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

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Operator's Manual
Z
-45 XC
®
™
from Z4525XCF-1501
from Z4525XCM-1501
Serial Number Range
CE
with
Maintenance
Information
Original Instructions
Second Edition
Second Printing
Part No. 1305353GT

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  • Page 1 Operator's Manual Serial Number Range -45 XC ® ™ from Z4525XCF-1501 from Z4525XCM-1501 with Maintenance Information Original Instructions Second Edition Second Printing Part No. 1305353GT...
  • Page 2 Copyright © 2017 Terex Corporation Second 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. "XC" is a trademark of Terex South Dakota, Inc. Complies with EC Directive 2006/42/EC...
  • Page 3 Second 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 personnel, safety, which is best achieved by our joint efforts.
  • Page 4 Operator's Manual Second Edition • Second Printing Introduction Platform controls symbology and related Secondary boom up/down machine movement: Platform level Drive forward/reverse Platform rotate Jib boom up/down Steer right/left Primary boom up/down Turntable rotate Primary boom extend/retract ® -45 XC ™...
  • Page 5 Second Edition • Second Printing Operator's Manual Introduction Ground controls symbology and related Sequential functions and movement: machine movement: Drive and steer. • Platform level Interlocked functions: Elevated drive speed. • Elevated drive in an off-level condition. • Platform rotate Drive enable when the boom is rotated past the •...
  • Page 6 Operator's Manual Second Edition • Second Printing 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 importance number and serial number of your machine, along to Genie.
  • Page 7 Second Edition • Second Printing Operator's Manual 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 8 Operator's Manual Second Edition • Second Printing Symbol and Hazard Pictorials Definitions Symbol and Hazard Pictorials Definitions Crush hazard Keep away from Read the operator’s Overhead obstruction Collision hazard moving parts manual Electrocution hazard Maintain required Tip-over hazard Tip-over hazard Tip-over hazard clearance Electrocution hazard...
  • Page 9 Second Edition • Second Printing Operator's Manual Symbol and Hazard Pictorials Definitions Manual force No smoking. Explosion hazard Burn hazard Explosion hazard No flame. Stop engine. Wheel load Tire specifications No smoking Explosion hazard Fire hazard Lifting point Platform tie-down Lifting &...
  • Page 10 Operator's Manual Second Edition • Second Printing Symbol and Hazard Pictorials Definitions Voltage rating for Maximum capacity Runaway hazard Color coded Pressure rating for air direction arrows line to platform power to platform Recovery procedure if tilt alarm sounds while elevated.
  • Page 11 Second Edition • Second Printing Operator's Manual General Safety General Safety Part No. 1305353GT ® -45 XC ™...
  • Page 12 Operator's Manual Second Edition • Second Printing General Safety ® -45 XC ™ Part No. 1305353GT...
  • Page 13 Second Edition • Second Printing Operator's Manual General Safety Part No. 1305353GT ® -45 XC ™...
  • Page 14 Operator's Manual Second 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 15 Second Edition • Second 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 or proximity to electrical current.
  • Page 16 Operator's Manual Second Edition • Second Printing Work Area Safety If the platform load is greater than 301 kg, or Do not depend on the tilt alarm as a level indicator. 274 kg with Aircraft Protection Package do not The tilt alarm sounds in the platform only when the move the platform into the unrestricted range of machine is on a severe slope.
  • Page 17 Second Edition • Second Printing Operator's Manual Work Area Safety Do not raise the boom Do not push off or pull when wind speeds may toward any object outside exceed 12.5 m/s. If wind of the platform. speeds exceed 12.5 m/s Maximum allowable when the boom is raised, manual force –...
  • Page 18 Operator's Manual Second Edition • Second Printing Work Area Safety Operation on Slopes Hazards Do not modify or alter an aerial work platform 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, the machine.
