the platform level Emergency Stop button to the on position to switch up and the level of...
  • Page 24 Operator's Manual Operator's Manual First Edition • Second Printing Controls Platform Control Panel 1 Horn button 9 LCD display 2 Secondary boom up/down switch 10 Drive enable switch 3 Platform level switch 11 Boom function speed controller 4 Not used 12 Dual axis proportional control handle for primary boom up/down and turntable rotate left/ 5 Machine not level indicator light...
  • Page 25 First Edition • Second Printing Operator's Manual Operator's Manual Controls Platform Control Panel 7 Proportional control handle for drive function and thumb rocker for steer function 1 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 panel Release the button and the horn will stop.
  • Page 26 Operator's Manual Operator's Manual First Edition • Second Printing Controls 12 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.

  • Page 27: Inspections

    First Edition • Second Printing Operator's Manual 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. The inspection is designed to discover if anything Do Not Operate Unless: 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, safety and Platform entry mid-rail or gate responsibilities manuals are complete, legible and in the storage container located in the Lanyard anchorage points 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 Do Not Operate Unless: malfunctions are discovered, the machine must be tagged and removed from service.
  • Page 30 Operator's Manual First Edition • Second Printing Inspections At the Ground Controls Test Machine Functions 8 Pull out the platform red Emergency Stop 1 Select a test area that is firm, level and free of button to the on position. Turn the key switch to obstruction.
  • 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 in 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 27 Slowly move the drive control handle in the boom to the stowed direction indicated by the blue arrow on the position.
  • Page 33 First Edition • Second Printing Operator's Manual Inspections Test Limited Drive Speed Result: The maximum achievable drive speed with the primary boom extended should not 33 Press down the foot switch. exceed 0.21 foot / 6.5 cm/s. 34 Raise the primary boom approximately If the drive speed with the primary boom moved 3 feet / 82 cm.
  • Page 34 Operator's Manual First Edition • Second Printing 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 You learn and practice the principles of safe machine operation contained in this operator’s overhead obstructions and high voltage manual.
  • Page 35 First Edition • Second Printing Operator's Manual Inspections Inspection for Decals with Words Part No. Decal Description Determine whether the decals on your machine 1257157 Platform Control Panel have words or symbols. Use the appropriate 1258982 Label — Wheel Load inspection to verify that all decals are legible and 1258499 Label —...
  • Page 36 Operator's Manual First Edition • Second Printing Inspections 52947 Serial 1261936 1257157 1254595 114427 52475 1261933 72086 31060 Label 38149 227213 219626 1257156 Ground 1254814 Controls Side 1280819 1261933 1258982 Safety Label 52865 72086 52475 72086 1258982 1272242 114390 1258499 40434 27207 114117...
  • Page 37 First Edition • Second Printing Operator's Manual Inspections Inspection for Decals with Part No. Decal Description Symbols 1258499 Label — Lifting Diagram, Z-33/18 114248 Label — Tip-over Hazard, Tilt Determine whether the decals on your machine Alarm have words or symbols. Use the appropriate Label —...
  • Page 38 Operator's Manual First Edition • Second Printing Inspections Serial 1272242 1258500 1257157 1254595 114427 52475 114249 72086 114252 Label 219626 1257156 Ground Controls 1254814 Side 114249 1258982 Safety 72086 Label 52475 40434 72086 1258982 133067 82487 1258499 27207 Chassis 114345 82481 Platform 219958...

  • Page 39: Operating Instructions

    First Edition • Second Printing Operator's Manual 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. Do Not Operate Unless: Using the machine for anything other than lifting personnel, along with their tools and materials, to...
  • Page 40 Operator's Manual First Edition • Second Printing Operating Instructions Emergency Stop Emergency Power Use emergency power if the primary power source Push in the red Emergency Stop button to the fails. off position at the ground controls or the platform controls to stop all machine functions.
  • Page 41 First Edition • Second Printing Operator's Manual Operating Instructions Operation from Platform To Drive 1 Press down the foot switch. 1 Turn the key switch to platform control. 2 Increase speed: Slowly move the drive control 2 Pull out both ground and platform red Emergency handle off center.
  • Page 42 Operator's Manual First Edition • Second Printing Operating Instructions Drive Enable To determine the slope grade: Measure the slope with a digital inclinometer OR Light on indicates that the boom use the following procedure. has moved just past either non-steer wheel and the drive You will need: function has been interrupted.
  • Page 43 First Edition • Second Printing Operator's Manual Operating Instructions Machine Not Level Indicator Light After Each Use 1 Select a safe parking location–firm level If the tilt alarm sounds when the surface, clear of obstruction and traffic. platform is raised, the Machine Not Level indicator light will come 2 Retract and lower the boom to the stowed on and the drive function in one...
  • Page 44 Operator's Manual First Edition • Second Printing Operating Instructions Standard batteries 1 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. 2 Replace the battery vent caps.

  • Page 45: Transport And Lifting Instuctions

    First Edition • Second Printing Operator's Manual Transport and Lifting Instructions Be sure the turntable is secured with the turntable rotation lock before transporting. Be sure the unlock the turntable for operation. Do not drive the machine on a slope that exceeds the uphill, downhill or side slope rating.
  • Page 46 work may not be modified or hor approval. property of Genie Industries Operator's Manual First Edition • Second Printing ndered upon request. Transport and Lifting Instructions enie Industries Securing to Truck or Trailer for Securing the Platform – Z-33/18 Transit Make sure the platform is in the stowed position.
  • Page 47 First Edition • Second Printing Operator's Manual Transport and Lifting Instructions Lifting Instructions Fully lower and retract the boom. Remove all loose items on the machine. Use the turntable lock pin to secure the turntable. Determine the center of gravity of your machine Observe and Obey: using the table and the picture on this page.

  • Page 48: Maintenance

    Operator's Manual First Edition • Second Printing Maintenance Check the Hydraulic Oil Level Maintaining the hydraulic oil at the proper level is Observe and Obey: essential to machine operation. Improper hydraulic oil levels can damage hydraulic components. Daily Only routine maintenance items specified in checks allow the inspector to identify changes this manual shall be performed by the operator.
  • Page 49 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 this machine according to the procedures found in Proper battery condition is essential to good the service manual for this machine.

  • Page 50: Specifications

    Operator's Manual First Edition • Second Printing Specifications Z-33/18 Airborne noise emissions 39 ft 4 in 12 m Height, working maximum Sound pressure level at ground < 70 dBA workstation 32 ft 10 in 10 m Height, platform maximum Sound pressure level at platform <...
  • Page 51 First Edition • Second Printing Operator's Manual Specifications Range of Motion Chart FEET Part No. 1257144GT Z-33/18...
  • Page 52 Operator's Manual First Edition • Second Printing Specifications METERS Z-33/18 Part No. 1257144GT...
  • Page 54 California Proposition 65 WARNING Operating, servicing and maintaining this equipment, passenger vehicle or off-highway motor vehicle can expose you to chemicals including engine exhaust, carbon monoxide, phthalates, and lead, which are known to the State of California to cause cancer and birth defects or other reproductive harm.

This manual is also suitable for:

Genie z-33/18Genie z331816m- 1299Genie z3318m-1300Z331815m-101Z331816m-1299Z3318m-1300

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