  • Page 19 Second Edition • Second 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 20 Operator's Manual Second Edition • Second 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 21 Second Edition • Second 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 22 Operator's Manual Second Edition • Second Printing Work Area Safety Contact Alarm Safety Panel Cradle Safety Read, understand and obey all warnings and Bodily injury hazard. Failure to instructions provided with the contact alarm. use the Genie Panel Cradle according to the instructions and Do not exceed the rated platform capacity.
  • Page 23 Second Edition • Second Printing Operator's Manual Work Area Safety Pipe Cradle Safety Lockout After Each Use Read, understand, and obey all warnings and Select a safe parking location—firm level instructions provided with the pipe cradles. surface, clear of obstruction and traffic. Retract and lower the boom to the stowed Do not exceed the rated platform capacity.
  • Page 24 Operator's Manual Second Edition • Second 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 25 Second Edition • Second Printing Operator's Manual 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 26 Operator's Manual Second Edition • Second Printing Controls Ground Control Panel Engine idle (rpm) select switch Move the engine idle select switch to the turtle Diesel models: Oil pressure light position for foot switch activated low idle. Light on and engine stopped: Tag the machine Move the engine idle select switch to the rabbit and remove from service.
  • Page 27 Second Edition • Second Printing Operator's Manual Controls 18 Function enable button 14 Platform rotate switch Press and hold the function enable button to Move the platform rotate switch to the right and enable the functions on the ground control the platform will rotate to the right.
  • Page 28 Operator's Manual Second Edition • Second Printing Controls Platform Control Panel With Hour Meter ® -45 XC ™ Part No. 1305353GT...
  • Page 29 Second Edition • Second Printing Operator's Manual Controls Part No. 1305353GT ® -45 XC ™...
  • Page 30 Operator's Manual Second Edition • Second Printing Controls Platform Control Panel with Hour Platform overload indicator light Meter Light flashing indicates the platform is overloaded. The engine will stop and no Horn button functions will operate. Remove weight until the light goes off and then restart the engine.
  • Page 31 Second Edition • Second Printing Operator's Manual Controls 12 Work light switch (if equipped) 14 Dual axis proportional control handle for drive and steer functions. Move the work light switch up to activate the lights. Move the work light switch down to turn Proportional control handle for drive function off the lights.
  • Page 32 Operator's Manual Second Edition • Second Printing Controls 15 Drive speed select switch 19 Engine idle (rpm) select switch Machine on incline symbol: Low range Move the engine idle select switch to the turtle operation for inclines. position for foot switch activated low idle. Machine on level surface symbol: High range Move the engine idle select switch to the rabbit operation for maximum drive speed.
  • Page 33 Second Edition • Second Printing Operator's Manual Controls 22 Proportional control handle for secondary boom up/down function Move the control handle up and the secondary boom will raise. Move the control handle down and the secondary boom will lower. 23 Primary boom extend/retract switch Move the primary boom extend/retract switch up and the primary boom will...
  • Page 34 Operator's Manual Second Edition • Second Printing Controls Platform Control Panel With LCD Display ® -45 XC ™ Part No. 1305353GT...
  • Page 35 Second Edition • Second Printing Operator's Manual Controls Part No. 1305353GT ® -45 XC ™...
  • Page 36 Operator's Manual Second Edition • Second Printing Controls Platform Control Panel with LCD Platform overload indicator light Display Light flashing indicates the platform is overloaded. The engine will stop and no Horn button functions will operate. Remove weight until the light goes off and then restart the engine.
  • Page 37 Second Edition • Second Printing Operator's Manual Controls 12 Work light switch (if equipped) 14 Dual axis proportional control handle for drive and steer functions. Move the work light switch up to activate the lights. Move the work light switch down to turn Proportional control handle for drive function off the lights.
  • Page 38 Operator's Manual Second Edition • Second Printing Controls 15 Drive speed select switch 22 Proportional control handle for secondary boom up/down function Machine on incline symbol: Low range operation for inclines. Move the control handle Machine on level surface symbol: High range up and the secondary operation for maximum drive speed.
  • Page 39 Second 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 40 Operator's Manual Second Edition • Second Printing Inspections Pre-operation Inspection  Alarms and beacons (if equipped)  Contact alarm  Be sure that the operator’s, safety, and  Nuts, bolts and other fasteners responsibilities manuals are complete, legible and in the storage container located in the ...
  • Page 41 Second 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 42 Operator's Manual Second Edition • Second Printing Inspections At the Ground Controls Test the Tilt Sensor 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 43 Second Edition • Second Printing Operator's Manual Inspections At the Platform Controls Test the Foot Switch 19 Push in the platform red Emergency Stop Test Emergency Stop button to the off position. 15 Turn the key switch to platform control and 20 Pull out the red Emergency Stop button to the restart the engine.
  • Page 44 Operator's Manual Second Edition • Second Printing Inspections Test the Steering Test the Drive Enable System 26 Press down the foot switch. 32 Press down the foot switch and lower the boom to the stowed position. 27 Press the thumb rocker switch on top of the drive control handle in the direction indicated 33 Rotate the turntable until the primary boom by the blue triangle on the control panel OR...
  • Page 45 Second Edition • Second 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 61 cm. 47 With the boom fully stowed, drive the machine onto a slope where the chassis pitch angle is 38 Slowly move the drive control handle to the full greater than 4.5°.
  • Page 46 Operator's Manual Second Edition • Second Printing Inspections 54 Return to level ground and stow the boom. 62 Lower the primary boom to the stowed position or drive in the opposite direction. 55 With the boom fully stowed, drive the machine onto a slope where the chassis pitch angle is Result: The machine should drive.
  • Page 47 Second Edition • Second Printing Operator's Manual Inspections Test the Oscillating Axle (if equipped) Test the Lift/Drive Select Function 71 Start the engine from the platform controls. 75 Press down the foot switch. 72 Drive the right steer tire up onto a 15 cm block 76 Move the drive control handle off center and or curb.
  • Page 48 Operator's Manual Second Edition • Second Printing Inspections Test the Contact Alarm (if equipped) 81 Operate each machine function. 77 Do not activate the foot switch and press on Result: All machine functions should not the contact alarm cable to release the actuator operate.
  • Page 49 Second Edition • Second Printing Operator's Manual Inspections Test Aircraft Protection Package (if equipped) Note: Two people may be required to perform this test. 84 Extend the primary boom approximately 30 cm. 85 Move the yellow bumper at the bottom of the platform 10 cm in any direction.
  • Page 50 Operator's Manual Second 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  sloped surfaces Do Not Operate Unless:  unstable or slippery surfaces You learn and practice the principles of safe ...
  • Page 51 Second Edition • Second Printing Operator's Manual Inspections Decal Inspection Part No. Decal Description 214932 Ground Control Panel* Use the pictures on the next page to verify that all 219952 Label – Emergency Lowering decals are legible and in place. 219956 Label –...
  • Page 52 Operator's Manual Second Edition • Second Printing Inspections ® -45 XC ™ Part No. 1305353GT...
  • Page 53 Second Edition • Second Printing Operator's Manual 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 54 Operator's Manual Second Edition • Second Printing Operating Instructions Starting the Engine All models If the engine fails to start after 15 seconds of At the ground controls, turn the key switch to cranking, determine the cause and repair any the desired position.
  • Page 55 Second 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 machine functions and turn the on position.
  • Page 56 Operator's Manual Second 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 both ground and platform red handle off center. Emergency Stop buttons to the on position.
  • Page 57 Second 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 58 Operator's Manual Second Edition • Second Printing Operating Instructions Tilt Sensor Activation Settings When the Machine On Incline indicator light is on and the tilt Z-45 XC alarm sounds, the following Tilt/Slope (front to back) 4.5° functions are affected; drive 660 lbs/300 kg 1000 lbs/454 kg functions are disabled.
  • Page 59 Second Edition • Second Printing Operator's Manual Operating Instructions Drive Enable Drive Speed Select Light on indicates that the boom has moved just past either non-steer wheel and the drive function has been interrupted. Machine on incline symbol: Low range •...
  • Page 60 Operator's Manual Second Edition • Second Printing Operating Instructions Standstill Regeneration Under emergencies, the DPF standstill regeneration can be interrupted in three ways: When the LCD screen displays the message "Regen Warning Lvl 1" (level 1 or higher), the DPF ...
  • Page 61 Second Edition • Second Printing Operator's Manual Operating Instructions Using the control buttons 2 and 3 below the Using the control buttons 2 and 3 below the LCD screen, select "Diagnostics" from the LCD screen, select "Initiate Regen". Press the Main Menu.
  • Page 62 Operator's Manual Second Edition • Second Printing Operating Instructions 11 If the engine is not already running, the LCD The LCD screen will display the message " screen displays the message "Start Engine". Warning: Machine must be in a nonflammable environment".
  • Page 63 Second Edition • Second Printing Operator's Manual Operating Instructions Generator (if equipped) 14 The regeneration process auto-advances and once it is completed the LCD screen displays To start the generator, move the message "Regen Successful". the generator toggle switch to the on position.
  • Page 64 Operator's Manual Second Edition • Second Printing Operating Instructions Machine Not Level Indicator Light Platform Capacity Selection Range of motion is controlled automatically based If the tilt alarm sounds when the on platform load. platform is raised, the Machine Not Level indicator light will come on Unrestricted Range of Motion: and the drive function in one or both...
  • Page 65 Second Edition • Second Printing Operator's Manual Operating Instructions Platform Capacity Selection with Aircraft Platform Overload Indicator Light Protection Light flashing indicates the Range of motion is controlled automatically based platform is overloaded. The on platform load. engine will stop and no functions will operate.
  • Page 66 Operator's Manual Second Edition • Second Printing Operating Instructions Contact Alarm (if equipped) After Each Use The contact alarm is designed to alert ground Select a safe parking location—firm level personnel when an operator makes contact with surface, clear of obstruction and traffic. the platform control panel, interrupting boom Retract and lower the boom to the stowed movement, sounding an alarm and flashing...
  • Page 67 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-45 XC is not recommended. If the machine must be towed, do not exceed 3.2 km/h. Part No. 1305353GT ®...
  • Page 68 Operator's Manual Second Edition • Second Printing Transport and Lifting Instructions Securing to Truck or Trailer for Securing the Platform - Z-45 XC 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 69 Second 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. 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 70 Operator's Manual Second Edition • Second Printing 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 71 Second Edition • Second Printing Operator's Manual 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 72 Operator's Manual Second Edition • Second Printing 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 73 Second Edition • Second Printing Operator's Manual Maintenance 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 the service manual for this machine. Machines that have been out of service for more than three months must receive the quarterly inspection before they are put back into service.
  • Page 74 Operator's Manual Second Edition • Second Printing Specifications Specifications Z-45 XC Platform dimensions, 6 foot 183 cm x 76 cm Height, working maximum 15.86 m Platform leveling self-leveling Height, platform maximum 13.86 m Platform rotation 160° Height, stowed maximum 2.25 m AC outlet in platform standard Horizontal reach, maximum...
  • Page 75 Second Edition • Second Printing Operator's Manual Specifications Z-45 XC Range of Motion Chart Z-45 XC Range of Motion Chart with Aircraft Protection Part No. 1305353GT ® -45 XC ™...
  • Page 76 Operator's Manual Second Edition • Second Printing Specifications Contents of EC Declaration of Conformity - 1 <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 77 Second Edition • Second Printing Operator's Manual Specifications Contents of EC Declaration of Conformity - 2 <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, Conformity assessment procedure: art.12 (3) (a), with the application of European Harmonized Standard EN 280:2013+A1:2015.
  • Page 78 Operator's Manual Second Edition • Second Printing Specifications ® -45 XC ™ Part No. 1305353GT...
  • Page 79 Second Edition • Second Printing Operator's Manual Specifications Z -45 XC Part No. 1305353GT Operator s Manual Second Edition • Second Printing Part No. 1305353GT ® -45 XC ™...